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

This SBIR Phase I project is focused on fabricating and evaluating dense and durable refractory based Rhenium, Rhenium/Molybdenum and Rhenium/HfC, TaC and SiC functional composites in net shape using UTRON's innovative, compact and cost-effective High Pressure Combustion Driven Powder Compaction (CDC) technology. The major application is for MDA's high performance Divert and Attitude Control System (DACS) nozzle liner systems for advanced propulsion. Some of the unique advantages are: faster process cycle time (e.g., milliseconds), much higher densification, ability for simple/complex geometries, micro/nano powder consolidation with functional multi-layered materials, substantial cost savings due to much less or no materials wastage unlike the wrought, forged, cast, machined or plasma sprayed parts, superior surface quality (e.g., micron/sub-micron finishes) and scaling up potential. We propose to develop R&D samples of 0.5 inch diameter cylindrical ring, 3.5 inch long dogbones and small scale (<1 inch diameter) truncated conical nozzle liner and scientifically characterize key CDC process optimization, manufacturing strategy, physical properties, surface quality/roughness, microstructure, microchemistry and mechanical/high temperature properties. Our proposed R&D efforts will be integrated by closely working in partnership with MDA subcontractors for more multi-level complex shapes and other novel competitive composite alloys of Rhenium/Molybdenum with carbides, borides, and silicides in Phase II.