SBIR Phase II: Rapid Fabrication of Titanium Boride (TiB2) Anodes for Electrolysis of Aluminum

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This Small Business Innovation Research (SBIR) Phase II project will develop non-consumable and wettable titanium diboride (TiB2)-based cathodes with near-theoretical densities and purity. Phase I demonstrated that titanium and boron powders could be reactively consolidated to produce near-theoretical density TiB2 parts using plasma pressure compaction. A 4-inch diameter by 3/8-inch thickness near-net shape cathode will be fabricated for evaluation in Phase II, and a novel water jet nozzle and abrasive jet mixer tube will be developed based on TiB2. Phase II will also develop zirconium dioxide (ZrO2)- and titanium (Ti)-toughened titanium diboride composites for evaluation as cutting tools. TiB2 electrodes are expected to provide better performance, cost-effectiveness, a hazard-free workplace, and environmentally benign processing in aluminum production; and it is now thought that rapidly consolidated, near net-shape TiB2 parts can also be used in cutting tools for hard metal machining, in mixing tubes for abrasive jets, and in nozzles for water jets.