Dynamic Magnetic Consolidation (DMC) Process for Fabricating Advanced Nanostructured Components from Nano Powders

This SBIR project of Phase I proposes to develop and advance a process technology called Dynamic Magnetic Compaction (DMC). This technology will be useful for fabricating nanostructured components of various material systems such as ceramics, metals, high temperature alloys, and composites from their respective nano powders. The fabrication of nano components from nano powders requires the consolidation technique that can transfer high energy in a fast manner without sacrificing nano grain size. The proposed DMC consolidation technology has the capability to achieve this. The DMC process can be scaled for the production scale. Our preliminary cost and feasibility estimates of commercial systems indicate that transition from lab to commercial systems will be reliable and economical. This project will create a new world class, high rate production process - DMC, that will have impact on key U.S. industries. In Phase I, for a feasibility demonstration, nano ceramic powders of SI3N4 and wear material powders of tungsten carbides will be consolidated into 0.5" diameter and 2" long rods. The components will be tested for their nano properties such as grain size, strength, hardness, and other relevant characteristics.