Gamma Alloys

Gamma Alloys has patented manufacturing procedures, utilizing nanotechnology, to reinforce aluminum alloys.We achieve properties previously unreachable and enable applications so far unimagined.We create metal-matrix-composites reinforced with artificial precipitates. The result is materials with increased stiffness, improved wear resistance, and superior strength, at both room and elevated temperatures.

History

In the mid 1990’s, conversations between Drs. Harrigan and Sommer took place directed initially at the development of aluminum matrix composites reinforced with alumina nanoparticles. Many other researchers were trying as well to introduce nano particles into metals by aggressive ball milling.The difficulty with this approach to nano ceramic particle generation was the large amount of contamination that was introduced into the nanoparticle population during the milling process. Contamination was caused by the comminution of the internal parts of the ball mill itself as well the organic lubricants used in the milling process to prevent agglomeration of the newly formed nano ceramic particles, we chose not to pursue this technique. For this reason, the research project was put on hold.

At that juncture, Dr. Harrigan was also beginning his independent effort to fabricate Al MMCs using spherical micron sized alumina particles as a reinforcement.In 2007, Dr Al Sommer and Mark Sommer were looking for lightweight robust materials for use in race car engines. They contacted Dr. Harrigan to understand how far along he was with his Al MMC development using micron size spheres of alumina. He had made much progress in the intervening years and a scale-up of the equipment to make the spheres had taken place. At that point, all the pieces of the puzzle necessary to create Gamma Alloys came together.

A path to commercialize these new Al MMCs was laid out, and Gamma Alloys was founded in 2008. Gamma currently controls all aspects of the manufacturing process via a vertical integration, from powder formulation to finished machining parts ready for installation. Today, Gamma Alloys’ materials are used in applications from structural parts of automotive engines, to military helicopter transmissions, to cleats for athletic running shoes.

In late 2011, Dr. Sommer visited Dr Marc Leparoux of EMPA in Thun, Switzerland. Dr. Leparoux had developed a means of generating alumina nano size particles in a plasma beam. He demonstrated the decoration of micron size alumina spheres with alumina nanoparticles in his equipment. Essentially a source now existed to reopen the dream all of had to create an Al MMC reinforced with nano alumina particles. Work began with nano alumina particles produced by Dr. Leparoux’s plasma reactor but soon switched to similar commercially available nano alumina particles. Drs. Harrigan and Curreli then developed a commercially feasible method to directly decorate alumina nanoparticles onto aluminum powder particles.

The advantages of using nano size ceramic particles as a reinforcement over micron size versions of the same ceramic are multiple. Micron size ceramic particles stiffen, make the composite more wear resistant and generate an Endurance Limit during cyclic fatigue testing not found with unenforced aluminum alloys. Nano ceramic particles do all of the above improvements while also improving the mechanical properties at all temperatures up to the melting point of the alloy matrix.

 What is an MMC?

A metal matrix composite (MMC) of aluminum is a material comprised of an aluminum alloy and at least another constituent part, such as a ceramic (aluminum oxide, silicon carbide, etc).

How are MMCs made?

Typically, these Al-MMCs are made by dispersing the ceramic (reduced into a powder form) into aluminum powder (the matrix). The resulting MMC, still in powder form, is then compacted, pressed, and consolidated into a monolithic material by heat treatment.

NP Advantages

These nanoparticles also improve several physical properties such as wear resistance, friction coefficient, thermal conductivity, and Elastic Modulus. Another advantage of using nanoparticles is that our aluminum MMCs can be worked with standard metalworking techniques, such as extrusion, forging, or rolling.

Vision
“This ease of machining, combined with a highly modular manufacturing process, creates world of possibilities to be explored”“We are taking aluminum alloys into applications previously unimaginable for the traditional Al MMCs”