Project overview
SHAPE aims to enhance electrical contact materials through innovative Metal Matrix Composites (MMC) and Functionally Graded Composites (FGC), reducing energy losses and promoting efficient use. For instance, the production of Cu-based MMCs and FGCs utilizes advanced additive manufacturing (AM) technologies like Selective Laser Melting (SLM), Binder Jetting (BJT), and Fused Filament Fabrication (FFF) along with conventional Spark Plasma Sintering (SPS). These AM methods result in less machinery, material waste, and labour compared to traditional techniques. This unique production approach sets SHAPE apart in the materials research landscape, offering novel insights into fabrication processes not explored by previous researchers.
The innovative objectives and potential impacts and benefits of SHAPE are:
- Electrolytic recycling of Cu scrap sheets for producing Cu metal matrix powders.
- Electroless Cu coating of SiC ceramic particles for better matrix-reinforcement interaction.
- Synthesis of composite powders using High energy ball milling (HEBM) process.
- Transformation of irregularly shaped composite powders to spherical morphology via. spheroidization technique and making them much more suitable for the AM process.
- AM of non-functional (constant reinforcement ratio) MMC and functionally graded (reinforcement ratio grading) FGC electrical contact materials.
- Recycling Copper and SiC particles from end of life (EOL) composite electrical materials and reintroducing them into the electrical contact production process.
