Investment Cast Net Shaped Complex Lubricating Channels Navy SBIR FY2013.1 Sol No.: Navy SBIR FY2013.1 Topic No.: N131-001 Topic Title: Investment Cast Net Shaped Complex Lubricating Channels Proposal No.: N131-001-0987 Firm: Materials & Electrochemical Research (MER) Corp. 7960 S. Kolb Rd. Tucson, Arizona 85756-9237 Contact: Sharly Ibrahim Phone: (520) 574-1980 Web Site: www.mercorp.com Abstract: Producing complex net shape, narrow, long, and curved lubrication channels within the body of an investment cast article using controlled solidification investment casting (CSIC) process is a technically challenging problem. MER is proposing a novel technology to resolve the CSIC technical limitations by utilizing PolyCapillary material (PCM), an advanced powder metallurgy technology, to produce channel forming materials with tailorable mechanical and metallurgical properties to match and work with those of the target investment cast high purity aluminum alloy. The technologies have the advantage of producing large diameter tubes with micro porous walls that have a fraction of the base metal mechanical properties. Mechanically, the micro porous tubes will have the advantage of matching the shrinkage pattern of the investment cast Aluminum alloy. Metallurgically, the PCM process can produce tubes from different materials to eliminate cross contamination between the tubes and the aluminum alloy that can produce brittle conditions within the investment cast article near thin sections. Prefabricated channels produced via PCM will have the advantage of producing net shape complex lubricating channels within the body of an investment cast article with minimal impact on the CSIC process in terms of production volume and process cost. The PCM produced lubricating channels. Benefits: The proposed PCM process will have the advantage of producing complex passage ways in cast metal articles with compatible mechanical and materials properties. The net shape produced channels will eliminate costly secondary processing steps to economically produce lubrication and cooling channels. It will enable the design of complex cavity geometries within a cast metal article which will benefit civilian and military applications. Return