US-Egypt Cooperative Research: Corrosion-Resistant Ceramic-Metal Joints Prepared by a Novel Transient Liquid Phase Method

0709664 Butt描述：该项目支持爱达荷州博伊西博伊西州立大学材料科学与工程系Darryl Butt博士与埃及赫勒万中央冶金研究发展学院Madiha Shoeib博士合作进行的合作研究。他们计划研究陶瓷-金属连接的腐蚀。一种新的瞬态液相（TLP）连接工艺由美国的一个成员开发成功地连接陶瓷。然而，陶瓷通常仅在与诸如金属的不同材料接合时才有用。本文的目的是确定新型TLP工艺在陶瓷与金属连接中的有效性。美国研究小组将在高温钙钛矿La0.9Ca0.1FeO3和各种金属合金之间制造接头，如NiAl，Hastalloy X，Inconel 625，316L不锈钢和HT-9不锈钢。他们将研究连接过程的动力学和热力学，并对接头进行机械测试和表面表征。埃及小组将进行高温腐蚀研究、晶间腐蚀研究、应力腐蚀开裂研究和接头的附加表面表征。结果将有助于确定这种方法是否可以应用于工业环境，如石油工业，汽车工业和航空航天工业。这些新型接头的开发在气体分离中具有特定的应用，更具体地，环境稳定的钙钛矿-金属接头是用于从天然气生产基于膜的合成气的使能技术。目前，在诸如离岸海岸石油平台、阿拉斯加荒野和非洲许多国家的偏远地区钻探石油期间，由于运输气体而不是液体燃料的高成本，天然气被燃烧而不是运输和使用。通过合成气和费托工艺将天然气转化为液体燃料将产生环境和经济效益。包括拥有两项钙钛矿化合物专利的Butt博士在内的几个研究小组已经证明，La0.9Ca0.1FeO3等化合物可用于有效地从空气中分离氧气，随后与天然气在催化剂上反应，产生CO和H2（合成气）。证明钙钛矿和合金之间可以产生耐用的连接，将产生一种具有显著经济效益的使能技术。智力优势：PI计划将他们开发的TLP连接工艺技术应用于陶瓷和金属的连接。他们将进行高温腐蚀、晶间腐蚀和应力腐蚀开裂研究，以及接头的表面表征。将不锈钢与陶瓷结合起来是一个有趣的突破。这项研究与该领域知识的发展有关。该提案可能导致具有潜在应用的科学进步。创新的方法可以有非常有前途的应用，为各种结构的应用，其中两种材料（陶瓷和金属）是可取的，因为这两种材料的固有和不同的属性。这项工作的影响可能有助于理解陶瓷-金属连接及其界面微观结构，力学和腐蚀行为。更广泛的影响：该项目可能会导致更好地了解TLP在关键环境中的加入行为。其结果可能会导致在各个工业领域的新的或改进的应用。美国和埃及的科学家拥有优秀和互补的资格。美国博士后研究人员和学生将参与该项目。该项目得到了美国-埃及联合基金方案的支持，该方案向两国的科学家和工程师提供赠款，以开展这些合作活动。

0709664ButtDescription: This project supports collaborative research by Dr. Darryl Butt, Materials Science and Engineering Department, Boise State University, Boise, Idaho in collaboration with Dr. Madiha Shoeib, Central Metallurgical Research & Development Institute, Helwan, Egypt. They plan to study the corrosion of ceramic-metal joining. A novel transient liquid phase (TLP) joining process developed by a member of the U.S. group has successfully joined ceramics. However, ceramics are often only useful when joined with dissimilar materials such as metals. The objective here is to determine the effectiveness of the novel TLP process in joining ceramics to metals. The U.S. group will fabricate joints between the high temperature perovskite La0.9Ca0.1FeO3 and various metal alloys such as NiAl, Hastalloy X, Inconel 625, 316L Stainless Steel, and HT-9 Stainless Steel. They will study the kinetics and thermodynamics of the joining process and perform mechanical testing and surface characterization of the joints. The Egyptian group will perform high temperature corrosion studies, intergranular corrosion studies, stress corrosion cracking studies, and additional surface characterization of the joints. The results will help determine if this method can be applied in an industrial environment such as the petroleum industry, the automotive industry, and the aerospace industry. The development of these novel joints has specific application in gas separations, more specifically environmentally stable perovskite-metal joints is an enabling technology for membrane-based syngas production from natural gas. Currently, during drilling of oil in remote areas such as off shore oil platforms, the Alaskan wilderness, and many countries in Africa, natural gas is flared rather than transported and used, due to the high cost of transporting gas rather than liquid fuels. Conversion of natural gas to liquid fuels via the syngas and Fischer-Tropsch processes would yield environmental and economic benefits. Several groups, including Dr. Butt who has two patents on perovskite compounds, have demonstrated that compounds such as La0.9Ca0.1FeO3 can be used to efficiently separate oxygen from air for subsequent reaction with natural gas over a catalyst to produce CO and H2 (syngas). Proving that durable joints can be produced between perovskites and alloys, would result in an enabling technology with significant economic benefits.Intellectual Merit: The PIs plan to apply the TLP joining process technique they have developed to join ceramics and metals. They will conduct high temperature corrosion, intergranular corrosion, and stress corrosion cracking studies, in addition to surface characterization of the joints. It is an interesting breakthrough to join stainless steel to ceramics. The research is relevant for the development of knowledge in the field. The proposal could lead to scientific progress with potential applications. The innovative approach could have very promising applications for various structural applications where the two materials (Ceramics and Metals) are desirable because of the inherent and different properties of the two materials. The impact of this proposed work may contribute to the understanding of the ceramic-metal joining and its interface microstructure, mechanical and corrosion behavior. Broader impacts: The project could lead to better understanding of TLP joining behavior in critical environments. The results could lead to new or improved applications in various industrial fields. The US and Egyptian scientists have excellent and complementary qualifications. U.S. Post doctoral researchers and students will be involved in the project. This project is being supported under the US-Egypt Joint Fund Program, which provides grants to scientists and engineers in both countries to carry out these cooperative activities.