High Temperature Sensor for Consolidation of Refractory Metals and Alloys

MATSYS proposes to develop and demonstrate a high temperature sensor technology to enable (1) densification of nanostructured refractory metals and alloys into fully dense bulk materials with the desired microstructure; (2) densification of temperature-sensitive materials, such as reactive powder blends and nanostructured powders; and (3) damage measurement of metallic structural materials. This effort will build on our unique expertise in high temperature eddy current sensing during Hot Isostatic Pressing to design and demonstrate a new generation of sensors for consolidation of temperature-sensitive materials. To date the maximum temperature reached with in situ sensor monitoring is about 1250°C. A current unsolved challenge is the consolidation of tungsten and other refractory metal powders, including nanostructured material, that require a maximum temperature above 1250°C for full consolidation. Successful consolidation of nanostructured metals and alloys into nanostructured fully dense composites will enable the introduction of a new class of materials for a wide range of military applications, while damage measurement of metallic structural materials will enable the application of this technology for fatigue life prediction of gun barrels. Additional applications include transparent ceramic for armor applications, as well as optical devices, windows, and lenses that are more durable than single crystals and conventional glass.