SBIR Phase I: Impact Bonding of Near Net-Shaped Ceramics to Metals Driven by Hydrogen Produced from Rapid Oxidation of Aluminum

这个小企业创新研究（SBIR）第一阶段项目的更广泛的影响/商业潜力是，它消除了以前用于连接陶瓷和金属的方法的限制，并允许新的陶瓷和金属粘合部件渗透到新的市场。许多新的陶瓷和金属粘合部件将用于汽车、航空航天、化学、国防、挖掘和核工业，由于两种材料的良好性能，它们的需求量很大。这种债券的一个直接机会是冲击凿子市场。该项目的长期机遇将为刀具市场、装甲、耐磨板、隔热材料、电气元件和许多其他产品创造优质产品。这种新功能将改变许多制造工艺，并为工程师提供更多的设计可能性。除了帮助参与零件测试的大学生获得教育经验外，该项目最终将为陶瓷和金属粘合零件的大规模生产创造美国制造业就业机会。该项目的智力价值在于利用并极大地扩展了先前工作中对不同金属碰撞结合的发现，以推进对陶瓷如何与金属碰撞结合以及这些结合接头如何在剧烈冲击疲劳循环测试中存活或潜在退化的科学理解。虽然通过其他方法形成接头时已经记录了金属/陶瓷界面的疲劳循环测试，但PI和团队寻求通过使用近网形冲击粘结来优化金属/陶瓷界面的强度和耐久性时进行疲劳循环测试。以前将陶瓷附着在金属上的方法仅限于钎焊和粘合剂，每种方法都受温度和强度的限制。由于连接材料的不同压缩性能，其他连接陶瓷和金属的机械方法在冲击疲劳循环中根本不起作用。该项目旨在出版关于冲击粘合陶瓷和金属的开创性出版物，并将进一步提高对高速冲击粘合系统的了解。特别令人感兴趣的是陶瓷/复合材料（如碳化钨）与硬化钢的冲击粘合，因为它具有直接的工业应用。

The broader impact/commercial potential of this Small Business Innovation Research (SBIR) Phase I project is that it removes the limitations of the previous methods used to join ceramics and metals and allows for new ceramic and metal bonded parts to infiltrate novel markets. Many new ceramic and metal bonded parts will be fabricated for the automotive, aerospace, chemical, defense, excavation and nuclear industries where they are in high demand due to the favorable properties of both materials being joined. One immediate opportunity for this type of bond is the impact chisel market. Long term opportunities from this project will result in superior products being created for the cutting tool market, armor, wear plates, thermal insulation, electrical components, and many others. This new capability will change many manufacturing processes and allow engineers more design possibilities. In addition to aiding the educational experience of university students involved in part testing, this project will ultimately result in the creation of U.S. manufacturing jobs for the mass production of ceramic and metal bonded parts. The intellectual merit of this project is to utilize and greatly expand upon the findings of impact bonding dissimilar metals from previous bodies of work to advance the scientific understanding of how ceramics impact bond to metals and how these bonded joints survive or potentially degrade when undergoing intense impact fatigue cycle testing. Although fatigue cycle testing on metal/ceramic interfaces has been documented when the joint is formed through other methods, the PI and team seek to perform fatigue cycle testing when metal/ceramic interfaces are optimized for strength and durability by the use of near net-shaped impact bonding. Previous methods of attaching ceramics to metals have been limited to brazing and adhesives, each of which is limited by temperature and strength. Other mechanical methods of joining ceramics and metals will simply not hold up during impact fatigue cycling due to the different compression properties of the joined materials. This project aims to produce pioneering publications on impact bonding ceramics and metals and will also further enhance the knowledge of high velocity impact bonding systems. Of particular interest is the impact bonding of ceramics/composites such as tungsten carbide to hardened steel because of immediate industrial applications.