ULTALITE® DEVELOPMENT STATUS & SUMMARY

      • CYCO-Tech commenced the development of ULTALITE®AL-MMC in early 1990’s. The development was accelerated in 1994 when the Company received a matching grant from the Australian Federal Government Agency “Energy Research and Development Corporation”. The majority of the early development work focused on material mixing and processing to establish a satisfactory ‘Bill of Materials’, the grade and quality of flyash ceramic materials and casting of ULTALITE®ingots.

      • Subsequently, a number of different prototype Automotive components were produced for testing, including alternator and power steering pulleys, disc brake rotors and brake drums. Some details of these earlier test results are available on the website www.cyo-systems.com.

      • During late 2001, PSA Peugeot Citroen contracted CYCO Systems to produce 50 ULTALITE® prototype brake drums similar in design to their existing cast iron brake drums. During 2002 supply arrangement were established in China for cost effective manufacture of the Die Sets, production of castings, and access to research and testing facilities at Ningbo #52 National Research Institute of China.

      • Delivery of the prototype brake drums for Peugeot was completed in early 2003. Peugeot undertook in-house testing of these prototypes, and although the results were positive in qualifying the potential of ULTALITE®, it was clear that further work was required to improve flyash distribution and consistency of the formulation to achieve the optimum level of wear and heat resistance required for the brake drum application.

      • CYCO Systems has made significant progress during the past 18 months in improving the ULTALITE® processing equipment and methodology, assessment and selection of more suitable base flyash material, and worked with its supplier in Ningbo, China, to improve casting techniques and controls, assisted by Professor Kenong Xia from the University of Melbourne, a metallurgist and world leader in the technology for semi solid metal processing.

      • This work culminated in the production of new batches of ULTALITE®AL-MMC brake drum prototypes in early 2004 in preparation for brake dynamometer testing.

      • A series of Brake Dynamometer tests were conducted at Brake Testing International (BTI) in UK to evaluate performance of ULTALITE® Brake drums in comparison with standard OE cast iron Brake drums. Results of this successful test program can be found under the “Research” section.

      • The ULTALITE®brake drums achieved a very positive result, and have been viewed favorably by Peugeot as the above tests were conducted with Peugeot’s standard friction lining that is currently utilised with their conventional cast iron brake drums.

      • In the past special non standard brake linings have been required for use with Aluminium or AL-MMC brake drums. CYCO believes to be utilising standard friction linings is a World First Achievement, which demonstrates the suitability and robustness of ULTALITE®AL-MMC.

      • CYCO also embarked on a three year project in March 2004 in conjunction with the Melbourne University and the Australian Research Council to optimize the patented mixing and metal processing system, together with the development of the ULTALITE® AL-MMC formulation for disc brake rotors, Automotive pulleys, con-rods etc.

      • CYCO is also conducting further research and development in conjunction with ACL Bearing Company in Tasmania to develop a pre-mixed tablet or “puck” to achieve greater efficiency in the mixing and processing of ULTALITE®® AL-MMC material.