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It has been shown that fly ash can be incorporated in aluminum alloy matrix using stir casting and pressure infiltration techniques; additions of fly ash have been shown to decrease the density and coefficient of expansion of aluminum and increase its wear resistance. This paper summarizes the work in progress at University of Wisconsin-Milwaukee and Eck Industries, Inc. on incorporating fly ash in aluminum castings to decrease the cost and weight of selected industrial components. Aluminum alloy A356 - fly ash and 319-fly ash composite ingots and selected parts were successfully cast in sand and permanent molds using conventional foundry techniques from large scale heats (400 pounds). The sand and permanent mold castings including differential carriers, intake manifolds, brake drums and outdoor equipment castings show adequate castability of the melts containing fly ash particles.

Aluminum Metal Matrix Composites (AMMCs) have similar but not identical casting characteristics of the base aluminum alloy. The differences in viscosity and the presence of ceramic particles cause unique casting issues, many of which can be addressed in the casting design process. The properties of AMMCs are different than both aluminum and cast iron in many ways. Those differences create design opportunities that are sometimes overlooked. This paper will attempt to develop a framework for the design issues surrounding AMMC castings.