SBIR-STTR Award

In response to MDA’s innovative manufacturing approaches, we propose to fabricate and evaluate high strength, higher temperature W-25Re base alloys and their select composite materialsof Hf, HfC, TaC for erosion resistant throats (for second or third stage rocket motors. Required number of units are 100s to thousands and cost reduction in manufacturing and rapid delivery processing are critical. UTRON Kinetics proposes a cost-effective and rapid manufacturing (e.g., milliseconds of compaction time) method called high pressure Combustion Driven Powder Compaction (CDC) technology to fabricate fine grained (<50-75 microns) W-25Re based alloys and composites with Hf, HfC for solid rocket hollow throat applications. The major objectives of the Phase I SBIR effort will be focused on fabricating and scientifically characterizing W-25Re alloys and select composites with small % of alloying additions such as Hf, HfC, TaC in select geometrical shapes (mechanical test coupons, small scale disks and small scale throat (hollow cylinder) using UTRON’s innovative, cost-effective and compact Combustion Driven Powder Compaction (CDC) at high pressures (e.g., 150 tsi). The samples will be fabricated using commercially available fine powder as raw materials and geometries to be fabricated include 0.5 inch or 1inch diameter cylindrical disks, 3.5 inch long tensile dogbones as well as small scale hollow hollow throat using the available tooling. We will develop the key CDC process optimization for various proposed alloys, suitable sintering response in hydrogen or suitable environment (e.g., vacuum sintering), density changes, geometry/surface/part quality, select mechanical tensile properties at room and elevated temperatures (e.g., 4100-4500 degF or higher in consultation with MDA sponsor and subcontractors, microstructures and microchemistry. Based on the optimum process conditions, representative small scale hollow throat liner (Phase I) and other large thrust throat components will also be fabricated using a special die/punch assembly and scaling up in Phase II. Further process optimization on the most promising W-25Re alloys or the alloy composites, scaling up and rapid manufacturing strategies will be established and continued in Phase I Option and Phase II/ III.

Keywords:
Combustion Driven Powder Compaction, Cost-Effective And Rapid Manufacturing, Less Shrinkage, W-25re Alloys, Composite Materials, High Temperature Protection, Minimal Wastage O

Based on the successful Phase I results, The major objectives of the Phase II SBIR effort will be focused on further continuation and development of CDC compaction of W-25Re and other composite materials, processing optimization, fabricating test coupons and small scale throat/prototype large scale parts for the MDA/prime contractor part needs (Aerojet, Raytheon) and scientifically characterizing the materials behavior including high temperature properties and select hot-fire testing in coordination with MDA sponsors and establish cost-effective manufacturing for transition to MDA sub-systems such as SM3-BlockIIA, Block IIB applications. Proposed materials include W-25Re alloys and select composites with small % of alloying additions such as Hf, HfC, TaC, HfN in select geometrical shapes (mechanical test coupons, small scale disks and small scale throat/large scale prototype part using UTRON?s innovative, cost-effective and compact Combustion Driven Powder Compaction (CDC) at high pressures (e.g., up to 150 tsi). The samples will be fabricated using commercially available fine powders as raw materials and geometries to be fabricated include 3.5 inch long tensile dogbones, disks (1-1.5 inch diameter) as well as small scale throat/large scale prototypes for potential hot-fire testing. We will develop the key CDC process optimization for various proposed materials, suitable thermal processing/sintering, geometrical and physical property (density) changes, geometry/surface/part quality, select mechanical tensile properties at room and elevated temperatures (e.g., RT to 3750-4100-4500 degF or higher in consultation with MDA sponsor and subcontractorsAerojet/SORI), microstructures and microchemistry. Based on the optimum process conditions, representative small scale hollow throat liner and other large thrust throat components will also be fabricated using a special die/punch assembly and scaling up in Phase II. Further process optimization on the most promising W-25Re alloys or the alloy composites and rapid manufacturing strategies will be established and continued in Phase II and Phase III.

Keywords:
Combustion Driven Higher Pressure Powder Compaction, High Temperature Propulsion Component, Near Net Shaping, Rocket Motor Components, High Temperature Protection, Improved Me