SBIR-STTR Award

This Phase 1 project will result in wear-resistant nanoceramic cutting tools for use in ultraprecision machining operations. In previous research, we have discovered a method for producing fully dense, bulk ceramic materials which retain their nanoscale grain size. Characterization of these materials has demonstrated that the nanoceramics have exceptional wear resistance with an extremely fine surface finish. As an example, we have been able to produce nanograined ceramics with wear resistance that is 4x better than their micrograined counterpart. In this effort, we will apply our processing technique to produce bulk ceramic materials with grain sizes <100nm, densities >99%, and surfaces finishes below 50nm. We will then characterize these materials for their usefulness as ceramic cutting tools. We anticipate that the combination of ultrafine grain size and nearly full density will impart the required properties to this new generation of materials. In the Phase 2 effort, we will work with our partner, Tempo Technology Corp., to optimize the scale-up to produce large bulk samples and then to optimize the properties of the cutting tools for the best combination of wear resistance and toughness. The Phase 3 effort will address the manufacture and commercialization of specific nanoceramic cutting tools. COMMERCIAL APPLICATIONS: The nanoceramic cutting tools developed in this project are expected to replace diamonds in a variety of applications. In those cases where diamond interacts with the workpiece, we expect that the ceramic materials will exhibit better stability and lower reactivity. In addition, the nanoceramics are expected to exhibit many properties similar to diamond, such as cutting tool sharpness and wear resistance. Until now, there has been no suitable alternative to diamond for ultraprecision cutting operations. However, we expect that the nanoceramics will match many properties of diamond, and may actually exceed it in terms of toughness due to the retained nanograin size.

This project merges two breakthroughs in nanomaterials research to produce a new generation of materials of single phase and composite materials with an extraordinarily fine scale and uniform structure for use in high performance cutting tools. By combining Rapid Solidification Processing of metastable ceramic powders and Transformation Assisted Consolidation (TAC) of compacts, we are able for the first time to produce bulk samples that have high density while still retaining the nanoscale grain size.For single phase ceramics, we are able to produce sintered structures with grain sizes smaller than 20nm at 99+% of theoretical density. Our previous research into these materials has shown that such nano-ceramics have extraordinarily high wear resistance, low friction, and high strength.In case of ceramic composites, we were able to produce a homogeneous distribution of two or more ceramic phases, each of which retards the grain coarsening of the other and provides mechanical reinforcement. The result is a material with a grain size 10nm and that combines the advantages of composite structures with those of nanomaterials.Our goal in this project is to extend the technologies developed to data to produce ceramic nano-nanocomposites in which all the phases are nanoscale and are suitable for high performance cutting tools. These components will have properties such as toughness and wear resistance that are superior to conventional ceramics and composites whose grain sizes have m dimensions.Commercial Applications:Ceramic nano-nano-composites have wide applicability where high strength, high toughness, excellent wear resistance and high temperature capability are needed. This includes cutting tools, engine components, and heat resistant materials such as brake, valve seats, cylinder liners and so forth