MAINSTREAM ENGINEERING CORP — Department of Defense SBIR Phase I: AF161-068

Description

ABSTRACT: The Phase I proposal presented here details a procedure to produce metal encapsulated carbon nanotubes (CNTs) for integration into wiring for high-temperature applications. The addition of CNTs into traditional metal wiring improves high-temperature conductivity by reducing the losses due to lattice vibration at elevated temperatures. The process is based on a simple, scalable, one-pot process that uses emulsion chemistry to coat a metal on the surface of the nanotubes. This coating will create a copper-coated CNT nanopowder which enhances the binding of CNT to the wire matrix, improves mixability, and limits aggregation. In addition, the emulsion chemistry enhances the CNT/Cu interface, improving both electrical and mechanical properties between the CNT and copper matrix. The consulting investigator has previously developed the emulsion chemistry process for polymers. The process will be adapted for coating CNTs with metals and the coated CNTs will be leveraged with Mainstreams expertise in nanocomposite manufacturing.; BENEFIT: The development of copper wire with increased ampacity and thermal stability offers significant benefits for next-generation aircraft. Adding aligned carbon nanotubes (CNTs) into the electrical wiring reduces the losses associated with elevated wire temperature, increasing the aircrafts operational window. The proposed composite wire will be light-weight and have increased conductivity and ampacity. These properties combine to reduce required wire diameter and wire weight and can present significant savings in fuel costs. Commercial aircraft would benefit similarly and microelectronic systems could benefit from the decrease in wire diameter necessary to handle the required currents.