Development of Ultra-High Strength Intrinsically Corrosion Resistant Steels Using High Pressure Powder Compaction Technology

In response to OSD/NAVY’s need for landing gear component applications, We propose to develop advanced high strength steels using CDC compaction manufacturing. Common materials used are 4340 steel, 300M, and AerMet 100. AerMet 100 has superior material properties to 4340 and 300M. Landing gear components made from AerMet 100 has had success within the USN. However this is an expensive and limited supply material. The nominal material property values for AerMet 100 are 250-ksi 0.2 percent yield strength, 285-ksi ultimate strength, and 100 ksivin. An ultra high strength stainless steel with mechanical properties equivalent to AeroMet 100 and the corrosion resistance of a PH 13-8 (H1025) is desired. Representative desirable properties include: UTS (ksi) > 290 YS (ksi) > 245 KIC (ksiãin) > 100 KISCC (ksiãin) > 70. UTRON proposes an innovative manufacturing process technology called the high pressure Combustion Driven Powder Compaction (CDC) to manufacture near net shape quality, dense, fine grained and mechanically durable high density ferrous based components such as Carpenter’s Custom 465 stainless martensitic steels, Aermet 100, 17-4 PH and Other PH 13-8 Mo martensitic stainless steel as base materials and select optimized alloying additions such as (e.g., Al, Nb, Hf, Zr, Re) to further improve the mechanical and corrosion properties as well as select composite dispersoids such as carbides such as boron carbide, silicon carbide. Some of the unique process advantages of CDC technology include higher green and sintered part densities, ability to produce novel alloys with near net shape parts, single/multi-layered materials, minimal shrinkage attributes compared to conventional means and improved microstructures/properties. We propose to develop competitive high strength and corrosion resistant steel alloys using high pressure CDC and suitable post-process HIPing, sintering/heat treatment strategies with improvement in mechanical and stress corrosion properties. Microstructures, microchemistries and properties of the optimized alloys will be developed. In Phase II, we plan to further focus on the optimum alloys and develop near net shape complex manufactured components as well as scale-up of the press/tooling hardware.