Subject
- Posted on
Aluminum-Boron Composite?
- 03-13-2009
March 13, 2009, 12:28 pm
One of my clients is working on a new mechanism that's going to require a
high performance control system.
Whenever this happens I start suggesting exotic materials to the
mechanical engineering team. This isn't so much because I think that the
product will fail without them, or that I think they're a good idea
(they're 'exotic' because people are generally smart enough not to use
them, after all). Rather, it's because if the ME team is thinking about
how to shut up the crazy systems engineer and his ideas of exotic
materials, one of the things they do is think of how to keep the
resonances up with _ordinary_ materials.
(RCM-ers: basically once you've gotten all the other limiting factors out
of the way, the performance of a positioning system is limited by the
resonances of the hunk of stuff you're trying to shove around, so raising
the resonances as high as possible, and to some extent deadening them,
makes for a higher achievable bandwidth).
We've already dismissed Magnesium (goes "thunk" when you hit it, instead
of "piiiiiiiiing" like Aluminum, but its modulus is low and their
favorite machine shop is scared of flammable metal), Beryllium-Aluminum
alloys (stiff stiff stiff, but Marketing and that danged machine shop
whine about toxicity, of all things!), Stainless brace members (stiff,
but too heavy, too hard to figure out how to do Al on the inside and SS
on the outside), and my latest piece de resistance, Silicon Carbide
(stiffer than Be-Al, but totally wacko -- you may as well build the whole
thing out of glass -- but if I can make it seem to be even remotely sane
then other things start looking reasonable, no?).
I recall about ten years ago a lot of press on boron fibers in an
aluminum matrix making for a very stiff material. Since then I haven't
heard about it, or if I have it's been one of those things that's always
10 years down the road.
Have any of you seen this used anywhere? Seen any ink on it? Have any
reason to believe it's any less wacko than building a heavy machine out
of silicon carbide and hoping that no one drops it off a forklift?
Thanks in advance.
--
http://www.wescottdesign.com
Re: Aluminum-Boron Composite?
We looked at the Boron/aluminum composite for a piezo actuator for
DARPA, ended up going with 4140 steel. It cost too much and was hard
to machine.
Idea: Use carbon fiber composite. Carbon composite structures are
about 80% as stiff as steel but weighs 40%
How about controlling the resonance with a piezo actuator?
Re: Aluminum-Boron Composite?
It's not easy keeping up with the favored ceramic-reinforcement-of-the-month
for metal-matrix composites. One that seems to have lasted is 3M's Nextel
aluminum-matrix composite; it's reinforced with fibers of either zirconia or
alumina, I forget which.
This stuff is pretty miserable to machine, as one would expect, but the
materials suppliers offer recommendations. The last I wrote about
metal-matrix composites was maybe 7 or 8 years ago, and it was all diamond
tooling at that time.
Mass is low, stiffness is very high, damping...I don't know. Since it's
light and stiff, I would suspect very high resonant frequencies. Call 3M.
Silicon carbide, alpha or beta, is a nightmare to work with; special
ultra-high temperature sintering and diamond grinding, all the way.
Your supplier shop is wise to stay clear of beryllium-aluminum. That's for
people who feel comfortable machining plutonium pits for H-bombs. <g> It is
dangerous and is only justified for some aerospace applications. They used
it for Formula One engine blocks for a while, but they realized quickly they
had an intolerable liability on their hands and outlawed it.
--
Ed Huntress
Re: Aluminum-Boron Composite?
I do not know where to find data, but fishing rod manufacturers were
using boron (or maybe it was boron carbide )with epoxy. It did not
have any advantages over carbon epoxy and was a pain to work with.
The boron fibers made hellacious splinters.
I believe Toyota was using kaowool or fibrafrax as a reinforcement for
aluminum pistons. As I remember they used a pressure system to force
the melted aluminum into a mold where the reinforcing material had
been previously placed.
