We offer an advanced technology for low-energy basalt-fiber and zirconia-fiber composite materials production, based on our know-how for low-power (0.5Wh/L) Stoichiometric Oxy-Hydrogen Gas generation.
Oxy-Hydrogen (OH, HHO) gas-plasma flame has the unique property to heat up various hard materials up to their melting and boiling point. For example, Zirconium Dioxide (Zirconia – ZrO2) boils up at 4,300 deg.C, Tantalum-Hafnium Carbide (Ta4HfC5) boils up at 5,530 deg.C, etc. Basalt Rock could be melted at about 1,400 deg. C and drawn in fibers 5-10 microns thick and several thousand meters long. Zirconia (ZrO2) fibers can be melted at 2,715 deg.C and also drawn in long thin fibers.
A large range of various Composite materials could be produced, using both kinds of fibers – 3 times lighter, 5 times stronger and 20 times cheaper than the steel, as construction rebars, beams, pipes, profiles, boards, panels, elements, tiles, road pavements, railway sleepers, car/ship/machinery bodies & parts, columns/poles, ropes, fabrics, insulation, aerospace craft and structural applications, etc. In a composite material, Zirconia fibers, being much stronger and high-temp-melting, can be used as reinforcing strings, while Basalt fibers can play the role of “glue”, sticking together all the fibers.
Steel strings could be also added to the composite for special performance needs. All fibers are being knitted together and then lightly OH-flame-treated until all fibers weld their surfaces to each other into an extremely strong, flexible, shock/fire/water/corrosion-resistant element, several times stronger, lighter and cost-effective than the steel.
Thanks to our high-effective technology for low-power production of OH gas, and the low price of the Basalt and Zirconia, the final product’s price will be very competitive.
Basalt and Zirconia fibers can be used for high-precision 3D-printing.
Fiber pass through a nozzle and is immediately heated by the OH gas-plasma flame of a micro-burner, attached to the nozzle. The result is fiber’s surface partial melting in part of the second.
Than the semi-melted fiber is laid and welded to the fiber beneath, following the computer-designed contour. Thus, layer after layer, a massive, extremely strong and computer-precised structure of any shape can be automatically built.
Thanks to the basalt raw material and the low-power OH gas price, the cost of the 3D-printed end element will be very low. Laser beams could be used as well to help with the high temp needed, but OH flame usage is crucial for the welding process.