Low cost alternatives to expensive complex manifold pipe shapes used in high temperature (3000F-4500F) missile control systems.

Current state-of-the-art technology for Strategic Missile Post Boost Control Systems is niobium (Nb) alloy tubing formed and welded in complex shapes with built-in hot valve mechanisms. Other metals used in the system include TZM connectors and tantalum(Ta) alloy valve pistons. And since these materials are not resistant to the corrosive effects of solid propellant combustion products, they must be internally coated for protection. The system is heavy, difficult to fabricate and inspect, and expensive.Previous work has demonstrated that rhenium is the best structural material for use in the combustion products of solid propellants. It is nearly inert nearly up to its melting point (3180¿¿C) and retains significant strength up to 2500¿¿C (4500¿¿F). Butrhenium is very dense (21 g/cc), difficult to form, and expensive. In this program, Powdermet proposes to combine several novel and innovative techniques to fabricate lightweight, inexpensive rhenium composite components that are applicable to StrategicMissile Post Boost Control Systems. Significantly reduced weight and higher performance due to higher temperature capabilities. Other applications include both solid and liquid rockets, aircraft engines, gun barrels, nuclear systems for commercial usesand pollution control.