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Affordable Manufacturing of Refractory Metal Components
Navy SBIR 2014.2 - Topic N142-125 SSP - Mr. Mark Hrbacek - [email protected] Opens: May 23, 2014 - Closes: June 25, 2014 N142-125 TITLE: Affordable Manufacturing of Refractory Metal Components TECHNOLOGY AREAS: Materials/Processes, Weapons ACQUISITION PROGRAM: TRIDENT II (D5), ACAT I RESTRICTION ON PERFORMANCE BY FOREIGN NATIONALS: This topic is "ITAR Restricted". The information and materials provided pursuant to or resulting from this topic are restricted under the International Traffic in Arms Regulations (ITAR), 22 CFR Parts 120-130, which control the export of defense-related material and services, including the export of sensitive technical data. Foreign nationals may perform work under an award resulting from this topic only if they hold the "Permanent Resident Card", or are designated as "Protected Individuals" as defined by 8 U.S.C. 1324b(a)(3). If a proposal for this topic contains participation by a foreign national who is not in one of the above two categories, the proposal may be rejected. OBJECTIVE: Develop and demonstrate advanced additive manufacturing techniques for low-cost manufacturing of refractory metal components for Navy strategic missile post-boost propulsion systems. DESCRIPTION: Current manufacturing techniques for refractory metal components are complex and labor intensive. SSP desires to reduce the cost and skill required to manufacture these components through more efficient use of raw materials along with a reduction of machining, multiple setups, and labor hours. One possible approach is use of Advanced Additive Manufacturing, which has demonstrated the ability to fabricate metallic parts with significant reductions in cost and lead-time compared to traditional manufacturing methods. To-date, the majority of additive manufacturing technology development has focused on conventional structural materials such as titanium. Application of this technology to refractory metal alloy components holds even greater potential to drive affordability given the high raw material costs and complex processing methods associated with these products. The primary objective of this SBIR topic is to develop, demonstrate, and validate new manufacturing technologies in complex parts made of refractory metals (e.g., Ta-10W, C103, TZM, Mo41Re, W, and Re) for low-cost and rapid fabrication of post-boost control system hot-gas valve and manifold components while meeting performance requirements levied upon conventionally manufactured parts. Key performance requirements include surviving exposure to greater than 3,200 degree Fahrenheit gaseous environment for 10 minutes at 550 psi. Key challenges include tailoring advanced additive manufacturing processes and systems (e.g. electron beam, laser melting) to refractory metal alloys, understanding processing-structure-property relationships, evaluating the characteristics of engineered products fabricated using direct deposition or other methods, and addressing scale up for fabrication of full scale components with significant dimensional and geometric complexity. PHASE I: Develop processes and demonstrate the fabrication of simplified, subscale article for C103 and develop and discuss approaches for fabrication of at least one more of the refractory metals/alloys listed above in the description. A suitable sub-scale demonstration article would be tubing with a 2 inch length, 1 inch OD, and 0.1 inch wall thickness. The process must also demonstrate scalability. Measure physical and mechanical properties of refractory metal alloys fabricated using the advanced additive manufacturing technique and validate that they meet or exceed the properties derived from traditional processing methods. Conduct mechanical property testing of fabricated specimens, microstructural evaluation, and verify adequate performance to advance to full scale representative components. Identify technology and manufacturing development challenges and approach associated with insertion of manufactured parts to address in Phase II. PHASE II: Conduct design and analysis of relevant hot gas valve and manifold components to be built with advanced additive manufacturing methods. Develop, fabricate, demonstrate, and validate full-scale component prototypes using advanced additive manufacturing techniques. Test manufactured prototypes in relevant environments and verify acceptably low degradation of mechanical properties or grain structure. Quantify the cost and schedule benefits of fabricating hot gas valve and manifold refractory metal components using advanced additive manufacturing method. PHASE III: Test manufactured prototypes in full-scale ground test. Navy Strategic Systems Programs will provide the assets and test support as Government Furnished Equipment and Services. SSP plans to transition the technology into several aspects of the program for both further development of throttleable valves as well as currently produced items on the PBCS Gas Generator. PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: There is the potential that this technology could be adapted for use on thrusters used on commercial spacecraft. REFERENCES: 4. Sciaky Inc. Additive Manufacturing Site, http://www.sciaky.com/additive_manufacturing.html. KEYWORDS: Additive Direct Manufacturing; Direct Metal Deposition; Refractory Metals; Hot Gas Valves and Manifolds; Post Boost Control System; Strategic Missiles
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