SBIR Phase II: Microwave Heating of Reaction-Bonded Silicon Carbide Ceramics

这个小型企业创新研究（SBIR）二期项目为反应结合碳化硅（RBSC）提供了一种创新的低成本方法。RBSC是机械密封的首选材料，在许多主要的生产线上，机械密封是关键的、昂贵的部件。RBSC的高成本限制了它的使用，有利于更便宜、寿命更短的材料。微波加热工艺，结合较低成本的原材料，解决了RBSC成本问题。第一阶段的研究确定了生产RBSC的工艺范围，其弯曲强度高于行业平均水平。第二阶段的研究将产生可靠的高强度RBSC。第二阶段的关键目标是优化全碳预成形和微波渗透方法，以制造用于工业评估的原型机械密封。新的RBSC将根据机械密封行业批准规范进行特征描述。将研究包括3D打印在内的创新成型工艺，以快速形成复杂的、定制的、近净的渗透预制件。预期的结果是一种商用、轻量化、高强度的RBSC，将是现有和新应用的首选。该项目更广泛的影响/商业潜力将包括显著降低耐磨应用的成本。低成本、高性能的机械密封将提高效率，减少因泵故障而导致的停产成本。RBSC提供比碳化钨、石墨或氧化铝部件更长的整体寿命，进一步降低了生命周期成本。机械密封的平均成本为每英寸750美元，直径可达15英寸。这项研究将使RBSC成本降低50%，开发出可行的高性能产品，并满足市场需求。最近主要碳化硅供应商的整合提供了一个开放的市场，以支持一个新的，独立的RBSC来源。RBSC工艺采用更环保的微波工艺，时间、能源和温室气体减少了50%至80%。微波RBSC产品的商业示范将提供必要的推动力，鼓励其他制造商采用更清洁、更有效的微波处理。该项目还通过高中项目和至少四名本科工程合作学生支持科学技术工程数学（STEM）教育。

This Small Business Innovation Research (SBIR) Phase II project enables an innovative low cost approach to reaction bonded silicon carbide (RBSC). RBSC is a preferred material for mechanical seals, which are critical, costly components in many major manufacturing lines. The high cost of RBSC limits its use in favor of cheaper, shorter lived materials. A microwave heating process, combined with lower cost raw materials addresses RBSC cost issues. Phase I research identified a process range for producing RBSC with flexural strength above the industry average. The Phase II research will yield reliably high strength RBSC. The key objective for Phase II is optimization of all-carbon preform formation, and microwave infiltration methods, to fabricate prototype mechanical seals for industrial evaluation. The new RBSC will be characterized according to mechanical seal industry approval specifications. Innovative forming processes including 3D printing will be studied for the ability to quickly form complex, custom, near net preforms for infiltration. The anticipated result is a commercially ready, lightweight, high strength RBSC that will be preferred for existing and new applications.The broader impact/commercial potential of this project will include significant cost reductions for wear resistant applications. A low-cost, superior performance mechanical seal will improve efficiency, with fewer costly production shut-downs due to pump failures. RBSC provides a longer overall lifetime than tungsten carbide, graphite, or alumina parts, further reducing life cycle costs. Mechanical seals cost on average $750 per inch of diameter, ranging up to 15" across. This research will enable a 50% reduction in RBSC cost, developing a viable, high performance product, along with market demand. Recent consolidation of major silicon carbide suppliers provides an opening in the market to support a new, independent RBSC source. The RBSC process uses a greener microwave process, with time, energy and greenhouse gas reductions of 50 to 80%. The commercial demonstration of microwave RBSC product will provide a needed boost to encourage other manufacturers to uptake cleaner, efficient microwave processing. The project also supports Science Technology Engineering Mathematics (STEM) education through high school projects and at least four undergraduate engineering co-op students.