Manassas, VA, United States
Manassas, VA, United States
SEARCH FILTERS
Time filter
Source Type

Grant
Agency: Department of Defense | Branch: Missile Defense Agency | Program: STTR | Phase: Phase I | Award Amount: 99.95K | Year: 2010

This Phase I STTR effort will be focused on fabricating and scientifically characterizing Mo/Re (59 Mo-41 Re), and W-25Re alloys with other alloying additions such as small % of dispersion strengthening materials such as zirconia, hafnia, tungsten carbide, Hafnium (Hf), Zirconium, TaC, Hf-based carbides in select geometrical shapes using UTRON Kinetics''s innovative, and cost-effective Combustion Driven Powder Compaction (CDC) at higher pressures (e.g., up to 85-150 tsi). The samples will be fabricated using commercially available fine powders and select geometries to be fabricated include 1 inch diameter cylindrical disks, 3.5 inch long tensile dogbones as well as small scale near net shape geometry such as hollow cylinder valves using the existing tooling. We will develop the key CDC process optimization for various proposed alloys, suitable sintering response in hydrogen or suitable environment (e.g., vacuum/hydrogen sintering), density changes, geometry/surface/part quality, select mechanical tensile properties at room and elevated temperatures (e.g., 3500 F or higher in consulation with MDA sponsor and subcontractors such as ATK/SORI), microstructures and microchemistry. Based on the optimum process conditions, representative small scale hollow valve/liner (Phase I) and other complex high temperature components will also be fabricated using a special die/punch assembly and scaling up in Phase II. Further process optimization on the most promising W-Re and Mo/Re alloys or the dispersion strengthened alloy composites and rapid manufacturing strategies will be established and continued in Phase II and Phase III.


Nagarathnam K.,Utron Kinetics, LLC | Massey D.,Utron Kinetics, LLC | Opeka M.,U.S. Navy
International Journal of Powder Metallurgy (Princeton, New Jersey) | Year: 2011

Details of the high-pressure combustion-driven powder compaction (CDC) process are presented with particular reference to the consolidation of refractory metal and alloy powders. Rapid load cycles (ms) at pressures up to 2,069 MPa (150 tsi) result in highgreen-density net-or nearnet-shape parts that exhibit minimal shrinkage during sintering and fine-grain equiaxed microstructures. CDC tungsten and rheniumbase alloys retain strength levels >172 MPa (25,000 psi) at 1,927°C. As an example of the utility of CDC, the performance of tungsten and molybdenum in X-ray targets is assessed. The properties of CDC refractory metals and alloys offer potential for new commercial applications in the energy, electronics, defense, and biomedical sectors.


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: Defense Advanced Research Projects Agency | Program: SBIR | Phase: Phase I | Award Amount: 99.99K | Year: 2012

The DARPA is seeking rapid innovative manufacturing for turbine components in Vulcan Program. We, at UTRON Kinetics, propose a modern rapid Combustion Driven Advanced Powder Compaction Manufacturing to fabricate simple and complex shapes of various refractory alloys and composites using Mo-Re, with Nb, Ti-aluminides, and carbides for temperatures of 3500 degF as a proof of concept in Phase I and we then focus on the most promising materials and manufacturing using CDC in Phase I option and further scaling up in Phase II. Gasturbine materials include superalloys, single crystal materials etc which have limits for the operating temperatures (<900 degC is commonly used!!). Developing advanced high temperature materials with required mechanical and thermal properties (for temperature of 3500 degF) using metal matrix composites of Mo-Re with Niobium/Titanium aluminides and composites and Making several of these materials in a suitable near net shape or net shape component form rapidly and cost-effectively (30- to 50% less expensive than by conventional means of fabrication) with significant reduction of materials wastage using CDC method forms the basis for this DARPA SBIR innovation proposed research. The major objectives of the Phase I effort will be focused on fabrication, testing and materials performance characterization of CDC compacted Molybdenum/Rhenium, alloys with Niobium, Ti-and select composites of aluminides, and carbides. The proof of concept in Phase I is added demonstrating the higher pressure consolidation rapidly and uniquely in near net shape and net shape forms with advantages to process select groups of materials and shapes of DOD and industry interest and evalauate properties at 150 tsi. Other advantages include near net shaping ability, and materials properties after suitable sintering/heat treatment. Select geometrical shapes such as 1 inch diameter cylinders/disks, 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 of property testing of coupons and small scale turbine blade/hollow disk components of fabrication. Compositions will be optimized in consultation with DARPA sponsors in Phase I. Appropriate experimental process optimization at much higher compaction pressures (e.g., up to 150 tsi) will be developed as an integral part of Phase I, Phase I option and Phase II. Key CDC process optimization, suitable sintering/heat treatment response, near or net shaped part quality, microstructural/microchemistry properties, and mechanical properties such as hardness and other strength/ductility properties at room and elevated temperature upto 3500 degF will be evaluated in Phase I for optimized samples. In Phase I Option, we will focus our attention on the most promising alloys of interest, establish cost-effective discrete manufacturing strategies based on the potential DOD/commercial aerospace end user needs in consultation with DARPA sponsors. In Phase II, Based on the optimum process condition and sintered properties of CDC samples, we will further develop other advanced lightweight/stronger alloys of interest to anticipated potential end users (e.g., GE, General Dynamics), procure the suitable hardware/tooling for scaling up and optimize the manufacturability of discrete parts on the most promising alloys developed in Phase I & Phase I Option by consulting and working with the appropriate DARPA technical program officers. In Phase II, scaling up, materials/manufacturing of complex components will be planned


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.


