SBIR Phase I: Development of Metal-A-to-Metal-A Joint Technology for an Advanced Metal Injection Molding (MIM) Process

该小型企业创新研究（SBIR）第一阶段项目旨在开发一种新型的“绿色状态”连接工艺，该工艺与用于生产高度复杂的金属注射成型（MIM）零件的独特粉末注射成型原料兼容。该项目正在探索形成“完美联合”的可行性。在这种情况下，完美的接头被定义为不能通过微观结构、化学或其他材料特性的差异与基材区分开的接头。目前的金属连接方法如焊接、钎焊、反应粘结和粘合剂连接的非均匀性限制了它们在某些高性能应用中的使用，在这些高性能应用中，均匀的性能是非常重要的。MIM的独特之处在于，成形是在与微观结构开发分开的单元操作中完成的。在正在开发的工艺中，连接将在成型之后，但在最终的热处理步骤之前进行-以这样的方式，两个接触的成型部件之间的界面在微观尺度上完全消除。该项目的商业潜力是广泛的。在商业方面，这项新技术不仅可以找到高性能的应用，其中均匀的性能非常重要，而且还可以找到更常见的应用。特别是，如果它是成本有效的，新的连接技术将经常被用来取代由当前昂贵的连接方法制成的接头。预计这项技术将大大降低制造此类物品的成本。一个广泛的应用领域是中空产品的生产。该技术可用于生产涡轮机发动机以及超级计算机的热交换器。制造成本低但质量高的中空产品可以替代目前的实心零件，用于高重量有害的应用，例如，航空和航天.在社会方面，该项目启动了小型制造商和学术机构之间的伙伴关系;为研究生提供实际研究经验;使当地高中的少数民族学生有机会从事研究和当地制造;并加强美国的制造业基础，提供财富和就业机会。

This Small Business Innovation Research (SBIR) Phase I project aims to is develop a novel "green-state" joining process that is compatible with a unique powder injection molding feedstock used for the production of metal injection molded (MIM) parts of high complexity. This project is exploring the feasibility of forming a "perfect joint". In this context, a perfect joint is defined as one that cannot be distinguished from base material by differences in microstructure, chemistry, or other material properties. The non-homogeneity of current metal joining methods such as welding, soldering, reaction bonding, and adhesive joining limits their use in certain high performance applications in which uniform properties are highly vSalued. MIM is unique in that the shaping is done in a separate unit operation from microstructural development. In the process under development, joining will take place after shaping, but before the final thermal processing step - in such a way that the interface between two contacting molded parts is completely eliminated on a microscopic scale.The commercial potential of this project is wide-ranging. On the commercial side, this new technology will not only find high performance applications for which uniform properties are greatly valued, but also applications that are far more common. In particular, provided it is cost effective, the new joining technology will often be used to replace joints made by current expensive joining methods. This technology is expected to greatly reduce the cost of manufacturing such items. A broad area of application is in the production of hollow products. The technology could be used to produce heat exchangers for turbine engines as well as supercomputers. Inexpensively made but high quality hollow products could conceivably replace current solid parts in applications where high weight is detrimental, e.g., aerospace. On the societal side, this project initiates the partnership between a small manufacturer and an academic institution; provides practical research experience for a graduate student; exposes minority students in local high schools to opportunities in research and local manufacturing; and strengthens the manufacturing base of the U.S., providing wealth and jobs.