Dan
Re: Aluminum-Boron Composite?
Well, it did have one advantage: Those rods were solid, not hollow, and the
shafts were very skinny. They didn't have to be made over a mandrel, but the
fibers did have to be cut to specific lengths in a progression. It was
tricky and nobody wanted to handle the damned stuff, because those fibers
could poke an inch or more into your skin. They were downright dangerous.
I tried a boron fiber fly rod at a fishing show around 15 years ago. It was
very nice, but it was too quick for me. Just like getting used to graphite
flyrods, they required a big change in the timing of your casts.
Yeah, there are laminations that are sintered, and forced
injection/infiltration that works somewhat like reaction-injection molding
(RIM) of reinforced plastics, and a powder metallurgy process. There may be
other ways by now. Those methods were all in use 20 years ago.
--
Ed Huntress
Re: Aluminum-Boron Composite?
Tim Wescott wrote:
Tim: Check out M Cubed Technology. They offer an aluminum entrained
silicon carbide material that is really cool stuff. Most common
materials have a Youngs/mass ratio all within spitting distance of each
other. Beryllium is the exception as is silicon carbide. The aluminum
entrainment toughens it considerably. It is offered on a few
configurations, one takes a porous sintered preform and uses a vacuum to
draw the aluminum into the matrix, another is a high percentage if SiC
nodules in aluminum for casting. Both must be fabricated to near net
shape while green and ground to final dimension.
I used it in the past as a spar for an air bearing gantry system. nicely
dead, fairly tough, and incredibly stiff.
Oh, BTW, it ain't cheap.....
Jeff
Re: Aluminum-Boron Composite?
On Fri, 13 Mar 2009 20:57:33 -0400, jeff wrote:
It's OK if it isn't cheap. As a systems engineer my job isn't to do the
other engineer's work for them, it's to get the system as a whole to work
well.
Generally I find that the best way to do motivate the design engineers is
_not_ to say "just make it this good because I am a systems engineer and
I am therefore closer to God than you*". Rather, I try to find _a_
solution that will take things in the direction that I want them to go.
Most good design engineers would rather die than adopt, unchanged, a
design from some egghead systems engineer, so by suggesting a design I
establish a bar that they are very motivated to jump over. Then they go
out and find _the_ solution that really solves the problem.
It's kind of a Brer Rabbit thing. Or maybe Tom Sawyer. Something like
that.
* I am, of course, but it doesn't do to rub their noses in it :-).
--
http://www.wescottdesign.com
Re: Aluminum-Boron Composite?
Tim Wescott wrote:
If I suggest using exotic materials in my place they will definitely
consider it and probably end up using it. Then they are like that. For
one job we had a copper and stainless steel composite piece where the
two materials were friction welded together before being machined to the
final shape. The copper was used because of its thermal behaviour and
the stainless steel was used for its rigidity and strength. All of this
had to end up with minimal inclusions (empty pockets in the material for
those that are not familiar with the term) too.
However I know where you are coming from Tim.
--
********************************************************************
Forth based HIDECS Consultancy
Mob: +44 (0)7811-639972
Tel: +44 (0)1235-811095
Going Forth Safely ..... EBA. www.electric-boat-association.org.uk..
********************************************************************
Re: Aluminum-Boron Composite?
Bruce Varley wrote:
At cryogenic temperatures (4.2K) this is hardly a problem.
--
********************************************************************
Forth based HIDECS Consultancy
Mob: +44 (0)7811-639972
Tel: +44 (0)1235-811095
Going Forth Safely ..... EBA. www.electric-boat-association.org.uk..
********************************************************************
Re: Aluminum-Boron Composite?
Tim Wescott wrote:
Oh, you sly fox, you!
You need also to raise the resonance of the rails the moving stuff rides on.
How about giant germanium crystals? (Laminated aluminum sheet has good
damping.)
Jerry
--
Engineering is the art of making what you want from things you can get.
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