MMC Cast Parts

Casting of a high quality metal matrix composites (MMC) component is a remarkable achievement. Process conditions need to be closely monitored and controlled to produce reliable, consistent and high integrity lightweight components. Although the casting operation is a challenge to be overcome, it is only one of many steps in the production of MMC components.
REL engineers, this process has been streamlined and automated to minimize material handling through the integration of advanced robotics and part tracking systems.

Part Tracking

A part can be tracked from the finished product back through the manufacturing process to see what process conditions were used to manufacture that given component. This is an extremely useful tool for internal quality assessment and external liability review.

Inspection Capabilities

X-ray and fluorescent penetrant inspection (FPI) can be used to verify that all components leaving the plant meet the highest possible quality standards to avoid failure.

Heat Treatment

Finding the right heat treatment for your MMC components is dependent on the final application and operating conditions of a structural MMC component. REL is constantly working to optimize heat treatment cycles to optimize the microstructure of the MMC parts. With a scanning electron microscope (SEM with EDS capabilities) REL has the ability to see the effects of heat treatment cycles on the microstructure of cast composites.

Machining

Machining monolithic alloys and machining ceramic reinforced MMC components are two totally different worlds. Feeds, speeds and cutting depths need to be adjusted in addition to tooling changes to machine composite material. Typically this means diamond tooling is required to machine these components. This increase in tooling cost directly affects the costs of reinforced alloys. This is a great impetus to only put reinforcement in areas that need addition stiffness, strength and/or wear resistance. This is where preform technology shines as REL’s formed ceramic precursors will only be in areas where it is absolutely necessary, thus reducing expensive machine operations.

Finishing/Packaging

Finishing operations are crucial in determining ‘the look’ or the ‘sex appeal’ of a finished product. CNC mills and routers are integrated into assembly lines to put on the final touches to a great product.

Learn the different Machines that are used in MMC production.
Contact REL today to see how they can help with a process optimization to make you more competitive in this global environment.