Nanostructured Tungsten Rhenium Components for Propulsion Systems

Revolutionizing the space propulsion industry through innovative, relatively low-cost, manufacturing techniques is extremely needed. Specifically, advancements are needed for components in new high-powered electrical, beamed energy, and nuclear propulsion systems. Innovative processes for fabricating large, net shape, nanostructured tungsten-rhenium components are proposed. Innovative liquid precursors, tungstic acid and perrhenic acid, will be used in conjunction with powders. Vacuum Plasma Spray parameters will be developed to deposit nanostructured W-Re material. The techniques will then be used to fabricate samples for microstructural characterization and tensile testing. After optimization, non-eroding throats will be fabricated and hot fire tested at ATK/Thiokol at no cost to the Phase I effort. Tungsten is being used for its high melting temperature and chemical stability, and rhenium is used to improve ductility. The ability to fabricate nanostructured tungsten-rhenium components to net shape will revolutionize the ultra high temperature materials industry.