SBIR Phase II: Magnetohydrodynamic Formation of Metal Monospheres

NSF小企业创新研究第二阶段项目继续研究和开发一种商业工艺，用于制造单尺寸分散的球形粉末（尺寸为1-10微米），这些粉末来自熔化温度高达200℃的金属。将设计、制造和开发一种独特的磁流体动力学（MHD）射流激振器，作为生产高公差单球粉末必不可少的系统组成部分（例如，电子工业对表面贴装组件的球栅阵列的要求）。防止滴云聚结的静电方法有待进一步发展。完成凝固冷却装置的研制。具体的行业质量控制标准和测试将适用于合格的单球产品。最后，对制造成本进行精细分析，并制定完整的商业计划。该项目的预期结果是为商业大规模生产单球体提供技术基础。这种独特的工艺创新用于大规模生产单球，将为电子焊锡球和膏体、粉末冶金、复合材料、磁流变流体、催化剂载体、固/流体反应和众多其他用途提供精确和经济的粉末的主要新来源。

This NSF Small Business Innovation Research Phase II project continues research and development of a commercial process for the manufacture of mono-size-dispersed, spherical powder (size 1-10 micron) from metals melting up to 200C. A unique magnetohydrodynamic (MHD) jet exciter will be designed, fabricated and developed as a component of the system essential to producing monosphere powder to high tolerances (e.g., as demanded by the electronics industry of ball grid arrays for surface-mount components). The electrostatic means, for preventing coalescence in the drop cloud, will be developed further. Development of cooling means for solidification will be completed. Specific industry quality control standards and testing will be applied to qualify the monosphere product. Finally, a refined analysis of cost of manufacture, and a complete business plan will be produced. The outcome expected from this project is the technology base for the commercial, large-scale production of monospheres. This unique process innovation for large-scale production of monospheres, will provide a major new source of precise and economical powder for electronic solder balls and paste, powder metallurgy, composites, magnetorheological fluids, catalyst carriers, solid/fluid reactions and a multitude of other uses.