Green Body Machining of Domes

New applications, such as the JCM and Small Diameter Bomb (SDB), require affordable, durable domes with multiple-waveband transparency (i.e., near-IR, MWIR or LWIR, and MMW). Cost effective fabrication of such a dome, will require achieving the optimal balance between competing requirements. Choice of durable dome materials, with suitable transparency, high speed/tight tolerance fabrication techniques, and incorporation of suitable grid/resonant structures to provide EMI shielding and suitable MMW transmission are all critical to the development of a tri-mode seeker dome designs. It is proposed for this Phase 2 program to create a more deterministic process stream utilizing green machined dome blanks to produce a predictable, dimensionally consistent product for down stream processing. The resulting robust process will result in cost saving through improved powder utilization, increased yields, reduced labor and materials costs at final finishing, and more predictable material properties in the final dome deliverable. The green machining process is equally applicable to ALON and Spinel dome blanks. Aspects of this development program will result in improved binder systems for green machining; heat treatment schemes and fixturing to produce consistent dimensional accuracy; methodology and predictive tools for near net shape processing domes, processes for recycling powder; and methods for defect inspection of dome blanks.