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

这个SBIR二期项目将创造一种在分子水平上将陶瓷与金属粘合在一起的工业工艺。由于粘合材料的不协调，到目前为止，在建立坚固的粘合方面的尝试尚未成功。该项目的目标是开发一种先进的、计算机控制的自动粘接机，能够快速、安全地将网状陶瓷硬质合金以以前不可用的配置冲击连接到工具钢。自动焊接机将允许以一种经济高效的方式快速生产高质量的近净或净形状零件。随着这种简单方法的普及，预计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特性，如陶瓷的强度和耐磨性，与另一种材料的特性，如铝的轻质特性。工程师可以将更便宜、更轻、更坚固和多功能的材料部件融入到新的产品设计中。例如，许多新的陶瓷和金属结合部件可能被制造用于汽车、航空航天、化工、国防、挖掘和核工业。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。冲击粘合在粘合机中进行，并使用铝/水反应专家PI最近开发的便携式且非常强大的墨盒技术。子弹在一个低电压的封闭室中起爆，这会导致水分子的解离和铝的快速氧化，从而以安全和受控的方式产生非常高压的氢，而不使用高压、炸药或易燃火炮推进剂。本研究的关键技术课题包括冲击能量、产生的氢气推进和粘接后的冲击能量吸收。我们的目标是一种制造工艺，它将生产出具有优异连接强度的不同材料复合材料部件，这些部件将在采矿、拆除、挖掘、建筑、石油天然气钻探等恶劣环境中经受住冲击疲劳循环，以及许多更有潜力的行业。其他连接陶瓷和金属的机械方法，如铜焊和粘合剂，没有持续的冲击疲劳循环。这些卓越的产品具有耐磨性，将惠及多个行业，包括刀具市场、电气和隔热元件、防弹装甲等。该项目旨在出版关于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。该奖项反映了NSF的法定使命，并通过使用基金会的智力优势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.