Dynamic Consolidation of Powders for Very Large Components

BMDO seeks development of novel methods to cut tabrication cost of metallic spacecraft and interceptor structures. UTRON proposes to develop an innovative rapid powder consolidation technique called Combustion Driven Dynamic Consolidation (CDDC) to consolidate metal (and other) powders. This technique is versatile and can be applied to various material systems such as metal and alloy powders, intermetallic-based powders, ceramics, composites, nanophase materials and their composites. This technology can be developed as a cost effective, ultrafast consolidation technique to produce powder metallurgical (P/M) components on an industrial scale. During Phase I, UTRON proposes to: 1) Experimentally demonstrate the consolidation of fine metal powders using a pulsed CDDC system to achieve close to theoretical density; 2) Determine the green densities of the consolidated samples and examine the microstructures of the consolidated samples; 3) Show that a repetitively pulsed (quasi-continuous) powder consolidation device can be built; and 4) Develop a conceptual model of the process to help guide experimental efforts and development of more effective implementation of the pulsed CDDC system. Anticipated Phase II objectives will be to: Demonstrate repetitively pulsed operation in a quasi-continuous mode, and demonstrate the technique for consolidation of powders on a prototype laboratory scale. This technology will be transferable to consolidation of metallic, intermetallic, and ceramic monolithic materials and composites applied to structural applications in many industries. In general, P/M parts and products made from advanced particulate materials will find new applications in automotive, aircraft engine electronic packaging, computer peripheral equipment, and medical markets.