Manufacturing of metal-metal Interpenetrating Phase Composites using semi-solid forming

• Applicants: Professor Dr.-Ing. Mathias Liewald; Professor Dr.-Ing. Frederik Zanger
• Subject Area: Primary Shaping and Reshaping Technology, Additive Manufacturing
• Term: since 2017
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 392513301

Interpenetrating Phase Composites (IPC) are characterised by a continuous three-dimensional structure of all material components and thus show completely different properties than fibre or particle reinforced composites, for example. IPC are manufactured by infiltrating an open-pored structure (preform) with a matrix material. However, due to the deficits of current manufacturing processes, the potential of this type of composites has not yet been fully exploited. In this respect, a new process route for producing IPC was developed based on the semi-solid forming technology during the first funding period. Here, metal-ceramic IPC were investigated, consisting of open-pore structures made of Al2O3 and a matrix alloy of AlSi7Mg0,3. Furthermore, numerical modelling of the infiltration process as well as characterization of the mechanical and structural properties of the produced components represented essential research topics. Overall, promising results were achieved regarding the manufacturability of IPC, but also limits were shown for the properties achieved by the investigated material pairing. In the second funding period, knowledge gained is therefore to be transferred to metal-metal IPC on the one hand and to a more complex component geometry on the other. As preforms, steel lattice structures will be produced using a new additive manufacturing process developed at the Institute of Production Technology (wbk, KIT). The matrix alloy used continues to be AlSi7Mg0.3, thus allowing the existing results to be used as a basis. Scientific objective of the wbk are the determination of process parameters for producing lattice structures, which are optimally adapted to the infiltration via semi-solid forming. Research topics of the IFU focus on the transfer of the findings from the first funding period to the production of an application-oriented lever geometry, considering the aluminium-steel material pairing. Finally, comprehensive analysis of the component properties will be carried out jointly.

• DFG Programme: Research Grants