SBIR-STTR Award

The major objectives of the Phase I effort will be focused on CDC high pressure compaction/fabrication, post-processing, testing and materials performance/baseline preliminary material modeling of the kinetic behavior of the energetic material compositions based on select geometry and CDC materials properties. CDC compacted candidate reactive fragment warhead/projectile materials include Hf/Al, W/Al, Al/Boron, Hf/Zn, Zr/Zn, Zr/Al, or Ta/Al, Mo/Al, and select materials with boron, molybdenum oxide and/or sulfur. Select geometrical shapes such as 0.5 inch diameter cylinders/disks, near spheroidal pellet shapes (e.g., 0.5 inch diameter), and 3.5 inch long tensile dogbones will be fabricated using the available 300 ton CDC press and existing die/punch assemblies for initial exploration. Compositions will be optimized in consultation with OSD sponsors to obtain densities closer to 7 g/cc or higher. Appropriate experimental process optimization at much higher compaction pressures (e.g., 50 to 150 tsi) will be developed as an integral part of Phase I and Phase II. Key CDC process optimization, suitable sintering/heat treatment responses, near or net shaped reactive fragments/warhead spheroidal pellet part quality, microstructural/microchemistry properties, and mechanical properties such as hardness and other strength durability properties at room temperature will be evaluated in Phase I. In Phase II, scaling up, materials/manufacturing of reactive fragment warhead components such as multiple-pressing of several spheroidal shaped warheads etc will be planned and the developed CDC parts after optimum processing conditions.

Keywords:
Combustion Driven Compaction, Cdc High Pressure P/M Compaction, Improved Densification, Less Materials Wastage, Net Shaping, Micro/Nano Powder Compacts, Superior Mechanical/Du

We propose in Phase II effort to continue and further optimize and scale up to fabricate the large diameter fragmenting test cylinders/complex geometries using innovative and Cost-effective Combustion Driven Rapid Powder Compaction Manufacturing as a follow-up of the successful development and materials properties/reactivity up to 6000 ft/s of CDC compacted reactive fragment materials from the Phase I efforts. CDC compaction process optimization is planned to develop additional materials properties, advanced alloy development with enhanced reactivities than equivalent steels, scaling up to fabricate for larger/complex geometries of reactivity test cylinders of various sizes of OD and wall thicknesses as per the sponsor's (OSD-ONR-NSWC) needs. Small and medium scale spheres/cylinders also will be developed for preliminary screening for materials behavior and reactivities. Advanced alloys proposed include combonations of Zr-Zn-W and other addvanced alloys,and mechanical, microstructural and microchemistry will be correlated with CDC compaction/post-process conditions based on select geometry and CDC materials properties. Potential alloying include tungsten, W-Ni-Fe, W, W/Zr/Zn, Nanomaterials of aluminum, Iron, Copper etc as examples) and reactivity enhancing materials in small concentrations such as nanoAluminum or Cryomilled Al-Zr-Zn alloys with Zr-Zn-W to obtain reactivities as a proof of concept and extend for other alloys in Phase II. Phase II option will be focused on the most promising alloys for specific needs from OSD sponsors/ potential industry end users such as NSWC,ATK, Aerojet or General dynamics etc, for their commercial applications.

Keywords:
Combustion Driven Compaction, CDC manufacturing technology, high pressure powder consolidation, higher compaction pressures, net shaping, less materials wastage, improved dens