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

The proposed work is mainly focused on developing Composite Alloys of W-Re, 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 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 cast, superior surface quality (e.g., micron/sub-micron finishes), and scaling up potential. Representative disks, hollow cylinders, and select 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 I. Our R&D efforts are planned in 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 will be done in Phase II and Phase III.