PROCESS DESIGN AND CONTROL SOFTWARE FOR IMPROVING CERAMIC COMPONENT MANUFACTURING Sandia National Laboratories has developed the ability to characterize and model the powder compaction process in detail, and to address and control density gradients in powder compacts that cause shape distortion and differential shrinkage in ceramics manufacturing. Proprietary 3D finite element code packing and compaction models, and process control tools are available to enable the production of ceramic components with tighter tolerances at lower costs. In addition to state-of-the-art computational facilities and a complete computational package including meshing, modeling, and graphical presentation, Sandia also possesses capabilities in the areas of hydrostatic and triaxial compaction testing to characterize materials properties, and X-ray radiography, ultrasound, and computed tomography for density characterization. In addition, Sandia is developing computational models of the sintering process, which are expected to enhance ceramic component design and manufacturing capability. Applications Structural and electronic ceramics manufacturing, particularly for high-performance components. Pharmaceutical tablet/pill production. Powder metallurgy and pressed metal parts. Geologic industries such as civil engineering and mining. Potential Benefits Improved component tolerances to less than 1% through predictable and controlled pressing/forming. Reduced manufacturing cost by minimizing or eliminating green machining and hard grinding. Improved component reliability and performance. Reduced time to market for new products and improved trouble shooting for new or existing compaction processes. Insight into improved die designs. Demonstrated Achievements A finite element method computer model has been developed and validated that predicts ceramic powder compaction behavior. Realistic simulations of ceramic powder compaction have been completed and validated in commercial manufacturing environments. Characterization tools to measure flow, friction, compaction, and compacted density gradients have been developed and refined to support model development and application. A working model is currently being refined in collaboration with members of a US ceramics industry consortium. Powder packing simulations are also being validated in collaboration with US universities. References Numerous papers (available upon request) have been published by Sandia staff on compaction and related processing topics. Sandia staff contributed towards and edited a recent MRS topical bulletin on compaction science and technology, and have also been recognized as symposium organizers, meeting chairs and invited speakers. Sandia is interested in partnering with industry to further develop reliability and failure analysis of glass and ceramic components. Companies interested in partnering with Sandia should be willing to sponsor a collaborative project via a Cooperative Research and Development Agreement (CRADA) with Sandia. For further information please respond by mail or fax to Sheila Pounds by June 29, 1999 at Sandia National Laboratories, MS-1380, P. O. Box 5800, Albuquerque, New Mexico 87185-1380. Fax: (505) 843-4163. Please indicate the date and title of this CBD notice. E-MAIL: Sheila L. Pounds, slpound@sandia.gov. Posted 06/14/99 (W-SN342510).

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