Low Cost ALON

This program will first establish a low-cost aluminum oxynitride (ALON) powder synthesis process, known to yield powder that can readily be densified to optical transparency. This program will then establish a new low-cost source for transparent ALONwindows. In Phase I, MSI will demonstrate a proven, low-cost method for synthesizing ALON powder. The process will utilize carbothermal reduction of high purity alumina in a nitrogen atmosphere to form ALON directly, avoiding AlN entirely. Startingconstituents (Al2O3 and carbon powders) will be weighed, blended, reacted at elevated temperature in a nitrogen atmosphere, and then milled. Chemical purity, phase purity, lattice parameter, particle size, particle size distribution, and surface area ofthe resulting powders will be measured. In the Phase I Option, the ability to densify the powder to optical transparency will be verified, and scale up of the powder synthesis will be initiated. In Phase II, MSI will develop a high-volume continuousprocess for producing ALON powder and establish a complete transparent ALON fabrication capability. In addition, we will investigate ways to streamline the ALON fabrication process that could eliminate one or more major process steps.Transparent ALONarmor offers superior protection against small caliber armor piercing projectiles at substantially reduced weight and thickness. Initially, this program will provide a low-cost source of high purity ALON powders. Subsequently, when the Phase II programhas been completed, a new low-cost source for transparent ALON components will have been established. A primary defense application for transparent ALON is low-cost, light-weight, large-area transparent armor panels for military land vehicles andaircraft. Commercial personnel security vehicles will also benefit from the technology developed in this program.