Grant
Agency: Department of Defense | Branch: Navy | Program: SBIR | Phase: Phase II | Award Amount: 726.20K | Year: 2012

We propose in Phase II effort to continue and further optimize and scale up to fabricate the large diameter fragmenting test cylinders/complex geometries using innovative and Cost-effective Combustion Driven Rapid Powder Compaction Manufacturing as a follow-up of the successful development and materials properties/reactivity up to 6000 ft/s of CDC compacted reactive fragment materials from the Phase I efforts. CDC compaction process optimization is planned to develop additional materials properties, advanced alloy development with enhanced reactivities than equivalent steels, scaling up to fabricate for larger/complex geometries of reactivity test cylinders of various sizes of OD and wall thicknesses as per the sponsor's (OSD-ONR-NSWC) needs. Small and medium scale spheres/cylinders also will be developed for preliminary screening for materials behavior and reactivities. Advanced alloys proposed include combonations of Zr-Zn-W and other addvanced alloys,and mechanical, microstructural and microchemistry will be correlated with CDC compaction/post-process conditions based on select geometry and CDC materials properties. Potential alloying include tungsten, W-Ni-Fe, W, W/Zr/Zn, Nanomaterials of aluminum, Iron, Copper etc as examples) and reactivity enhancing materials in small concentrations such as nanoAluminum or Cryomilled Al-Zr-Zn alloys with Zr-Zn-W to obtain reactivities as a proof of concept and extend for other alloys in Phase II. Phase II option will be focused on the most promising alloys for specific needs from OSD sponsors/ potential industry end users such as NSWC,ATK, Aerojet or General dynamics etc, for their commercial applications.


Grant
Agency: Department of Defense | Branch: Missile Defense Agency | Program: SBIR | Phase: Phase I | Award Amount: 149.99K | Year: 2012

In response to MDA"s innovative manufacturing approaches, we propose to fabricate and evaluate high strength, higher temperature W-25Re base alloys and their select composite materialsof Hf, HfC, TaC for erosion resistant throats (for second or third stage rocket motors. Required number of units are 100s to thousands and cost reduction in manufacturing and rapid delivery processing are critical. UTRON Kinetics proposes a cost-effective and rapid manufacturing (e.g., milliseconds of compaction time) method called high pressure Combustion Driven Powder Compaction (CDC) technology to fabricate fine grained (<50-75 microns) W-25Re based alloys and composites with Hf, HfC for solid rocket hollow throat applications. The major objectives of the Phase I SBIR effort will be focused on fabricating and scientifically characterizing W-25Re alloys and select composites with small % of alloying additions such as Hf, HfC, TaC in select geometrical shapes (mechanical test coupons, small scale disks and small scale throat (hollow cylinder) using UTRON"s innovative, cost-effective and compact Combustion Driven Powder Compaction (CDC) at high pressures (e.g., 150 tsi). The samples will be fabricated using commercially available fine powder as raw materials and geometries to be fabricated include 0.5 inch or 1inch diameter cylindrical disks, 3.5 inch long tensile dogbones as well as small scale hollow hollow throat using the available tooling. We will develop the key CDC process optimization for various proposed alloys, suitable sintering response in hydrogen or suitable environment (e.g., vacuum sintering), density changes, geometry/surface/part quality, select mechanical tensile properties at room and elevated temperatures (e.g., 4100-4500 degF or higher in consultation with MDA sponsor and subcontractors, microstructures and microchemistry. Based on the optimum process conditions, representative small scale hollow throat liner (Phase I) and other large thrust throat components will also be fabricated using a special die/punch assembly and scaling up in Phase II. Further process optimization on the most promising W-25Re alloys or the alloy composites, scaling up and rapid manufacturing strategies will be established and continued in Phase I Option and Phase II/ III.


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: Missile Defense Agency | Program: SBIR | Phase: Phase II | Award Amount: 999.96K | Year: 2013

Based on the successful Phase I results, The major objectives of the Phase II SBIR effort will be focused on further continuation and development of CDC compaction of W-25Re and other composite materials, processing optimization, fabricating test coupons and small scale throat/prototype large scale parts for the MDA/prime contractor part needs (Aerojet, Raytheon) and scientifically characterizing the materials behavior including high temperature properties and select hot-fire testing in coordination with MDA sponsors and establish cost-effective manufacturing for transition to MDA sub-systems such as SM3-BlockIIA, Block IIB applications. Proposed materials include W-25Re alloys and select composites with small % of alloying additions such as Hf, HfC, TaC, HfN in select geometrical shapes (mechanical test coupons, small scale disks and small scale throat/large scale prototype part using UTRON"s innovative, cost-effective and compact Combustion Driven Powder Compaction (CDC) at high pressures (e.g., up to 150 tsi). The samples will be fabricated using commercially available fine powders as raw materials and geometries to be fabricated include 3.5 inch long tensile dogbones, disks (1-1.5 inch diameter) as well as small scale throat/large scale prototypes for potential hot-fire testing. We will develop the key CDC process optimization for various proposed materials, suitable thermal processing/sintering, geometrical and physical property (density) changes, geometry/surface/part quality, select mechanical tensile properties at room and elevated temperatures (e.g., RT to 3750-4100-4500 degF or higher in consultation with MDA sponsor and subcontractorsAerojet/SORI), microstructures and microchemistry. Based on the optimum process conditions, representative small scale hollow throat liner and other large thrust throat components will also be fabricated using a special die/punch assembly and scaling up in Phase II. Further process optimization on the most promising W-25Re alloys or the alloy composites and rapid manufacturing strategies will be established and continued in Phase II and Phase III.


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.

Loading Utron Kinetics, LLC collaborators
Loading Utron Kinetics, LLC collaborators