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

这个小型企业创新研究（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局限性，并允许新的陶瓷和金属结合部件渗透到新市场。 许多新的陶瓷和金属结合部件将被制造用于汽车，航空航天，化工，国防，挖掘和核工业，由于这两种材料的良好性能，它们的需求量很大。 这类债券的一个直接机会是冲击凿市场。 从这个项目的长期机会将导致上级产品正在创建的切割工具市场，装甲，耐磨板，隔热，电气元件，和许多其他。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，该项目最终还将为陶瓷和金属结合零件的大规模生产创造美国制造业就业机会。 该项目的智力价值是利用并大大扩展了以前工作机构中的冲击结合异种金属的研究结果，以促进对陶瓷如何冲击结合到金属以及这些结合接头在经历强烈冲击疲劳循环测试时如何生存或潜在降解的科学理解。尽管已记录了通过其他方法形成接头时对金属/陶瓷界面进行的疲劳循环测试，但PI和团队试图在金属/陶瓷界面通过使用近净形冲击结合优化强度和耐久性时进行疲劳循环测试。以前将陶瓷附着到金属上的方法仅限于钎焊和粘合剂，每种方法都受到温度和强度的限制。由于连接材料的不同压缩性能，连接陶瓷和金属的其他机械方法在冲击疲劳循环期间将根本不起作用。该项目旨在出版有关陶瓷和金属冲击键合的开创性出版物，并将进一步提高对高速冲击键合系统的认识。由于直接的工业应用，特别感兴趣的是陶瓷/复合材料如碳化钨与硬化钢的冲击结合。

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.