High Temperature Propulsion Components for Advanced Solid DACS by Combustion Driven Powder Compaction (CDC) Technology

The proposed Phase II work is mainly focused on further continuing and developing Composite Alloys of W-25Re, Mo-Re, with Ta, Hf, HfC, and TaC for the application development of higher thrust-high temperature (e.g., TDACS FEDS) Large Thrust Pintles with potential weight reduction by suitable alloying and functional layering for advanced Solid DACS systems using UTRON’s 300, 400 or 1000 Ton CDC Press. Major advantages of CDC process are: faster process cycle time (e.g., milliseconds), much higher densification, less part shrinkage, improved mechanical/high temperature strength attributes, ability for micro/nano powder consolidation and simple/complex geometry, much less/no materials wastage, superior surface quality (e.g., micron/sub-micron finishes), ability to fabricate FGM layered materials, and scaling up potential. Having got excellent high temperature mechanical properties together with fine grained microstructures and improved densification under optimum conditions, we propose to develop similar Representative disks, solid or hollow cylinders or required desirable geometries, and several mechanical tensile dogbone samples will be processed to show the proof of concept and evaluated for CDC process optimization, thermal sintering responses, physical /geometrical/surface quality properties, microstructure, microchemistry and mechanical/high temperature properties in Phase II. Our R&D efforts are planned in continued collaboration with major MDA subcontractor (e.g., Aerojet) and SRI. Further advanced novel alloys, CDC process optimization, fabrication of specific geometries to MDA needs, extensive testing and scaling up efforts together with cost-effective manufacturing will also be done in Phase II and Phase III.