SBIR Phase I: Development of Metal-A-to-Metal-A Joint Technology for an Advanced Metal Injection Molding (MIM) Process

这个小企业创新研究（SBIR）第一阶段项目旨在开发一种新的“绿色状态”连接工艺，该工艺与用于生产高复杂性金属注射成型（MIM）部件的独特粉末注射成型原料兼容。这个项目正在探索形成一个“完美接头”的可行性。在这种情况下，完美接头被定义为无法通过微观结构、化学或其他材料性能的差异与基材区分的接头。当前金属连接方法的非均匀性，如焊接、焊接、反应键合和粘合剂连接，限制了它们在某些高性能应用中的应用，这些应用高度要求均匀性。MIM的独特之处在于，成形是在微观结构开发的单独单元操作中完成的。在正在开发的工艺中，连接将在成型后进行，但在最后的热加工步骤之前-以这样一种方式，两个接触成型零件之间的界面在微观尺度上完全消除。这个项目的商业潜力是广泛的。在商业方面，这项新技术不仅将发现高性能应用，而且将发现更普遍的应用。特别是，如果它是经济有效的，新的连接技术将经常被用来取代目前昂贵的连接方法所做的连接。这项技术有望大大降低制造此类产品的成本。广泛的应用领域是生产中空产品。该技术可用于生产涡轮发动机和超级计算机的热交换器。可以想象，廉价但高质量的中空产品可以在高重量有害的应用中取代目前的固体部件，例如航空航天。在社会方面，该项目启动了一个小型制造商和一个学术机构之间的伙伴关系；为研究生提供实践研究经验；为当地高中的少数民族学生提供研究和当地制造业的机会；加强美国的制造业基础，提供财富和就业机会。

This Small Business Innovation Research (SBIR) Phase I project aims to is develop a novel "green-state" joining process that is compatible with a unique powder injection molding feedstock used for the production of metal injection molded (MIM) parts of high complexity. This project is exploring the feasibility of forming a "perfect joint". In this context, a perfect joint is defined as one that cannot be distinguished from base material by differences in microstructure, chemistry, or other material properties. The non-homogeneity of current metal joining methods such as welding, soldering, reaction bonding, and adhesive joining limits their use in certain high performance applications in which uniform properties are highly vSalued. MIM is unique in that the shaping is done in a separate unit operation from microstructural development. In the process under development, joining will take place after shaping, but before the final thermal processing step - in such a way that the interface between two contacting molded parts is completely eliminated on a microscopic scale.The commercial potential of this project is wide-ranging. On the commercial side, this new technology will not only find high performance applications for which uniform properties are greatly valued, but also applications that are far more common. In particular, provided it is cost effective, the new joining technology will often be used to replace joints made by current expensive joining methods. This technology is expected to greatly reduce the cost of manufacturing such items. A broad area of application is in the production of hollow products. The technology could be used to produce heat exchangers for turbine engines as well as supercomputers. Inexpensively made but high quality hollow products could conceivably replace current solid parts in applications where high weight is detrimental, e.g., aerospace. On the societal side, this project initiates the partnership between a small manufacturer and an academic institution; provides practical research experience for a graduate student; exposes minority students in local high schools to opportunities in research and local manufacturing; and strengthens the manufacturing base of the U.S., providing wealth and jobs.