Date: Apr 18, 2008 Source: MDA (
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Summary:
MCT has developed microwave-based processes for producing high-quality, specialized metal composites. The company's technology offers reduced cost and processing time for manufacturing materials. MDA originally funded the technology through the SBIR program for its potential in improving materials for programs such as the Exoatmospheric Kill Vehicle (EKV). The company envisions its processes being used to make materials for armor, space structures, thermal management and electronics packaging, and tank and automotive components. MCT continues to examine commercialization strategies for the MDA-funded technology.
Technology Description:
Working with Pennsylvania State University researchers, MCT is using its microwave technology to enhance three of its existing composite manufacturing processes: pressureless metal infiltration, directed metal oxidation, and reaction bonding. MCT's microwave-assisted processes would compete with traditional resistance-heating methods such as those involving furnaces. MCT uses a custom-designed cavity to heat reinforcement preforms and infiltrant metal. In a microwave unit, volumetric heating occurs, meaning all the molecules in the work piece couple with the microwaves. Heating, therefore, occurs in a more uniform fashion throughout the part; whereas in the conventional furnace-heating process, a furnace element is heated and radiates to the part surface, with heat then radiating from the surface to the interior of the part. (In other words, when a furnace is used, the core of the material preform reaches an infiltration temperature much later than the areas nearer the surface.) But MCT's technology simultaneously affects the entire volume of the preform, reducing process time by 50 to 80 percent, according to MCT. Moreover, an added benefit of the process is superior microstructural characteristics of the final product.
By using powdered metals or adding susceptors such as silicon-carbide rods, MCT's microwave technology avoids generating the sparks that might occur when subjecting metal sheets or foils to microwaves. Susceptors heat up and then transfer the heat to the alloy without generating sparks. After the alloy reaches a certain temperature, it starts coupling directly with the microwaves.
Microwave energy has been commonly used for sintering ceramics and powdered metals, but MCT claims that its MDA-funded research for metal-infiltration-based composite manufacturing is a first. The company modified a commercial microwave oven for the initial testing, and later built a much larger unit with a 20-inch-diameter cavity, allowing researchers to work with pieces of about 6 × 12 × 14 inches.
MDA Origins:
MCT was funded by MDA through a Phase II SBIR award to improve processes for materials used in military systems such as the Exoatmospheric Kill Vehicle (EKV). Prototype materials emerging from the project are being offered to Raytheon for use in missile defense projects, according to MCT. Previously, in a Phase I program, MCT demonstrated the feasibility of the technology. The Phase II Program sought to further refine processes while developing prototype components of MDA interest.
Spinoff Applications:
Company researchers say the technology is ideal for producing body armor vest inserts, a market for which MCT already manufactures as many as 20,000 vest inserts each month. Additional application areas with potential include space structures, thermal management and electronics packaging, tank and automotive components, and missiles. In addition to the armor inserts, researchers say other applications—from heat sinks to high-quality mirrors to machinery used in semiconductor manufacturing—may exist.
Commercialization:
The current challenge for MCT is in scaling up the microwave equipment to handle larger pieces. The company also is focused on quantifying benefits of its methods and prototypes. Company researchers say they are building enough experience in terms of making components so that now they can begin to consider production rates and energy costs in more detail. The company has applied for two patents related to the MDA-funded technology. According to MCT, when commercialized, the technology should produce affordable, strong, stiff, lightweight components in many application areas such as space structures, armor, thermal management and electronics packaging, tank and automotive components, and missiles. Company leaders expect that MCT's current volume manufacturing infrastructure would allow rapid technology deployment of this technology in military and commercial markets.
Company Profile:
MCT has annual sales close to $60 million—with all products based on composites technologies. The company's production processes include a method called Primex, which is pressure-less metal infiltration. Another process, called Dimox, involves directed metal oxidation. The third process employed by the company is reaction bonding. MCT was founded in 1993 as subsidiary of Lanxide Corporation, a developer of advanced composite materials. In a 1995 venture capital deal, MCT spun out of Lanxide. MCT employs about 200 people and conducts manufacturing at two sites: in Connecticut and in Delaware. The company also has a branch office in Tokyo. MCT materials are currently used in semiconductor equipment and lightweight armor systems.
