Development of Advanced Ceramic Manufacturing Technology

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Advanced structural ceramics are enabling materials for new transportation engine systems that have the potential for significantly reducing energy consumption and pollution in automobiles and heavy vehicles. Ceramic component reliability and performance have been demonstrated in previous U.S. DOE initiatives, but high manufacturing cost was recognized as a major barrier to commercialization. Norton Advanced Ceramics (NAC), a division of Saint-Gobain Industrial Ceramics, Inc. (SGIC), was selected to perform a major Advanced Ceramics Manufacturing Technology (ACMT) Program. The overall objectives of NAC's program were to design, develop, and demonstrate advanced manufacturing technology for the production of ceramic exhaust valves for diesel ... continued below

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182 pages

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Pujari, V.K. April 5, 2001.

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Description

Advanced structural ceramics are enabling materials for new transportation engine systems that have the potential for significantly reducing energy consumption and pollution in automobiles and heavy vehicles. Ceramic component reliability and performance have been demonstrated in previous U.S. DOE initiatives, but high manufacturing cost was recognized as a major barrier to commercialization. Norton Advanced Ceramics (NAC), a division of Saint-Gobain Industrial Ceramics, Inc. (SGIC), was selected to perform a major Advanced Ceramics Manufacturing Technology (ACMT) Program. The overall objectives of NAC's program were to design, develop, and demonstrate advanced manufacturing technology for the production of ceramic exhaust valves for diesel engines. The specific objectives were (1) to reduce the manufacturing cost by an order of magnitude, (2) to develop and demonstrate process capability and reproducibility, and (3) to validate ceramic valve performance, durability, and reliability. The program was divided into four major tasks: Component Design and Specification, Component Manufacturing Technology Development, Inspection and Testing, and Process Demonstration. A high-power diesel engine valve for the DDC Series 149 engine was chosen as the demonstration part for this program. This was determined to be an ideal component type to demonstrate cost-effective process enhancements, the beneficial impact of advanced ceramics on transportation systems, and near-term commercialization potential. The baseline valve material was NAC's NT451 SiAION. It was replaced, later in the program, by an alternate silicon nitride composition (NT551), which utilized a lower cost raw material and a simplified powder-processing approach. The material specifications were defined based on DDC's engine requirements, and the initial and final component design tasks were completed.

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182 pages

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  • Other Information: PBD: 5 Apr 2001

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  • Report No.: ORNL/SUB/94-SP234/1
  • Grant Number: AC05-00OR22725
  • DOI: 10.2172/814138 | External Link
  • Office of Scientific & Technical Information Report Number: 814138
  • Archival Resource Key: ark:/67531/metadc734766

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Office of Scientific & Technical Information Technical Reports

Reports, articles and other documents harvested from the Office of Scientific and Technical Information.

Office of Scientific and Technical Information (OSTI) is the Department of Energy (DOE) office that collects, preserves, and disseminates DOE-sponsored research and development (R&D) results that are the outcomes of R&D projects or other funded activities at DOE labs and facilities nationwide and grantees at universities and other institutions.

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Creation Date

  • April 5, 2001

Added to The UNT Digital Library

  • Oct. 18, 2015, 6:40 p.m.

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  • March 30, 2016, 8:19 p.m.

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Pujari, V.K. Development of Advanced Ceramic Manufacturing Technology, report, April 5, 2001; United States. (digital.library.unt.edu/ark:/67531/metadc734766/: accessed July 18, 2018), University of North Texas Libraries, Digital Library, digital.library.unt.edu; crediting UNT Libraries Government Documents Department.