Ultrapure, Spherical, Monodisperse, Unagglomerated Nanopowders for Infrared Window Materials

The objective of this Small Business Innovation Research Phase I project is to develop a novel process for fabricating nanocrystalline ceramic powders for infrared windows. Nano-grained ceramic materials are expected to have sufficient mechanicalproperties to operate efficiently under the harsh operational environments experienced by infrared window materials on aircraft and missiles. In our proposed work, we will use an innovative method to fabricate nanocrystalline yttria powders for infraredwindow materials.High quality nano-yttria powder will be synthesized using a chemical precipitation route. The precipitate will undergo a series of agglomerate-reduction steps to yield a high purity, monodisperse, agglomerate-free powder. A very low temperaturecrystallization process is proposed instead of a conventional solid-state calcination step. This low temperature step is the key to obtaining agglomerate-free powder with final particle size of less than 25 nm. A narrow particle size distribution and highpurity are some of the other benefits of the proposed process. Successful completion of Phases I and II of the proposed project will result in an alternate synthesis method for manufacturing nano-powders for infrared windows and other advanced ceramic applications.The market for nano-ceramic powders is projected to reach $156 million by 2003. When this exploding market opportunity is coupled with the defense (industry and government) and commercial market needs for more durable infrared materials, a significantcommercial opportunity for these products is expected to develop in the near future.There are three distinct components to our commercialization strategy: (1) fabrication of nano-powders for Government agencies, (2) fabrication of nano-powders for captive use and for sale to other manufacturers, and (3) fabrication of near net shape endproducts using nano-powders.