Scaleable Spray Forming Technology for Consolidating Pyrophoric and Nanostructured Materials

"An innovative method for consolidating metallic powders at low temperatures into near net shape components and structures was discovered through prior research using aluminum powders. Now the opportunity exists for expanding this technology to a scaleableprocess for homogenous consolidation of multipurpose pyrophoric composites and particle reinforced metal matrix composites using aluminum powders. Solid-state spray forming (SSF) is a high-speed particle impact process for consolidating various metallicpowders, nonmetallic powders, and mixture thereof to a tailored density at thermally conditioned sub-liquidus temperatures. The object of the Phase I research is to investigate the feasiblity of using the SSF technology to produce aluminum nanophasematerials that have pyrophoric characteristics and to explore methods for consolidating nanophase and nanostructred powders. It is anticipated that the SSF technique can be scaled in Phase II to perform near net shape fabrication of multipurposepyrophoric devices and lightweight components and structures with nanostructured properties. Development of the SSF technology has excellent dual use applications because the process enables solid state consolidation of metallic and composite powders for industrial uses including rapid prototyping, thermal management materials, wear resistantcladding, composite structures and pyrophoric devices. The military applications include low cost methods