Doing the Impossible: Net-Shape Casting of Custom AlSiC Products "Our consultant told us it couldn't be done." This was a direct quote from a customer seeking .010" thick AlSiC metal matrix products. But like the old adage says: never say "never". Six months later, PCC-AFT's Composites  group was delivering these formerly unheard of, customized products in volume. How? Through a unique Pressure Injection Casting (PIC) process that allows for the production of metal matrix parts that designers could only dream of a few years ago. The customer's need for .010" thickness represented a five-fold improvement from the industry's leading capabilities at the time. In addition, they needed high thermal conductivity (170 W/m-K), low coefficient of thermal expansion (9 ppm/K) and high stiffness - done, done and done. No Assembly Required The nature of the net-shape casting process is such that complex three-dimensional parts can be manufactured with no costly, secondary machining required. The pressure-assisted infiltration of molten aluminum into the porous silicon carbide allows for near true net-shaped parts that can be created with complex geometries and material combinations. This process not only allows designers to set new standards of performance, it eliminates the need for assembly of multiple components. It is now possible to design parts with various shapes and combinations of low CTE materials like Al2O3 or SiC directly cast into the overall aluminum net shape. This is important as it now gives the designer the ability to vary the overall material composition and localized performance anywhere within a complex thermal structure. Products like complex finned heat sinks with low CTE device circuitry and mounting pads of electrically conductive or insulating materials can be designed. Furthermore, PIC net-shape casting makes it possible to produce parts with thin cross-sections that are not possible to machine. The ability to decrease plate thickness can yield overall top performance of the package with reduced weight. Ideal applications for this material and cost effective manufacturing technology are in areas that are dependent on strength, weight and thermal management, such as aerospace, electronics and microelectronics. Way Out of the Box Imagine a five-fold improvement in the performance of your industry. Now, imagine that performance boost at a lower cost. Have we mentioned that our products have been to Mars? Have questions about this technology and how it can impact your project? Contact Dr. Birol Sonuparlak at birols@pcc-aft.com or call 303.833.6140. | 
