Scale-Up Production of Large Spinel Reconnaissance Windows

This SBIR Navy Phase I Project proposes to scale up MER"s window technology to make larger, stronger, monolithic windows from spinel polycrystalline ceramic. This proposal presents a solution to the Navy"s need for durable, monolithic, infrared-transmitting sensor windows with hot pressed (HP) sizes up to 28"x30"x0.6"for reconnaissance purposes. The larger size window is limited by the available equipment. During sintering HIPping is used. The HIP size restrictions are 21.5"x35"at the moment. MER contacted vendors that will be able to HIP windows as large as 28"x32". This Phase I project will produce the necessary tooling for the production of the 28"x30"x0.6"and some smaller pane of 8"x8"x0.6". MER already demonstrated in previous project the production of hot pressed windows as large as 25"x32"x0.6". These windows were edge trimmed to 20.25"x27.25"x0.65"to be HIP. It is the main goal of this Phase I project to further develop, increase the strength, and optimize this technology. It is important to preserve the excellent optical properties of the smaller spinel windows. The smaller 8"x8"x0.6"I will be produced with the same conditions that the larger window will be produced. Even larger sizes could be pursued during Phase III, depending on the availability of financial resources.