SBIR Phase II: A Process for Preparing Nanometer-Sized Ceramic Particles at High Production Rates

这个小企业创新研究（SBIR）第二阶段项目将开发和商业化一种新技术，以大幅降低成本大规模生产纳米尺寸的陶瓷粉末。该技术，即联合雾化和反应技术（CART），包括提供含有反应物元素如氢、氧、碳、氮、氯、氟、硼或硫的雾化气体介质;制备过热到自发反应温度的金属合金熔体，在该温度下合金可以与所选择的反应物元素进行自持反应;以及引入反应物气体以同时与临界过热的合金熔体混合、熔化和反应，从而在雾化室中形成超细陶瓷颗粒。第二阶段项目将设计和建造一个原型中试规模的CART装置，以证明该技术应用于合成被认为具有最大商业潜力的选定金属的纳米氧化物的商业可行性。超细粉体的商业潜力在于催化剂、涂料和薄膜、导电膏、化妆品、电磁元件、电子设备、阻燃材料、磁性流体、烧结和注塑部件、陶瓷复合材料、磁性存储介质、磷光体、颜料、抛光介质和调色剂的生产。氧化铟锡（ITO）粉末用于制备溅射靶，用于沉积平板显示器技术中使用的透明膜。纳米晶材料可用于替代汽车、基础设施、海上结构、管道、容器、电子设备外壳等中的各种承重和非结构部件。纳米晶金属陶瓷和陶瓷是优秀的切削工具材料。透明纳米晶粒陶瓷可用于广泛的应用，包括透明陶瓷器具组件、透明“玻璃器皿”和艺术品。透明陶瓷也可用于执法、安全警察和装甲车人员的防弹装甲。

This Small Business Innovation Research (SBIR) Phase II project will develop and commercialize a new technology for mass producing nanometer-sized ceramic powders at dramatically reduced costs. The technology, Combined Atomization and Reaction Technique (CART), involves providing an atomizing gas medium containing a reactant element such as hydrogen, oxygen, carbon, nitrogen, chlorine, fluorine, boron, or sulfur; preparing a metal alloy melt super-heated to a spontaneous reaction temperature at which the alloy can undergo a self-sustaining reaction with the selected reactant element; and introducing reactant gas to concurrently mix, atomize, and react with the critically super-heated alloy melt to form ultra-fine ceramic particles in an atomizer chamber. This Phase II project will design and build a prototype pilot-scale CART apparatus to demonstrate the commercial viability of the technology as applied to the synthesis of nano-sized oxides of selected metals that are deemed to have the greatest commercial potential. The commercial potential of ultrafine powders are in the production of catalysts, coatings and films, conductive pastes, cosmetics, electromagnetic components, electronic devices, fire retardant materials, magnetic fluids, sintered and injection-molded parts, ceramic composites, magnetic storage media, phosphors, pigments, polishing media, and toners. Indium-tin oxide (ITO) powders are used to prepare sputtering targets for deposition of transparent films for use in flat-panel display technology. Nano-grained materials can be employed to replace various load-bearing and non-structural parts in automobiles, infrastructures, off-shore structures, piping, containers, electronic equipment housings, etc. Nano-grained cermets and ceramics are outstanding cutting tool materials. Transparent nano-grained ceramics can be utilized in a broad array of applications, including transparent ceramic appliance components, clear "glassware" and artistic artifacts. Transparent ceramics may also be used in ballistic protection armor by law enforcement, security police and armored car personnel.