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Manassas, VA, United States

Grant
Agency: Department of Defense | Branch: Missile Defense Agency | Program: SBIR | Phase: Phase I | Award Amount: 125.00K | Year: 2015

Utron Kinetics proposes to develop high temperature advanced ceramic based composites of R-NZP, and Nano-Zirconia based advanced composites and their functional composites in near net shape geometries using UTRON's innovative, compact and cost-effective High Pressure Combustion Driven Powder Compaction (CDC) manufacturing technology. A 300 Ton or 400 Ton CDC Press will be used for the proposed work. Major advantages of CDC process are: faster process cycle time (e.g.,milliseconds), much higher densification due to higher CDC pressures, ability for cold or hot pressing at higher pressures, less part shrinkage, better mechanical strength attributes, ability for micro/nano powder consolidation and simple/complex geometry, much less/no materials wastage, superior surface quality (e.g., micron/sub-micron finishes), and scaling up potential. Small scale (


Grant
Agency: Department of Defense | Branch: Navy | Program: SBIR | Phase: Phase I | Award Amount: 79.98K | Year: 2011

The major objectives of the Phase I effort will be focused on CDC high pressure compaction/fabrication, post-processing, testing and materials performance/baseline preliminary material modeling of the kinetic behavior of the projectile material compositions based on select geometry and CDC materials properties. CDC projectile/warhead fragment materials include tungsten alloys, Hf/Al, W/Al, Al/Boron, Hf/Zn, Zr/Zn, Zr/Al, or Ta/Al, Mo/Al, and select materials with boron, molybdenum oxide and/or sulfur including some polymer matrix composites indicating the potential for process flexibility. Select geometrical shapes such as 1 inch diameter cylinders/disks with 1 inch thickness will be fabricated using the available 300 ton CDC press and existing die/punch assemblies for initial exploration. Compositions will be optimized in consultation with OSD sponsors to obtain varying densities closer (e.g., 7 g/cc or higher). Appropriate experimental process optimization at much higher compaction pressures (e.g., 50 to 150 tsi) will be developed to obtain projectiles of controlled porosities as an integral part of Phase I, Phase I option and Phase II. Key CDC process optimization, suitable as-pressed higher density parts and /or any other less thermal processing sintering/heat treatment responses, net shaped part quality, microstructural/microchemistry properties, and mechanical properties such as hardness and other strength durability properties at room temperature will be evaluated in Phase I. In Phase II, scaling up, materials/manufacturing of advanced projectiles of desirable geometries for reactive fragment warhead components such as multiple-pressing of several pellets, projectile assemblies, spheroidal shaped warheads etc will be planned and the developed CDC parts after optimum processing conditions. One of the potential collaborators in the proposed SBIR is ATK.


Grant
Agency: Department of Defense | Branch: Navy | Program: STTR | Phase: Phase I | Award Amount: 80.00K | Year: 2014

The major objectives of the Phase I effort will be focused on CDC higher pressure combustion (using natural gas or hydrogen-GREEN MANUFACTURING) driven powder compaction fabrication of select alloys for Microwave Tube Related Component end uses for NAVY using powders of varying sizes and vacuum-grade purity such as Cupro-Nickel, Stainless Steels (e.g., 316 LN, Custom 465 high strength version), Monel 404 and select Molybdenum Based Alloys (e.g., Molybdenum, Mo-W, Mo-Hf-HfC, Mo-with Lanthanum Oxide; Mo-Re) and Other Competitive Alloys of stainless steel equivalents with reduced Ni content for feasibility. Select geometrical shapes of mechanical test coupons, small scale cylinders (0.66 inch/1.35 inch dia cylinders) and other geometries (including hollow-cylindrical geometry of 1.8 inch OD; 1.65 inch ID and 1 inch height using the most promising molybdenum based materials) will be fabricated using CDC method as a proof of concept. UTRON Kinetics"s uniquely controllable higher pressure compaction up to 150 tsi in rapid compaction times (milliseconds) and then process them for property evaluation. 300/400 Ton CDC compaction press is planned for use in the proposed work. Proposed research is planned to use the current tooling for mechanical test coupons, small scale cylinders, and modified tooling for the representative hollow cylinder geometry for NAVY"s MWT (in consultation with CPII) at UTRON Kinetics in Phase I and Option. Proposed tasks include suitable CDC compaction parameters, powder chemistry/morphologies, thermal post-processing, physical/geometrical properties of green and sintered parts under select thermal processing (e.g., vacuum, argon environment etc) conditions, mechanical strength/ductility properties at room temperature, microstructures, microchemistry, thermal and electrical conductivity, high vacuum leak resistance testing, and thermal cyclic stress behavior as required for microwave tube product end uses. We have both Georgia Tech and CPII as subcontract collaborators. Phase I option will be used also for further evaluation of the most promising samples in consultation with NAVY sponsors. More advanced material compositions, complex part fabrication, and scaling up for cost effective manufacturing will be evaluated in Phase II and beyond. Proposed work has several potential end users from the Industries as well as from the DOD.


