SBIR Phase II: Ultra High Temperature Microwave Processing of Ceramics

这个小型企业创新研究（SBIR）二期项目旨在解决超高温（UHT）陶瓷生产中对突破性技术的需求，包括纳米颗粒结构，以提高性能与成本比。UHT陶瓷的致密化通常具有挑战性。超高温微波辅助技术（MAT）炉的发展将通过更低的温度致密化和更快的加热周期大大提高超高温陶瓷产品的商业适用性。MAT，微波与辐射热的结合，被证明可以增强扩散，导致更细粒度的微观结构。该项目将MAT的使用范围扩展到1700摄氏度以上的温度，进入UHT陶瓷的烧结温度范围。将设计和建造一个原型UHT MAT炉，利用内部MAT系统设计专业知识和第一阶段的研究成果。专有的MAT建模软件将有助于优化炉的设计和工艺效率。将研究选定的UHT陶瓷，以演示与原型的烧结。目前有三家工业UHT陶瓷制造商对使用MAT烧结产品表示了浓厚的兴趣，他们将在该项目上进行合作。该项目更广泛的影响/商业潜力包括降低加工成本的性能增强，以及超高温（UHT）陶瓷使用的增长。UHT陶瓷的广泛应用将使电子、汽车和航空航天应用中的各种制造产品受益。UHT陶瓷的烧结过程是非常耗能的。UHT微波辅助技术（MAT）加工将减少50-80%的UHT陶瓷生产的能源消耗和温室气体排放。通过将MAT与可变速率烧结等技术相结合，该工艺可以取代压力辅助法。MAT还可以减少烧结助剂的使用，以提高耐蚀性和耐磨性以及高温强度。这一更快的过程使及时生产成为可能，并增强了相对于外国竞争对手的竞争力。最后，UHT MAT炉技术将带来新的和增值的产品，通过性能改进，从更细的粒度和降低成本。这将使美国制造商获得新的收入机会和就业增长。

This Small Business Innovation Research (SBIR) Phase II project addresses the need for breakthrough technologies in the production of ultrahigh temperature (UHT) ceramics, including nanograin structures, with improved performance-to-cost ratio. UHT ceramics are often challenging to densify. The development of UHT microwave assist technology (MAT) furnaces will dramatically improve the commercial applicability of UHT ceramic products through lower temperature densification and faster heating cycles. MAT, the combination of microwaves with radiant heat, is proven to enhance diffusion, leading to finer grained microstructures. This project will extend the use of MAT to temperatures above 1700 deg. C, into the range of sintering temperatures for UHT ceramics. A prototype UHT MAT furnace will be designed and built, capitalizing upon in-house MAT system design expertise and research results from Phase I. Proprietary MAT-modeling software will assist with optimizing furnace design and process efficiency. Selected UHT ceramics will be studied to demonstrate sintering with the prototype. Three current industrial UHT ceramic manufacturers, who expressed strong interest in using MAT for sintering products, will collaborate on the project.The broader impact/commercial potential of this project includes performance enhancements at reduced processing costs, and growth in the use of ultrahigh temperature (UHT) ceramics. Expanded uptake of UHT ceramics will benefit a wide array of manufactured products in electronics, automotive, and aerospace applications. The process of sintering UHT ceramics is extremely energy-intensive. UHT microwave-assist technology (MAT) processing will reduce energy consumption and green house gas emissions by 50-80% for UHT ceramic production. This process may replace pressure-assisted methods, by combining MAT with techniques such as variable rate sintering. MAT may also decrease the use of sintering aids to improve erosion and wear resistance, and high-temperature strength. This faster process enables just-in-time manufacture and enhances competition with respect to foreign competitors. Finally, the UHT MAT furnace technology will lead to new and value-added products, through property improvements from finer grain sizes and cost reduction. This will position American manufacturers for new revenue opportunities and job growth.