SBIR Phase II: Magnetohydrodynamic Formation of Metal Monospheres

这个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，用于从熔融温度高达200 ℃的金属中制造单尺寸分散的球形粉末（尺寸1-10微米）。 将设计、制造和开发一种独特的磁流体动力学（MHD）射流激励器，作为生产高公差单球粉末（例如，如用于表面安装元件的球栅阵列的电子工业所要求的）。静电手段，以防止在滴云聚结，将进一步发展。将完成凝固冷却方法的开发。将应用特定的行业质量控制标准和测试来鉴定单球产品。最后，一个精细的制造成本分析，和一个完整的商业计划将产生。该项目的预期成果是为商业化、大规模生产单微球奠定技术基础。 这一独特的工艺创新用于大规模生产单球体，将为电子焊球和焊膏、粉末冶金、复合材料、磁流变液、催化剂载体、固/液反应和许多其他用途提供一个重要的新的精确和经济的粉末来源。

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.