Metal Carbon Composite Manufacturing

Materials with enhanced specific conductivity and strength that retain the affordability and manufacturing simplicity of baseline metals are sought to aid the development of more efficient and reliable means to transfer power. Covetic materials are metal-carbon combinations created using novel manufacturing approaches that uniquely enable higher than predicted carbon levels and the formation of nano-scaled metal/carbon phases consisting of strong metal-carbon bonds and carbon networks. These features result in enhanced electrical and thermal conductivities and increased strength, while retaining similar densities. Initial manufacturing of covetic metals has generally utilized conventional metal melting techniques with the addition of micro-scaled carbon in the presence of an electrical field. Such approaches have been limited, however, by the formation of metal oxides that result in defect formation and are detrimental to performance enhancements. Recently, researchers at Argonne National Laboratory (ANL) have developed a vacuum-based technique for covetic metal manufacture that utilizes an electron beam to melt the component materials and also provide the required electrical current to the melt. This approach facilitates high heating and cooling rates (critical to affordable production) while eliminating detrimental metal oxide formation and, thus, has significant promise for the development of bulk products that utilize covetic based metals and alloys. In this SBIR technology transfer opportunity effort, DVTI plans to utilize its existing, industrial scale electron beam melting and deposition equipment to scale and commercialize the ANL covetic metal manufacturing advances (U.S. Patent No. 10,662,509 B2 and related). This is envisioned to include the manufacture of bulk covetic metals and the application of covetic metals (via vapor deposition) onto synthetic yarns for the creation of ultra-light, enhanced strength wiring. The latter will enhance the conductive yarn products that DVTI is currently manufacturing for multiple applications. To achieve this, a Phase I collaboration with ANL is planned. In this work, ANL will initially manufacture covetic copper ingots for evaporation in DVTI’s existing conductive yarn manufacturing line. Performance enhancements (conductivity, weight, strength, solderability) for conductive yarn products will then be assessed. ANL will also consult with DVTI to enable the transfer of its covetic metal manufacture techniques to DVTI. This will allow DVTI to use its industrial scale electron beam melting equipment to manufacture bulk covetic metal ingots and explore additional applications of interest. Initial work with covetic copper would be expanded to other covetic metal/alloy systems (Al, Ag and others) during the course of the program. This work is envisioned to result in both enhancements to DVTI’s existing product line of lightweight wiring and electro-magnetic interference shielding materials as well as the development of additional products (such as power transmission cables, electrical aircraft and vehicle cables, and advanced electrodes for renewable energy devices) based on the developed capability to affordably manufacture bulk covetic metals and alloys. The result will be significant energy savings due to the use of lighter weight materials on vehicles, aircraft, and spacecraft and more efficient energy transfer for grid and renewable energy applications.