High Performance Laboratory-Scale Gas Atomizer for Materials and Coatings Research
Abstract
This DURIP proposal from Tennessee Technological University (TTU) seeks to acquire a high performance laboratory-scale gas atomizer for fabrication of high-quality metallic powders with unique compositions and characteristics that are not commercially available. The multiconfigurable melt chamber permits processing of a very broad range of metal/alloy systems from a single atomizer platform, which is significantly different from any atomization systemscurrently available for research and development in the US. The refractory lined induction furnace offers melting temperatures up to 1700~C, while the cold crucible or non-contact furnace via plasma/arc allows melting and atomizing of reactive materials like titanium alloys and refractory metals with extremely high melting temperatures (such as tungsten, >3400~C).Gas atomization is the leading manufacturing process for production of high-grade metallic powders that can meet specific quality criteria such as spherical shape, closely-controlled chemical composition, high purity, and homogeneous microstructure. However, there are still numerous challenges remaining in this field, such as lack of understanding of key processing variables in controlling atomized powder quality and lack of cost-efficient atomization methods for production of fine powders (<10 ~m). Our goal is to address some of the challenges with the addition of the new atomizing equipment, focusing on: (1) understanding key processing variables that control atomized powder size and distribution using a Design-of-Experiment (DoE) approach, (2) developing a hybrid atomization process for making fine metallic powders, (3) establishing an atomization user facility for collaborative research, and (4) launching an atomization workforce training program.The requested equipment will provide a great impact for several DoD applications including the current coating development program supported by the Office of Naval Research (ONR) where the PI at TTU is working to design and synthesize higher-performing metallic coatings for shipboard gas turbine engines for current and future Navy ships. A novel cost-effective electrocodeposition process is employed in the coating development, which requires custom-made multi-element alloy powders with special characteristics for achieving the desired coating quality and performance. The equipment will also significantly impact other research activities at TTU relevant to DoD areas of interest, such as solid oxide fuel cells (SOFC) and metal additive manufacturing. The plan of establishing a new atomization user facility will also promoteresearch collaboration between TTU and other universities; initial collaborators from Purdue University and Tennessee State University have been identified. The proposed research equipment will further help to establish TTU as a regional frontrunner in advanced materials and manufacturing research with broader impacts extending from undergraduate/graduate education(including atomization workforce training) to regional K-12 STEM communities.
Document Details
- Document Type
- DoD Grant Award
- Publication Date
- Aug 20, 2019
- Source ID
- N000141912538
Entities
People
- Ying Zhang
Organizations
- Office of Naval Research
- Tennessee Technological University
- United States Navy