This Small Business Innovation Research (SBIR) Phase I project will develop zirconium di-bromide (ZrB2)/copper (Cu) electrodes for applications in (1) plasma spray coaters, (2) arc-jet plasma reactors, and (3) electrical discharge machining (EDM) electrodes. This material suffers little or no erosion from plasma arcs and sparks, which is a major problem in continuous operation of these commercial machines. These electrodes wear about 10-20 times less than traditional copper or graphite electrodes. Phase I will study the process variables of ZrB2 particle size, fraction of copper, and molten copper impregnation temperature in order to maximize useable electrode lifetime for each application. Electrodes will be prepared using selective layer sintering (SLS), a rapid prototyping technique. The technology is environmentally important in that arc-jet reactors are leading contenders for remediation processes for municipal waste, hospital waste, nuclear waste, waste lube oil recycling, aluminum recycling, and tire recycling. Further, ZrB2/Cu electrodes are less toxic than copper or graphite electrodes and also contaminate less due to a low erosion rate. These electrodes are expected to find extensive commercial applications.
