Novel Low Cost Machining Techniques for Making Rhenium Components for the Miniature Kill Vehicle (MKV)

In order to meet the goal of producing minature interceptors that cost less than $50K, new designs and lower cost manufacturing methods are required. The approached advocated in this proposal is to use novel machining techniques which have recently been developed and used to make rhenium test specimens. Rhenium is the material of choice for hot gas components used in Divert and Attitude Control Systems (DACS)and the high cost of machining this material has been the largest manufacturing cost driver. Ormond has recently begun working with Lockheed to qualify new abrasive machining technolgies that have the potential to dramatically reduce costs while at the same time avoid the surface damage caused by the current manufacturing methods. The feasibility of using the new techniques to cut, drill, groove, mill and turn rhenium parts will be demonstred in Phase I of this program.