High Strength Materials at Elevated Temperatures for High Pressure Turbines

The DARPA is seeking rapid innovative manufacturing for turbine components in Vulcan Program. We, at UTRON Kinetics, propose a modern rapid Combustion Driven Advanced Powder Compaction Manufacturing to fabricate simple and complex shapes of various refractory alloys and composites using Mo-Re, with Nb, Ti-aluminides, and carbides for temperatures of 3500 degF as a proof of concept in Phase I and we then focus on the most promising materials and manufacturing using CDC in Phase I option and further scaling up in Phase II. Gasturbine materials include superalloys, single crystal materials etc which have limits for the operating temperatures (<900 degC is commonly used!!). Developing advanced high temperature materials with required mechanical and thermal properties (for temperature of 3500 degF) using metal matrix composites of Mo-Re with Niobium/Titanium aluminides and composites and Making several of these materials in a suitable near net shape or net shape component form rapidly and cost-effectively (30- to 50% less expensive than by conventional means of fabrication) with significant reduction of materials wastage using CDC method forms the basis for this DARPA SBIR innovation proposed research. The major objectives of the Phase I effort will be focused on fabrication, testing and materials performance characterization of CDC compacted Molybdenum/Rhenium, alloys with Niobium, Ti-and select composites of aluminides, and carbides. The proof of concept in Phase I is added demonstrating the higher pressure consolidation rapidly and uniquely in near net shape and net shape forms with advantages to process select groups of materials and shapes of DOD and industry interest and evalauate properties at 150 tsi. Other advantages include near net shaping ability, and materials properties after suitable sintering/heat treatment. Select geometrical shapes such as 1 inch diameter cylinders/disks, 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 of property testing of coupons and small scale turbine blade/hollow disk components of fabrication. Compositions will be optimized in consultation with DARPA sponsors in Phase I. Appropriate experimental process optimization at much higher compaction pressures (e.g., up to 150 tsi) will be developed as an integral part of Phase I, Phase I option and Phase II. Key CDC process optimization, suitable sintering/heat treatment response, near or net shaped part quality, microstructural/microchemistry properties, and mechanical properties such as hardness and other strength/ductility properties at room and elevated temperature upto 3500 degF will be evaluated in Phase I for optimized samples. In Phase I Option, we will focus our attention on the most promising alloys of interest, establish cost-effective discrete manufacturing strategies based on the potential DOD/commercial aerospace end user needs in consultation with DARPA sponsors. In Phase II, Based on the optimum process condition and sintered properties of CDC samples, we will further develop other advanced lightweight/stronger alloys of interest to anticipated potential end users (e.g., GE, General Dynamics), procure the suitable hardware/tooling for scaling up and optimize the manufacturability of discrete parts on the most promising alloys developed in Phase I & Phase I Option by consulting and working with the appropriate DARPA technical program officers. In Phase II, scaling up, materials/manufacturing of complex components will be planned