Manufacturing Cost Reduction for Key Enabling Thermal Management Applications Using CTE Controlled Graphite Fiber Reinforced Al

"This proposal shows how innovations in producing a family of CTE controlled, high thermal graphite aluminum composites will reduce manufacturing costs and improve system performance for specific BMDO, Navy, and commercial applications. Technologiesdeveloped by a graphite fiber producer, paper textile manufacturer, and metal composites foundry will create a superior thermal management material ideally suited for high volume semiconductor packaging production. BMDO, through the AIT program, supportedan effort to develop a Ka-band solid-state transmitter (SST) based on IMPATT (Impact Avalanche Transit Time) diode technology as a significantly lower cost, more reliable upgrade to the current traveling-wave tube (TWT)-based transmitter for the PAC 3Missile. A light weight, fast machining composite with diamond matched CTE and high thermal conductivity will facilitate a revolutionary breakthrough in concurrent integration of piece part components. Also, Lockheed Martin's Naval Electronics andSurveillance Systems for Aegis destroyers could save an estimated 5000 lbs per ship set - realizing tremendous cost savings and performance benefits. Conventional materials are too heavy, too expensive, inadequate thermally, or are unable to obtain low,reproducible CTE needed for emerging BMDO requirements, as a result - the graphite aluminum and manufacturing innovations proposed are a key enabler to future electronics warfare development. If th