This Small Business Innovative Research (SBIR) Phase II project will develop 2000 degree Centigrade (C) molybdenum alumino-silicide (Mo(Si,Al)2) heating elements for advanced manufacturing processes such as sintering, brazing, annealing, semiconductor processing, ceramic processing, and pyrolysis of solid waste. Current technology in heating elements permits temperatures only as high as 1850-1900 degree C. The main technical barriers are (1) spalling of the silica protective layer at 1850-1900 degree C, which exposes the bare MoSi2 to catastrophic oxidation, and (2) extensive weakening by rapid grain growth. Phase II will (1) use alloying elements to form oxidation-resistant ternary phase Mo(Si,Al)2, which leads to the formation of a stable (up to 2080 degree C) adherent alumina layer, and (2) add nano-scale alumina or zirconia (~ 40 nanometers) to stabilize grain growth. Two compositions in the molybdenum-alumino-silicon ternary alloy phase field were identified, synthesized, and tested in Phase I. A rapid heat-up 2000 degree C element would be a quantum leap in heating element technology and lead advances in high temperature manufacturing. Rapid commercialization is expected because energy advantages and productivity (time wise) gains will accrue to the ceramic manufacturing, metal processing, compound semiconductor processing, glass processing, and joining industries. Total savings of nearly $40 million per year are anticipated in lower power consumption in the manufacturing industries that use this heating element technology.
