SBIR-STTR Award

Nanophase metal particles are becoming increasingly important in areas such as powder metallurgy, catalysis and energetic materials. One of the more important nanophase metals is aluminum . Although several promising routes for the production of this material exist, not one of these synthesis techniques have successfully addressed the issue of the oxidation of these same nanoparticles, which lead to the destruction of the benefits arising from their nanophase dimensions. AVEKA, Inc. proposes the use of their proprietary aspirator/dispersion technology in combination with a gas evaporative process in order to form a stable nanoparticle dispersion in an inert solvent. Standard polymerization techniques will then be used to form a protective fluoropolymer coating around the aluminum nanoparticles in-situ. After separation from the dispersion medium, a stable free-flowing nanopowder will be formed, which would be suitable for applications in energetic materials and metallurgy.

Benefits:
The formation of a stable, unoxidized aluminum nanoparticle would have several applications in the areas of propellants and other energetic material. These nanoparticles could also be utilized in the formation of ultra-high strength metal parts in the area of powder metallurgy

Nanophase particles are becoming increasingly utilized in several fields, including the properties arising from their small size and high surface areas. However, due to their high reactivity, oxides form on the surfaces of these particles and reduce their performance and value. This is especially true of aluminum nanoparticles used as energetic fuels. The burn rate of propellants using these materials can increase 1 to 2 orders of magnitude; however, this increased burn rate is lost when oxidation converts the surface of the aluminum nanoparticles to aluminum oxide. AVEKA, Inc. has shown during Phase I that their proprietary process can produce nanoparticles 20-30 nm in diameter and then protect these nanoparticles from oxidation by forming a 6-10 nm thick fluoropolymer coating around them by an in-situ reaction. During Phase II of this program, AVEKA will optimize the process discovered during Phase I and scale it up to a production rate of 1 kg/hr in their pilot plant facility. Current projections indicate that a maximum production rate of 5 kg/hr is possible using this process. AVEKA will further demonstrate the commercial potential of the process by coating iron nanoparticles for use in magnetic media.

Benefits:
The technology refined here will benefit the fields of energetic materials, catalysis and magnetic media.