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限制，并允许新的陶瓷和金属粘合部件渗透到新市场。许多新的陶瓷和金属粘结部件将被制造出来，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，这些行业对它们的需求很高。这类债券的一个直接机会是冲击性凿市场。该项目的长期机遇将为刀具市场、盔甲、耐磨板、隔热材料、电子元器件和许多其他产品创造出卓越的产品。这一新功能将改变许多制造流程，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的教育经验外，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的就业机会。该项目的学术价值是利用并极大地扩展了以前工作中关于冲击连接不同金属的发现，以促进对陶瓷与金属的冲击连接以及这些连接的连接如何在经历激烈的冲击疲劳循环测试时存活或潜在退化的科学理解。虽然在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和团队寻求在金属/陶瓷界面通过使用近净形状的冲击连接进行强度和耐久性优化时进行疲劳循环测试。以前将陶瓷连接到金属上的方法仅限于铜焊和粘合剂，每种方法都受到温度和强度的限制。由于连接材料的压缩性能不同，其他连接陶瓷和金属的机械方法在冲击疲劳循环过程中根本不起作用。该项目旨在出版有关冲击粘接陶瓷和金属的开创性出版物，并将进一步增强对高速冲击粘接系统的了解。尤其令人感兴趣的是陶瓷/复合材料(如碳化钨)与淬火钢的冲击连接，因为这是直接的工业应用。

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.