SBIR Phase II: Magnetohydrodynamic Formation of Metal Monospheres

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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.