Grant
Agency: Department of Defense | Branch: Missile Defense Agency | Program: SBIR | Phase: Phase I | Award Amount: 100.00K | Year: 2009

In response to MDA’s needs for non-eroding throats for controllable axial upper stages , UTRON proposes an innovative near net shape fabrication technology called High Pressure Combustion Driven Powder Compaction (CDC) with tremendous potential for cost-effective manufacturing of advanced cermet type of alloys of ceramics such as micro/nano HfC, HfB2, HfN, ZrC and/or with high temperature ductilizing refractory metal such as Rhenium or Rhenium based alloy as well as ZrC/HfC particulate based composites. Major advantages of CDC process are: faster process cycle time (e.g., milliseconds), much higher densification, less part shrinkage, better mechanical/high temperature strength attributes, ability for micro/nano powder consolidation and simple/complex geometry, much less/no materials wastage cast, superior surface quality (e.g., micron/sub-micron finishes) compared to cast/plasma sprayed/CVD parts, and scaling up potential. Representative (0.5 to 1 inch diameters) disks and select small scale throat ring samples will be fabricated to show the proof of concept and evaluated for CDC process optimization, thermal sintering responses, physical /geometrical/surface quality properties, microstructure, microchemistry and mechanical/high temperature properties in Phase I. Our proposed R&D efforts are integrated by close partnership with a major MDA subcontractor-Aerojet and SRI. Further advanced novel cermet advanced alloy development, CDC process control, fabrication of specific scaled up geometries, testing and scaling up efforts will be done in Phase II.


Grant
Agency: Department of Defense | Branch: Navy | Program: SBIR | Phase: Phase I | Award Amount: 99.99K | Year: 2010

The major objectives of the Phase I effort will be focused on CDC high pressure compaction/fabrication, post-processing, testing and materials performance/baseline preliminary material modeling of the kinetic behavior of the energetic material compositions based on select geometry and CDC materials properties. CDC compacted candidate reactive fragment warhead/projectile materials include Hf/Al, W/Al, Al/Boron, Hf/Zn, Zr/Zn, Zr/Al, or Ta/Al, Mo/Al, and select materials with boron, molybdenum oxide and/or sulfur. Select geometrical shapes such as 0.5 inch diameter cylinders/disks, near spheroidal pellet shapes (e.g., 0.5 inch diameter), and 3.5 inch long tensile dogbones will be fabricated using the available 300 ton CDC press and existing die/punch assemblies for initial exploration. Compositions will be optimized in consultation with OSD sponsors to obtain densities closer to 7 g/cc or higher. Appropriate experimental process optimization at much higher compaction pressures (e.g., 50 to 150 tsi) will be developed as an integral part of Phase I and Phase II. Key CDC process optimization, suitable sintering/heat treatment responses, near or net shaped reactive fragments/warhead spheroidal pellet part quality, microstructural/microchemistry properties, and mechanical properties such as hardness and other strength durability properties at room temperature will be evaluated in Phase I. In Phase II, scaling up, materials/manufacturing of reactive fragment warhead components such as multiple-pressing of several spheroidal shaped warheads etc will be planned and the developed CDC parts after optimum processing conditions.

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