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Industrial Nano Material Components with High Temperature Corrosion and Wear Resistance Performance for Energy Saving--IAP Research, Inc., 2763 Culver Avenue, Dayton, OH 45429-3723; 937-296-1806, www.iap.com 

Dr. Bhanumathi Chelluri, Principal Investigator, bhanu@iap.com 

Dr. John P. Barber, Business Official, john@iap.com 

DOE Grant No.  DE-FG02-03ER83679

Amount:  $749,966

In the power generation and transport industry, turbine engine efficiency is enhanced by operating at higher temperatures and speeds.  However, current materials have limited life at the high temperature (500°F) and the corrosive environment of turbine engine operation.  This project will develop a new class of nano-materials to meet such needs.  The materials not only will have ceramic-like properties (high hardness, wear and corrosion resistance) but also will display the ductility and fracture toughness of metals.  This unique combination of properties will be accomplished by the homogenous nano-ceramic dispersion into a metal matrix, followed by compaction, and low temperature sintering.  Phase I developed techniques for processing this new class of material, nano- ceramic strengthened metal matrix, via a powder processing route.  In particular, a new material, nickel matrix strengthened by nano Ni₃Si particles, was synthesized.  The material exhibited high hardness, low friction, and good corrosion resistance.  Phase II will:  (1) develop and optimize the nano-ceramic/metal matrix systems for a bearing application; (2) design and fabricate prototype bearings with the new material; and (3) test the bearing.

Commercial Applications and Other Benefits as described by awardee:  The new material systems should find a variety of applications: (1) in turbine engines for the power generation and transport industry; (2) in the chemical industry where robust mechanical components with wear and corrosion resistance are required; and (3) in electronic and other industries that require materials with advanced properties.