1. MMC Hammer Group members: Ed Barnard Lizzie Hager Jenny Lichter Kevin McComber 2-26-04

2. Overview Goal Goal Material Properties Material Properties Centrifugal Casting Process Centrifugal Casting Process Short Term Objectives Short Term Objectives Prototype Design and Mold Prototype Design and Mold Progress Progress Upcoming Experiments Upcoming Experiments

3. Halstead Goal The goal of our project is to manufacture a light-weight, high fracture toughness hammer using metal matrix composites. The goal of our project is to manufacture a light-weight, high fracture toughness hammer using metal matrix composites.

4. Carpenter, Koczak p. 310 Material Properties Conventional steel hammer: Conventional steel hammer: Carpenter 20Cb-3® Stainless Steel MMC hammer: MMC hammer: SiC / Ti-6Al-4V, V(%)=35 SiC / 6061 Alum, V% = 0.48 Important properties for a hammer: Important properties for a hammer: Density Density Tensile strength Tensile strength Modulus Modulus Wear resistance Wear resistance Fracture toughness Fracture toughness

5. Carpenter, Koczak p. 310 Material Properties Conventional steel hammer: Tensile measurements at RT Conventional steel hammer: Tensile measurements at RT MMC hammer: Tensile measurements at 0° C MMC hammer: Tensile measurements at 0° C

6. Centrifugal Casting Process

8. Poco Pressure Vessel Calculations Material σ UTS (ksi) Outer radius Outer radius (σ UTS ) min Brass30-901.081.16 Stainless steel 60-1501.041.08 Aluminum45-801.071.10 Graphite7-101.772.09 P max = 2200 psi = 150 atm S. F. : safety factor = 2 r i : inner radius = 1 inch

9. "Home" Short Term Objectives Making mold Making mold size size stability stability Ceramic scaffold Ceramic scaffold packing packing formation formation

10. Prototype design Hammer head Hammer head simple design simple design radially symmetric (conical) radially symmetric (conical) More complex designs can be implemented later More complex designs can be implemented later

11. Prototype Mold Two-piece mold Two-piece mold Conical to aid in the release Conical to aid in the release Sealed with an O-ring and bolted shut Sealed with an O-ring and bolted shut Swagelok connector to runner Swagelok connector to runner

12. Prototype Mold Top Mold

13. Progress Two ceramic layers per casting Two ceramic layers per casting Investigating interfaces Investigating interfaces 2µm TiC has been eliminated 2µm TiC has been eliminated Hardness tests Hardness tests

14. Upcoming Experiments Hardness test Hardness test SEM SEM Machine mold Machine mold Find an effective break-out ceramic for mold release Find an effective break-out ceramic for mold release Use and test new ceramic particles Use and test new ceramic particles

15. Projected Work Schedule

16. Works Cited “Carpenter 20Cb-3® Stainless Steel, Bar.” Accessed 22 Feb 2004. MatWeb.com, The Online Materials Database. 2004.. “Carpenter 20Cb-3® Stainless Steel, Bar.” Accessed 22 Feb 2004. MatWeb.com, The Online Materials Database. 2004.. Halstead, Gary. “Pictures from Dictionaire Paisonné du Mobilier Français.” Accessed 24 February 2004. Medieval and Renaissance Woodworking. 2003.. Halstead, Gary. “Pictures from Dictionaire Paisonné du Mobilier Français.” Accessed 24 February 2004. Medieval and Renaissance Woodworking. 2003.. “Home > Centrifuges RFQ Form.” Accessed 23 Feb 2004. Used-Line.Com : Used Hi- Tech and Scientific Equipment.. “Home > Centrifuges RFQ Form.” Accessed 23 Feb 2004. Used-Line.Com : Used Hi- Tech and Scientific Equipment.. Koczak, et al. “Metal-Matrix Composites for Ground Vehicle, Aerospace and Industrial Applications.” Fundamentals of Metal Matrix Composites. Boston: Butterworth-Heinemann, 1993. Eds. Suresh, S., Mortensen, A. and A. Needleman. 297-326. Koczak, et al. “Metal-Matrix Composites for Ground Vehicle, Aerospace and Industrial Applications.” Fundamentals of Metal Matrix Composites. Boston: Butterworth-Heinemann, 1993. Eds. Suresh, S., Mortensen, A. and A. Needleman. 297-326. “Poco Graphite AXM-5Q Specialty Graphite.” Accessed 25 Feb 2004. MatWeb.com, The “Poco Graphite AXM-5Q Specialty Graphite.” Accessed 25 Feb 2004. MatWeb.com, The Online Materials Database. 2004..