Net Shape Fabrication of Novel Projectile Materials Using Rapid Combustion Driven Ultra-High Pressure Powder Compaction (CDC) Manufacturing Navy SBIR FY2010.2 Sol No.: Navy SBIR FY2010.2 Topic No.: N102-149 Topic Title: Net Shape Fabrication of Novel Projectile Materials Using Rapid Combustion Driven Ultra-High Pressure Powder Compaction (CDC) Manufacturing Proposal No.: N102-149-0678 Firm: Utron Kinetics, LLC 9441 Innovation Drive Manassas, Virginia 20110 Contact: Karthik Nagarathnam Phone: (703) 369-5552 Web Site: www.utronkinetics.com Abstract: 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. Benefits: The potential commercial and military applications for the proposed CDC high pressure compaction technology include warhead parts, shaped charge liners, military ammunitions/projectiles/heat shields, gyroscopes, igniter components, electronic packaging/aerospace components, x-ray targets/tubes (e.g., Tungsten, Molybdenum, TZM, Rhenium or Moly Alloys), high performance welding and glass melting electrodes, RF damage resistant refractory rings used for linear collider copper disk structures, high temperature dies, brazing fixtures, electrical contacts, warheads (charge liners), rocket nozzles/liners, next generation accelerator parts (e.g., DOE applications), roller bearings, permanent /superconducting magnets, microelectronic packaging interconnects, sputtering/x-ray targets with conductive copper backing, mould dies with tough steel/copper backing, automotive/aerospace piston rings, valve seats, gears, and wear/corrosion resistant tribological components. Return