Next generation, low cost aluminium matrix composite inserts for the emerging global market.

Composite Metal Technology (CMT) and M.Wright &Sons (MWS) are collaborating on an Innovate UK funded project to accelerate the take-up of continuous fibre reinforced aluminium matrix composite materials (AMCs). The project is targetting a significant reduction in the piece cost of AMC inserts, and a shorter product development time for new component applications. AMC material, when used in the form of inserts cast within an aluminium component, is an efficient means of providing localised reinforcement and facilitating weight reduction. The work will involve the development of a new, standardised set of AMC inserts, with pre-determined mechanical properties, manufacturing feasibility and piece costs, available in short lead times. These inserts will incorporate novel 3D woven preforms produced by MWS, utilising a reduced proportion of alumina fibre but maintaining existing levels of strength and stiffness, through the exploitation of geometrical properties and advanced weaving techniques. In parallel, CMT and MWS will optimise manufacturing process parameters to reduce production costs and fibre wastage. A new mathematical model will enable the development of optimised infiltration process parameters for new designs. Taken together, these developments will address the remaining inhibitors to widespread adoption of AMC reinforcements for aluminium components and unlock the technology potential for customers in a broad range of industrial sectors.