A MELBOURNE heat treatment company has acquired from the US Department of Energy a metal hardening process, and is now working with a Swinburne University and Alstom Power in the US on the commercialisation of the technology.
MicroFuze International has acquired the microwave diffusion technology which protects surfaces against erosion and corrosion and is emerging as a promising springboard for new and improved metal performances.
According to the company, microwave diffusion technology has proved very effective in creating surface alloys that are currently difficult or relatively expensive to produce. It is predicted that industries using high performance alloys such as aerospace, defence, automotive, power generation and tool making will find immediate application for the technology.
Potential markets for microwave diffusion technology include heat treating, electroplating (chrome) replacement niche markets, pack coating – heat exchanges, turbine blade metallising and boronising, plus applications in the heat treating, hard facing and electroplating market.
At this stage, the company is focusing on smaller components (shoe box size) that are mission critical or have a high replacement cost. One example is carpet manufactures where a needle failure can cost up to $100,000 to shut down the manufacture, replace the needle, then start up again. MicroFuze is working with the largest carpet company in the US on this problem.
A report prepared by the Rowan Technology Group, a US based consulting firm that provides market evaluations for high technology products, concluded that the technology provides an alternative to conventional packed bed heat treatments. It judged the technology as cleaner and more effective, as well as having a lower process cost while retaining the advantages of diffusion treatment.
In addition, an over-the-pack process, under development by MicroFuze, would further improve marketability of the technology, as would extending it to nitriding and carburising.
The microwave diffusion technology was developed by the US Department of Energy’s Oak Ridge Facility in Tennessee to prevent field howitzer and tank cannon barrels from sagging during battle – a Viagra for cannons.
Microwaves diffuse donor metals such as chromium, boron and cerium into steel, aluminium and other metals to create surface alloys that offer high corrosion or abrasion resistance.
The microwaves are directed at specially designed microwave–susceptible crucibles in which the piece to be hardened is placed. The concentration of microwaves on the crucible generates extremely high heat at the surface of the piece in a very short time. This creates a plasma of donor metal ions that diffuse into the surface of the piece to create a surface alloy without changing the dimensions.
This technology is said to have significant advantages over conventional metal diffusion techniques, including rapid processing, surface heating which eliminates need to bring whole work piece to high temperature, ability to diffuse internal diameters, deep diffusion depths and the avoidance of changing the properties of the target metal.
Another advantage is that it is able to diffuse relatively large atoms, for example cerium, into substrates comprising relatively small atoms, for example aluminium.
The company is seeking Australian applications for the technology with the aim of working in partnership on the development of solutions to nagging and hitherto insoluble problems. For more information call MicroFuze International on 03 9824 8166.