SBIR Phase II: Ultra High Temperature Microwave Processing of Ceramics

这个小型企业创新研究（SBIR）第二阶段项目解决了生产超高温（UHT）陶瓷的突破性技术的需求，包括纳米颗粒结构，提高了性能与成本比。UHT陶瓷的致密化通常具有挑战性。 UHT微波辅助技术（MAT）炉的发展将通过更低的温度致密化和更快的加热周期大大提高UHT陶瓷产品的商业适用性。 MAT是微波与辐射热的结合，被证明可以增强扩散，从而获得更细的晶粒显微结构。该项目将把MAT的使用范围扩大到1700度以上的温度。进入UHT陶瓷的烧结温度范围。 一个原型UHT MAT炉将设计和建造，利用内部MAT系统设计专业知识和研究成果，从第一阶段。 专有的MAT建模软件将有助于优化熔炉设计和工艺效率。选定的超高温陶瓷将进行研究，以证明烧结与原型。 目前有三家工业UHT陶瓷制造商表示对使用MAT烧结产品有浓厚的兴趣，他们将在该项目上进行合作。该项目更广泛的影响/商业潜力包括在降低加工成本的情况下提高性能，以及增加超高温（UHT）陶瓷的使用。UHT陶瓷的扩大吸收将有利于电子，汽车和航空航天应用中的各种制造产品。 烧结UHT陶瓷的过程是非常耗能的。 UHT微波辅助技术（MAT）加工将使UHT陶瓷生产的能耗和绿色气体排放减少50-80%。通过将MAT与诸如可变速率烧结的技术相结合，该工艺可以取代压力辅助方法。 MAT还可以减少烧结助剂的使用，以提高耐腐蚀性和耐磨性以及高温强度。这一更快的过程使及时制造成为可能，并加强了与外国竞争者的竞争。最后，UHT MAT炉技术将导致新的和增值的产品，通过性能改善，从更细的晶粒尺寸和降低成本。这将使美国制造商获得新的收入机会和就业增长。

This Small Business Innovation Research (SBIR) Phase II project addresses the need for breakthrough technologies in the production of ultrahigh temperature (UHT) ceramics, including nanograin structures, with improved performance-to-cost ratio. UHT ceramics are often challenging to densify. The development of UHT microwave assist technology (MAT) furnaces will dramatically improve the commercial applicability of UHT ceramic products through lower temperature densification and faster heating cycles. MAT, the combination of microwaves with radiant heat, is proven to enhance diffusion, leading to finer grained microstructures. This project will extend the use of MAT to temperatures above 1700 deg. C, into the range of sintering temperatures for UHT ceramics. A prototype UHT MAT furnace will be designed and built, capitalizing upon in-house MAT system design expertise and research results from Phase I. Proprietary MAT-modeling software will assist with optimizing furnace design and process efficiency. Selected UHT ceramics will be studied to demonstrate sintering with the prototype. Three current industrial UHT ceramic manufacturers, who expressed strong interest in using MAT for sintering products, will collaborate on the project.The broader impact/commercial potential of this project includes performance enhancements at reduced processing costs, and growth in the use of ultrahigh temperature (UHT) ceramics. Expanded uptake of UHT ceramics will benefit a wide array of manufactured products in electronics, automotive, and aerospace applications. The process of sintering UHT ceramics is extremely energy-intensive. UHT microwave-assist technology (MAT) processing will reduce energy consumption and green house gas emissions by 50-80% for UHT ceramic production. This process may replace pressure-assisted methods, by combining MAT with techniques such as variable rate sintering. MAT may also decrease the use of sintering aids to improve erosion and wear resistance, and high-temperature strength. This faster process enables just-in-time manufacture and enhances competition with respect to foreign competitors. Finally, the UHT MAT furnace technology will lead to new and value-added products, through property improvements from finer grain sizes and cost reduction. This will position American manufacturers for new revenue opportunities and job growth.