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Microwave Sintering, Bonding, and Assembly of Metal and Ceramic Parts

Y-12 National Security Complex

Contact Y12 About This Technology

Publications:

PDF Document PublicationMicrowave Sintering Pages.pdf (395 KB)


Technology Marketing Summary

Microwave Sintering, Bondingand Assembly is a manufacturing technology that creates complex metal and cermet composite components using minimal equipment. Employing either powder-printing or powder-pressing processes, parts are made andsintered to approximately 60% density. These parts are assembled, and the resulting assembly is infiltrated with molten metal to bond the parts and create a solid metal/cermet or cermet/cermet composite component.

Description

The technology is versatile because the subparts can have different physical/chemical/material properties; it is flexible in that the designer can incorporate subparts blind voids, complex bends/tubes/traces and the technology remains simple: the manufacturer needs only a few small pieces of equipment, computer design files, and a selection of raw materials.

Benefits
  • Decreased manufacturing time and expense —Cutting, grinding and wear surfaces can be incorporated into components.
  • Minimal post-process machining — Complex component is ready for use once assembled.
  • Nearly limitless possible combinations of mechanical and thermal properties — Components can be designed to meet specific strength and temperature requirements.
  • Decreased need to warehouse critical components — Assemblies can be created quickly and as needed.
  • Reduced costs — Prototyping and field verification of design concepts are accomplished with minimal investment.
Applications and Industries
  • Armor and ballistic protection systems
  • Fins and nosecones for supersonic projectiles (leading edges)
  • Propulsors
  • Multi-material part manufacturing
  • Prototyping
  • Engine blocks
More Information

TRL 3: Analytical and experimental critical function and/or characteristic proof of concept.

Patents and Patent Applications
ID Number
Title and Abstract
Primary Lab
Date
Patent 7,857,193
Patent
7,857,193
Method of forming and assembly of parts
A method of assembling two or more parts together that may be metal, ceramic, metal and ceramic parts, or parts that have different CTE. Individual parts are formed and sintered from particles that leave a network of interconnecting porosity in each sintered part. The separate parts are assembled together and then a fill material is infiltrated into the assembled, sintered parts using a method such as capillary action, gravity, and/or pressure. The assembly is then cured to yield a bonded and fully or near-fully dense part that has the desired physical and mechanical properties for the part's intended purpose. Structural strength may be added to the parts by the inclusion of fibrous materials.
Y-12 National Security Complex 12/28/2010
Issued
Patent 8,061,580
Patent
8,061,580
Method of forming and assembly of metal parts and ceramic parts
A method of forming and assembling at least two parts together that may be metal, ceramic, or a combination of metal and ceramic parts. Such parts may have different CTE. Individual parts that are formed and sintered from particles leave a network of interconnecting porosity in each sintered part. The separate parts are assembled together and then a fill material is infiltrated into the assembled parts using a method such as capillary action, gravity, and/or pressure. The assembly is then cured to yield a bonded and fully or near-fully dense part that has the desired physical and mechanical properties for the part's intended purpose. Structural strength may be added to the parts by the inclusion of fibrous materials.
Y-12 National Security Complex 11/22/2011
Issued
Patent 8,701,970
Patent
8,701,970
Method of forming and assembly of metal and ceramic parts
A method of forming and assembling at least two parts together that may be metal, ceramic, or a combination of metal and ceramic parts. Such parts may have different CTE. Individual parts that are formed and sintered from particles leave a network of interconnecting porosity in each sintered part. The separate parts are assembled together and then a fill material is infiltrated into the assembled parts using a method such as capillary action, gravity, and/or pressure. The assembly is then cured to yield a bonded and fully or near-fully dense part that has the desired physical and mechanical properties for the part's intended purpose. Structural strength may be added to the parts by the inclusion of fibrous materials.
Y-12 National Security Complex 04/22/2014
Issued
Technology Status
Development StageAvailabilityPublishedLast Updated
ProposedAvailable04/17/201704/17/2017

Contact Y12 About This Technology

To: <otcp@cns.doe.gov>