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

SBIR第二阶段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。迄今为止的尝试由于被结合的材料的不一致性而没有成功地产生牢固的结合。该项目的目标是开发一种先进的，计算机控制的，自动化的键合机，将快速，安全地冲击键合网状陶瓷碳化物的工具钢的配置，以前没有。自动焊接机将允许以具有成本效益的方式快速生产高质量的近净或净形部件。预计随着这种简单方法的普及，设计配置的新机会将在多个行业中实现;由于单个部件可以利用多种材料的特性，例如陶瓷的强度和耐磨性，以及另一种材料的特性，例如铝的轻质特性。工程师可能会将更便宜，更轻，更强，多用途的材料部件纳入新产品设计。例如，许多新的陶瓷和金属结合的部件可以被制造用于汽车、航空航天、化学、国防、挖掘和核工业。随着陶瓷和金属结合部件的大规模生产进入商业化市场，该项目最终将在美国创造制造、销售和工程方面的就业机会。冲击结合发生在结合机内，并使用由铝/水反应专家PI最近开发的便携式和非常强大的盒技术。弹药筒在一个封闭的低压室中启动，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气，而无需使用高压、爆炸物或易燃的枪支推进剂。本研究的关键技术课题包括撞击能量、产生氢推进和键合后撞击能量吸收。目标是生产具有上级接合强度的异种材料复合材料部件的制造工艺，该异种材料复合材料部件将在诸如采矿、拆除、挖掘、建筑、石油天然气钻探和许多更多潜在行业的恶劣环境中经受住冲击疲劳循环。连接陶瓷和金属的其他机械方法，如钎焊和粘合剂，不能承受冲击疲劳循环。这些上级产品具有耐磨性，将使多个行业受益，包括切割工具市场、电气和隔热部件、防弹装甲等。该项目旨在出版有关陶瓷和金属冲击连接的开创性出版物，并进一步提高对高速冲击连接系统的认识。该奖项反映了NSF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.