ADVANCED POWDER METALLURGICAL TECHNIQUES FOR SPHERICAL RHENIUM METAL POWDER

Rhenium Alloys, Inc. (RAI) has been successful in developing a high density, low oxygen, spherical, rhenium metal powder (SRMP) using the Starmet process on our Phase I SBIR. We also, independently, successfully developed a plasma spheroidizing process toproduce a similar powder. (Figure 1 and Figure 2) RAI have completed some initial studies on consolidation using hydraulic pressure with metal dies at room temperature, experimented with vacuum plasma spraying, and begun direct hot isostatic pressing(D-HIP) to produce rods for mechanical testing samples. Agreements are in place to run trials and attempt the 3-D production of components using a laser additive manufacturing (LAM) process. The results of the Phase I SBIR point to a successful Phase IIdevelopment of near net shape components using a variety of advanced powder metallurgical (PM) techniques. We will offer several options with appropriate budgets for each method so that choices can be made as to which method(s) are most critical for earlydevelopment within the timeframe allotted by the SBIR process. Each method proposed will be useful in the cost reduction and manufacturing schedule reduction that is required for the SM-3 divert system, other DoD missile systems, and commercialcustomers.Rhenium Alloys, Inc. was founded in 1966 to develop powder metallurgical applications for rhenium. Our 35-year history in the development and sales of this key refractory metal has been well recorded. We have in place an organization of 39employees dedicated to the production and sales in the U.S. and internationally of PM rhenium products. Our distributors throughout the world have the key contacts to get the information out to our potential customers. We currently ship to every continentbut one, Antarctica, and our products are used there. We have, at this time, over 600 customers for our products. The response from potential customers for the spherical rhenium powder at the recent AIAA Joint Propulsion Conference in Huntsville, AL wasoverwhelming. We merely showed a few powder samples from our Phase I development and word of mouth about the development quickly spread. We are now processing orders for small test quantities as well as planning production expansion for product and yieldimprovements to meet the demand in the near future. Letters of commitment from Plasma Processes, Inc., Aeromet Corporation and others point to the demand for this key breakthrough in the processing of PM rhenium components.We will use every available method to announce the development of this new spherical rhenium powder to the world's scientists and engineers. Our home pages on the Internet with Thomas Register and Thomas Regional as well as our own at www.rhenium.com willfeature the new powder. Rhenium Alloys, Inc. is registered on the Central Contractor's Registry (CCR) and is an accredited government supplier. Our electronic commerce site at TPN is a value added network (VAN) and is approved for E-commerce by thegovernment. We will place ads in key technical publications such as Advanced Methods and Materials (ASM International), Powder Metallurgy International, and Thermal Spray Society Magazine. Brochures and direct-mail advertising will be used to market to keypotential customers in the thermal spray industry, propulsion industry, and key government installations that are developing high temperature applications. Several papers in collaboration with AeroMet Corporation, Plasma Processes, Inc., and RefracSystems, Inc. will be presented and published detailing the development of the powder as well as the near-net shape production methods made possible by its development. Our company will attend trade shows throughout the country to discuss the possibleapplications of SRMP. The technology developed during Phase II of this SBIR will be used for military, NASA, and commercial interests. This will generate considerable publicity as additional papers are written and published about the benefits of theseadvanced techniques. Key programs such as the SM-3 Navy Theater Wide missile defense system, SSTO, RLV, shuttle retro-rockets, satellite bi-propellant combustion chambers, and tactical missile throats/pintles will benefit from these developments. The AirForce/NASA/Commercial consortium working on IHPRPT will be able to run trials for the production of large, non-eroding throats for solid propellant launch vehicles. Initial conferences have been held to discuss additional funding and support for a PhaseIII effort with some of the IHPRPT materials development committee members. The initial programming of the computers at AeroMet Corporation has already begun and a large throat test unit in titanium has been produced as an example.Our initial projections for sales of SRMP are on the order of $200K in 2001 with 30-40% growth per year over the next 5 years. These figures may be a bit conservative based on the amount of support we have received for our Phase II effort and the commentsfrom potential customers. The market potential for spherical rhenium metal powder is in the millions of dollars over the next ten years.