Near Net Shape Manufacturing of Actuator Components by Rapid Combustion Driven Powder Consolidation Technology

In response to MDA's need for fabricating actuator components for DACS and other systems, UTRON proposes an innovative manufacturing technology called the high pressure Combustion Driven Powder Compaction (CDC) to manufacture near net shape quality actuator system components such as gears with improved densification, mechanical and microstructural attributes. The actuator gear system components are to be fabricated using advanced ferrous based alloys and select composites. Process advantages include higher densities, reduced shrinkage, rapid compaction process cycle times, reduced materials wastage, superior sub-micron surface finish, synthesis/process flexibility of novel nanocomposites, simple to complex geometry fabrication at competitively lower manufacturing costs compared to the traditional P/M and other fabrication methods. The major focus of Phase I is to demonstrate the proof of concept to fabricate the proposed materials in various geometries such as 1 inch diameter disks, mechanical test samples, rings and small scale gear at high CDC compaction pressures (150 tsi) and scientifically evaluate the physical, geometrical, microstructural, and mechanical properties with optimal sintering/heat treatments. More advanced alloys, scaling up and complex geometries will be developed in Phase II. The proposed work has been planned in collaboration with General Dynamics and Southern Research Institute.