MSE is engaged in developing and commercializing advanced materials and technologies including innovative metal forming processes and pressure controlled atomization processes (PCAP). We have also been successful in developing centrifugal casting processes for AI/SiCP metal matrix composite materials(CCMM).
Pressure Controlled Atomization Process (PCAP)
Technology Status
- Development of the initial thermal spray system initiated in 1990
- Designed and fabricated Engineering Demonstration Unit for the U.S. Air Force
- Boeing and the Air Force are currently evaluating the system as a hard chrome replacement alternative.
- Hardware and process improvements - three patents issued
- Private industry interest in funding non-line-of-site system development starting in 1999
Commercial Applications
- Alternative to hard chromium electroplating- protective and high-wear coatings
- Rapid prototyping/toolmaking
- Spray forming of permanent magnets
- Manufacturing of printed circuits
- Application of brazing alloys
- Powder and composites manufacturing
- Near-net shape fabrication
Advantages
- Low thermal input into substrate
- PCAP is currently the only thermal spray technology capable of spray-forming permanent magnets, EDM electrodes, and printed circuits.
- Precise control of deposition rates
- Variable width of spray plume
- Oxide-free deposits
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10-Foot Diameter PCAP Unit
Spray Plume
PCAP Formed Hemishells |
Cast Composite Metal Matrix (CCMM) Materials
- Process optimization, testing, and industry co-development efforts in progress
- Adapting the process to applications including armor, track shoes, and high-performance friction and wear components such as clutch
plates and disk brake rotors
- Planning the implementation of pilot scale facility for the production of friction and wear components for racecars, high-performance
snowmobiles and motorcycles
- Expanding intellectual property and technology position by licensing broad rights to practice patented technology
Commercial Applications
- Pistons and piston liners
- Brake rotors for light aircraft, motorcycles, racecars, commercial trucks, construction equipment, and snowmobiles
- Clutch plates for rotor aircraft, heavy trucks, tanks, and high-performance automobiles
- Armor and military hardware
Advantages
- Parts made with the process last longer and are less highly stressed because of lower operating temperatures
- Good dampening properties reduce, if not eliminate, squealing noises associated with steel brakes
- Weight savings translating to improved speed, emissions, fuel savings, and handling characteristics
- Homogenous, functionally graded structures, and preferential particle orientation allow for the tailoring of thermal and mechanical properties according to end use
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Centrifugally Cast Rotors |
