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

这个SBIR二期项目将创建一个在分子水平上将陶瓷与金属结合的工业过程。到目前为止，由于被粘合的材料不协调，在创建坚固的键方面的尝试还没有成功。该项目的目标是开发一种复杂的、计算机控制的、自动化的粘接机，它将快速、安全地将网形陶瓷碳化物粘接到工具钢上，这是以前无法实现的。自动粘接机将允许以经济有效的方式快速生产高质量的近网或网形零件。预计随着这种简单方法的推广，将在多个行业实现新的设计配置机会；由于单个部件可以利用多种材料的性能，如陶瓷的强度和耐磨性，具有另一种材料的性能，如铝的轻质性能。工程师们可以将更便宜、更轻、更坚固和多用途的材料部件纳入新产品设计中。例如，许多新的陶瓷和金属粘合部件可以为汽车、航空航天、化学、国防、挖掘和核工业制造。随着陶瓷和金属粘合部件的大规模生产商业化，该项目最终将在美国创造制造、销售和工程工作岗位。冲击粘接是在粘接机内进行的，使用的是由PI（铝/水反应专家）最近开发的便携且功能强大的墨盒技术。弹药筒在一个封闭的低电压室中启动，这导致水分子的解离和铝的快速氧化，在安全可控的方式下产生非常高压的氢，而不使用高压，炸药或易燃的枪推进剂。本研究的关键技术课题包括冲击能、生成氢推进和键后冲击能吸收。目标是制造一种制造工艺，可以生产出具有卓越连接强度的不同材料复合部件，这些部件可以在采矿、拆除、挖掘、建筑、石油天然气钻探以及许多其他潜在行业等恶劣环境中承受冲击疲劳循环。其他连接陶瓷和金属的机械方法，如钎焊和粘合剂，没有持续的冲击疲劳循环。卓越的产品是耐磨的，并将受益于几个行业，包括切削工具市场，电气和隔热组件，弹道装甲等。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。该奖项反映了美国国家科学基金会的法定使命，并通过使用基金会的知识价值和更广泛的影响审查标准进行评估，被认为值得支持。

This SBIR Phase II project will create an industrial process for bonding ceramics to metals at the molecular level. Attempts thus far have not been successful in creating robust bonds due to incongruities of the materials being bonded. The objective of this project is to develop a sophisticated, computer controlled, automated bonding machine that will rapidly and safely impact-bond net-shaped ceramic carbides to tool steel in configurations that were previously not available. An automated bonding machine will allow for a cost-effective way to rapidly produce high quality near-net or net-shaped parts. It is expected that as this simple method is popularized, new opportunities for design configurations will be realized in multiple industries; as single parts can take advantage of the properties multiple material, such as the strength and wear resistance of ceramics, with the properties of another, such as the light weight properties of aluminum. Engineers may incorporate cheaper, lighter, stronger, and multipurpose material parts into new product designs. For instance, many new ceramic and metal bonded parts may be fabricated for the automotive, aerospace, chemical, defense, excavation, and nuclear industries. This project will ultimately result in the creation of U.S. manufacturing, sales, and engineering jobs as the mass production of ceramic and metal bonded parts become commercially available.The impact-bonding occurs within a bonding machine and uses a portable and very powerful cartridge technology recently developed by the PI, an expert in aluminum/water reactions. The cartridges are initiated in an enclosed chamber with a low voltage, which causes the disassociation of water molecules and rapid oxidization of aluminum that generates very high-pressure hydrogen in a safe and controlled manner and without the use of high voltage, explosives or flammable gun propellants. Key technological subjects of this research include the impact-energy, generated hydrogen propulsion, and the post-bond impact-energy absorption. The goal is a manufacturing process that will produce dissimilar material composite parts with superior joint strength that will survive impact-fatigue-cycles in harsh environments such as mining, demolition, excavation, construction, oil gas drilling, and many more potential industries. Other mechanical methods of joining ceramics and metals, such as brazing and adhesives, have not sustained impact fatigue cycling. The superior products are wear resistant and will benefit several industries to include the cutting tool market, electrical and thermally insulated components, ballistic armor, and others. 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.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.