Net Shape Manufacturing of Functionally Grading Nano-Composite Materials for Gears Using High Pressure Combustion Driven Powder Compaction (CDC)

In response to Navy's needs for functional gradient gear materials development for applications such as V22-Aircraft/Helicopter, UTRON proposes an innovative manufacturing technology called the high pressure Combustion Driven Powder Compaction (CDC) to manufacture net shape quality, high density, mechanically durable and wear resistant ferrous based nanocomposite gear components with 9310 alloy, pyrowear 53, and CBS 600 as base materials and select dispersion of wear resistant nanocarbides such as boron carbide, silicon carbide and solid lubricants (e.g., molybdenum sulfide) by optimal sintering and heat treatment. Process advantages include superior sub-micron surface finish, synthesis/process flexibility of novel nanocomposites with ferrous alloys, less materials wastage, net shapes of simple to complex geometry at competitively lower manufacturing costs compared to the traditional wrought gear 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 or 0.5 inch diameter disks, dogbones and contact fatigue test rings at high pressures (150 tsi) and scientifically evaluate the physical, geometrical, microstructural, mechanical and select rotating contact fatigue wear properties with optimal sintering/heat treatments. This will be done in collaboration with Penn State's Applied Research Laboratory and Bell Helicopter-Textron.