Advanced Lightweight Insulator Composite Materials Development and Fabrication Using Higher Pressure Powder Consolidation

Utron Kinetics proposes to develop high temperature advanced ceramic based composites of R-NZP, and Nano-Zirconia based advanced composites and their functional composites in near net shape geometries using UTRON's innovative, compact and cost-effective High Pressure Combustion Driven Powder Compaction (CDC) manufacturing technology. A 300 Ton or 400 Ton CDC Press will be used for the proposed work. Major advantages of CDC process are: faster process cycle time (e.g.,milliseconds), much higher densification due to higher CDC pressures, ability for cold or hot pressing at higher pressures, less part shrinkage, better mechanical strength attributes, ability for micro/nano powder consolidation and simple/complex geometry, much less/no materials wastage, superior surface quality (e.g., micron/sub-micron finishes), and scaling up potential. Small scale (<1 inch diameter) rings, disks, and rectangular block samples will be fabricated and evaluated for CDC process optimization, thermal sintering responses, physical /geometrical/surface quality properties, microstructure, microchemistry and mechanical/high temperature properties. Our proposed R&D efforts will be integrated by closely working in partnership with a major subcontractor. Further advanced novel ceramic composite alloy development, CDC process control, testing and scaling up efforts will be done in Phase II. Approved for Public Release 14-MDA-8047 (14 Nov 14)