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Research Project Information




Research Project Summary Information



Novel Forming Techniques for Silicon Carbide Shapes(ST8984-1)

Silicon Carbide Products, Inc.,

Background

Silicon Carbide Products, Inc. (SCP) manufactures silicon nitride bonded silicon carbide shapes for use in the wear, refractory, and foundry industries. Under a previous NYSERDA-cofunded project, SCP prototyped an improved forming technique which has the benefits of fast cycle time and energy efficiency. This process, when commercialized, will broaden SCP’s market offerings. In addition, customer surveys indicate that almost half of SCP’s current customer base is interested in a wear-resistant grade of reaction bonded silicon carbide.

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Project Description

This project proposes to develop a higher density, wear-resistant grade of reaction bonded silicon carbide. This project will determine and develop shape making capability, provide demonstration parts to customers, develop formulation and process additions to increase fired density for wear-resistant applications, and develop a business plan.

Benefits

Significant energy savings and cycle time reduction will be realized from eliminating the need to dry the shapes, as is required with the slip casting process. The project will result in many benefits to New York State: • increased employment (2-4 jobs to be created within 12-18 months and 6-12 jobs within 3-5 years), • increased purchases from NYS-based companies for raw materials and supplies, • a NYS-based supplier of reaction bonded silicon carbide with a customer focus that is currently lacking in the industry, • sales to NYS companies, and • corporate and payroll tax revenues associated with increased sales.

Project Results

The project was successful in respect to improving the final fired density and increasing the wear-resistance of the material. This material effectively produced dish-shaped parts, cylindrical and flat plate-like parts, as well as bowl-shaped spray nozzles. It was difficult to cast intricate open-space three-dimensional shapes. By using end caps produced by Silicon Carbide Products, Inc., single ended recuperative burner systems can offer over a 50% energy savings over open-ended systems. The project no longer has commercial activity as the sole customer no longer buys from them.

Contractor

Silicon Carbide Products, Inc.,
361 Daniel Zenker Drive
Horseheads, NY 14845

Principle Investigator

Mark Witmer

Universities Involved

Technologies

Project Type:

On-site Process Improvement


Technologies Types:

Forming/Casting/Cutting

NYSERDA Contact Information

Miriam Pye
MEP@nyserda.ny.gov

Program

R&D - Mfg Tech & On-Site Pwr

Contract Details

Start Date: 1/11/2010
Project Status: Active
Contract Number: ST8984-1




Last Updated: 7/30/2014