NET SHAPE FABRICATION OF RHENIUM AND RHENIUM/HfC, TaC, SiC COMPOSITES FOR MDA-DACS NOZZLE LINERS USING HIGH PRESSURE COMBUSTION DRIVEN POWDER COMPACT

This MDA SBIR Phase II is focused on further developing and optimizing high density, mechanically durable high temperature Molybdenum/Rhenium, Rhenium and their alloys of Hf and HfC in net shape using UTRON's innovative, compact and cost-effective High Pressure Combustion Driven Powder Compaction (CDC) technology. The major application is for high performance Divert and Attitude Control System (DACS) nozzle liner systems (e.g., inlet and plenum liners) for MDA’s advanced propulsion (e.g., SM-3, KEI and ERAM) needs. The unique advantages are: net shaping ability, faster process cycle time (e.g., milliseconds), higher densification, ability for simple/complex geometries, micro/nano powder consolidation, functional multi-layered materials, substantial cost savings due to less or no materials wastage unlike the wrought or cast parts, superior surface quality (e.g., micron/sub-micron finishes) and scaling up potential. We propose to fabricate 0.5 inch diameter disks/rings, 3.5 inch long dogbones and nozzle liners of specific MDA subcontractor’s designs and scientifically characterize key CDC process optimization/manufacturing strategy, physical properties, surface quality/roughness, microstructure/microchemistry/crystal structures, texture effects, and mechanical/high temperature properties. Our R&D efforts will be integrated by closely working with MDA sponsors/subcontractors in Phase II and III for missile defense and other key commercial applications (e.g., advanced x-ray targets for bio-medical/security inspection applications).