FMSG: Eco: Integration and Recycling of High Quality Ceramics and Composites Enabled by Scalable Cold Sintering Manufacturing

冷烧结是一种新兴技术，能够在100摄氏度左右的温度下加工陶瓷和复合材料，而传统工艺通常需要在1000摄氏度左右的窑炉温度下进行更长时间的加工。这种加工过程中固有的能量减少使材料能够前所未有地整合，以创造新的复合材料。有机和无机材料的整合也为复合材料的再利用提供了独特的机会，从而通过减少废物和节约能源来提高可持续性。 在过去的十年中，美国已经在冷烧结领域建立了研究领导地位。 该项目旨在通过验证电容器所用材料的中试规模工艺，将这种领导地位扩展到制造领域。通过与美国陶瓷协会和宾夕法尼亚州技术援助计划（PennTAP）的合作，该团队将概述教育研讨会，以加速行业研究人员采用冷烧结。这些讲习班的重点是将职业学校的学生带到宾夕法尼亚州立大学进行暑期体验，可以作为一个试点模式，用于更大的努力，重点是将职业学校与研究密集型大学相结合。该项目将开发将冷烧结转化为电容器制造所需的概念验证演示。冷烧结依赖于施加的单轴压力和瞬时溶剂，以将陶瓷的烧结温度降低约一个数量级，低至约100摄氏度。这种聚合物和陶瓷共烧结的机会为合成可再加工的复合材料创造了一种方法。因此，拟议的工作将推动先进复合材料走向循环经济，通过展示可重整复合材料的合成，并通过降低再加工的能源成本。该项目的具体目标包括开发中试规模工艺，开发基于声学的表征工具，以及优化工艺条件，以确保电容器中使用的冷烧结复合材料的均匀性。过程优化的基础知识将通过现场技术获得，特别是阻抗谱，通过声学方法进行后处理无损表征，以及由机器学习支持的集成数据分析技术。优化的工艺将有利于各种应用，其中在降低的温度下烧结是有价值的，包括能量存储，结构材料，热管理和电子设备。整合研究、教育、和劳动力发展将是推进冷-该项目由工程理事会CBET部门和数学与物理科学理事会CHE部门共同资助。该奖项反映了NSF的法定使命，并通过使用基金会的智力价值和更广泛的评估被认为值得支持。影响审查标准。

Cold sintering is an emerging technology that enables processing of ceramics and composite materials at temperatures around 100 degrees Celsius, compared to traditional processes typically requiring longer times at kiln temperatures around 1000 degrees. This inherent energy reduction in processing enables unprecedented integration of materials to create new composites. The integration of organic and inorganic materials also provides a unique opportunity for the reuse of composites, thereby enhancing sustainability through both waste reduction and energy savings. The U.S. has established research leadership in cold sintering over the past decade. The project stands to extend this leadership into the manufacturing realm by validating a pilot-scale process for materials used in electrical capacitors. Through a partnership with the American Ceramic Society and the Pennsylvania Technical Assistance Program (PennTAP), the team will outline educational workshops to accelerate adoption of cold sintering by industry researchers. The workshops, focused on bringing students from vocational schools to Penn State for summer experiences, could serve as a pilot model for larger efforts focused on integrating vocational schools with research-intensive universities. The project will develop proof-of-concept demonstrations needed for translation of cold sintering to manufacturing of capacitors. Cold sintering relies on an applied uniaxial pressure and a transient solvent to reduce the sintering temperature of ceramics by approximately an order magnitude, down to about 100 degrees Celsius. This opportunity for co-sintering of polymers and ceramics creates an approach for the synthesis of re-processable composites. As such, the proposed work will drive advanced composites towards a circular economy, by demonstrating the synthesis of reformable composites, and by reducing the energy cost of re-processing. The specific goals of this project include the development of a pilot-scale process, the development of acoustic-based characterization tools, and the optimization of processing conditions to ensure uniformity of cold sintered composites used in capacitors. Foundational knowledge on process optimization will be obtained through in-situ techniques, specifically impedance spectroscopy, post-process nondestructive characterization through acoustic methods, and integrated data analytic techniques as supported by machine learning. The optimized processes will benefit a variety of applications where sintering at reduced temperatures is valuable, including energy storage, structural materials, thermal management, and electronic devices. Integration of research, education, and workforce development will be key to advancing cold-sintering research from the lab to commercial manufacturing.This project is jointly funded by the CBET Division of the Engineering Directorate and the CHE Division of the Mathematics and Physical Sciences Directorate.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.