HIP Can Design and Manufacturing

Hot isostatic pressing (HIP) of refractory compounds, refractory metals and other specialty ceramics and alloys is a core specialty at Exothermics. Our success with HIP-based processing of advanced materials has led to the development of unique expertise in design, fabrication and processing of exceptionally leak-tight HIP containers made from refractory metals, as well as other suitable metallic materials. Our HIP can design and fabrication capabilities include:

• Cylindrical, rectangular and other axisymmetric HIP containers up to 36”x60” size
• Complete facilities for controlled heating and hard offgassing (< 5x10-⁷ Torr), helium leak checking (< 5x10-⁹ sccm), and positive closure of HIP containers
• Extensive, demonstrated performance history with design and fabrication of HIP containers capable of surviving > 2000°C densification processing
• Inert gas glovebox with inboard and outboard oxygen monitoring to <1ppm O₂
• Complete sheet metal forming infrastructure capable for processing any suitable HIP container material up to 36” width and 0.060” thickness
• SolidWorks design software for engineering of HIP containers

Fusion Welding and Joining of the Refractory Metals (i.e., W, Ta, Nb, Mo)

The ultrahigh temperature materials and sputtering target fabrication efforts at Exothermics have required that we develop specialized skills around the sheet metal forming, electron beam welding, TIG welding of various Group IV and V reactive and refractory metals. This is an interesting spinoff of our baseline business activities which offers potential for product development and high quality service work in its own right. Our fusion welding and joining capabilities include:

• Inert gas glovebox with inboard and outboard oxygen monitoring to <1ppm O₂
• 200Amp and 350Amp Miller Synchrowave TIG welders connected to glovebox.
• Complete sheet metal forming infrastructure (hydraulic press brake, shears, rollers, etc) capable of processing refractory sheet metal stock up to 36” width and 0.060” thickness
• SolidWorks design software for engineering of sheet metal component assemblies and enclosures
• Ductile fusion welds on tantalum, niobium, iridium, rhenium, etc.

Vacuum Induction Melting

Exothermics has recently expanded into vacuum induction melting (VIM) of a variety of high purity ferrous and nonferrous alloys and elements. We have a large GNB vacuum induction melter equipped with a high capacity, quick turnaround dry pumping system. Our VIM capabilities include:

• Crucibles from 35 - 200# capacity for R&D to light production melts
• Varieties of Molds for Casting of Cylindrical and Rectangular shapes
• Specializing in VIM Melting of Ni, Co, Fe Alloys and the Rare Earths

Sputter Deposition Processing

Sputtering and other types of physical vapor deposition are a mainstay of our business. We consistently produce our own sputtering targets and deposit films on numerous substrate materials. A large portion of our work in the sputter deposition realm supports programs for DoD prime contractors and other DoD entities. Our sputter deposition processing capabilities include:

• DC and Bipolar Pulsed DC Magnetron Sputtering
• Low (45kHz) and Medium Frequency (400kHz) AC Magnetron Sputtering
• RF (2.0 & 13.56 MHz) Magnetron Sputtering
• Ion Assisted Deposition; DC and AC Substrate Biasing
• Sample Heating with Various Types of Motion (linear, rotary, etc.)
• Etch and Sputter Coating of Parts up to 36” Diameter

Toll Furnace Processing

We have a range of metal and graphite hot zone furnaces for thermal processing of refractory compounds, nonoxide ceramics, reactive metals, refractory metals and specialized alloys. All of our furnaces have vacuum or inert gas handling capabilities, featuring high performance pumping systems utilizing either turbomolecular pumps or high capacity blowers to establish clean backgrounds for vacuum or inert gas processing. Our toll furnace capabilities include:

• Turbomolecular pumped, 9x9x18inch moly hot zone furnace with 1600°C peak temperature capability (modification to 2100°C peak temperature planned for near future)
• Roots blower pumped, 12x16x28inch moly hot zone furnace with 1600°C peak temperature capability
• Roots blower pumped, 2x4x6inch graphite hot zone furnace with 2400°C peak temperature capability.
• Roots blower pumped, 14x16x48inch graphite hot zone furnace with 1800°C peak temperature capability.