Rapid Higher Pressure Combustion Driven Compaction for Near Net Shape Manufacturing of Higher Temperature Propulsion Components Using Advanced Refract

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.