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

该小型企业创新研究 (SBIR) 第一阶段项目的更广泛影响/商业潜力在于，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粘合部件渗透到新市场。 许多新型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，这些部件的需求量很大。 此类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切削工具市场、装甲、耐磨板、隔热材料、电气元件等创造优质产品。这项新功能将改变许多制造工艺，并为工程师提供更多设计可能性。 除了帮助参与零件测试的大学生获得教育经验外，该项目最终还将为美国创造大规模生产陶瓷和金属粘合零件的制造业就业机会。 该项目的智力价值在于利用并极大地扩展了先前工作中冲击粘合异种金属的发现，以促进对陶瓷如何冲击粘合到金属以及这些粘合接头在经历强烈冲击疲劳循环测试时如何生存或潜在退化的科学理解。尽管已经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 和团队寻求在通过使用近净形冲击粘合来优化金属/陶瓷界面的强度和耐用性时执行疲劳循环测试。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。由于连接材料的压缩特性不同，连接陶瓷和金属的其他机械方法在冲击疲劳循环过程中根本无法维持。该项目旨在出版有关冲击粘合陶瓷和金属的开创性出版物，并将进一步增强高速冲击粘合系统的知识。由于直接的工业应用，特别令人感兴趣的是陶瓷/复合材料（例如碳化钨）与硬化钢的冲击粘合。

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.