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Scale-Up Production of Large Spinel Reconnaissance Windows
Navy SBIR FY2013.2
| Sol No.: |
Navy SBIR FY2013.2 |
| Topic No.: |
N132-125 |
| Topic Title: |
Scale-Up Production of Large Spinel Reconnaissance Windows |
| Proposal No.: |
N132-125-1026 |
| Firm: |
Materials & Electrochemical Research (MER) Corp.
7960 S. Kolb Rd.
Tucson, Arizona 85756-9237 |
| Contact: |
Juan Sepulveda |
| Phone: |
(520) 574-1980 |
| Web Site: |
www.mercorp.com |
| Abstract: |
This SBIR Navy Phase I Project proposes to scale up MER's window technology to make larger, stronger, monolithic windows from spinel polycrystalline ceramic. This proposal presents a solution to the Navy's need for durable, monolithic, infrared-transmitting sensor windows with hot pressed (HP) sizes up to 28"x30"x0.6" for reconnaissance purposes. The larger size window is limited by the available equipment. During sintering HIPping is used. The HIP size restrictions are 21.5"x35" at the moment. MER contacted vendors that will be able to HIP windows as large as 28"x32". This Phase I project will produce the necessary tooling for the production of the 28"x30"x0.6" and some smaller pane of 8"x8"x0.6". MER already demonstrated in previous project the production of hot pressed windows as large as 25"x32"x0.6". These windows were edge trimmed to 20.25"x27.25"x0.65" to be HIP. It is the main goal of this Phase I project to further develop, increase the strength, and optimize this technology. It is important to preserve the excellent optical properties of the smaller spinel windows. The smaller 8"x8"x0.6" I will be produced with the same conditions that the larger window will be produced. Even larger sizes could be pursued during Phase III, depending on the availability of financial resources. |
| Benefits: |
MER intends to commercialize the reconnaissance spinel windows to the Navy, to other divisions of DoD, to other defense agencies, and to other defense contractors. MER will evaluate the potential market for IR application for the large windows and what are the market's price expectations. At the same time, MER will evaluate the market for ballistic applications for larger windows, and market expected cost and product specifications.
MER also intends to commercialize other transparent spinel products such as spinel domes, other transparent ceramics like AlON and YAG, and other structural ceramics such as SiAlON, Si3N4, and B4C. However, the commercialization of spinel ceramics is perceived as the best opportunity at this moment given its better mechanical and transmission properties. Spinel technology is a perfect match to MER market development objectives. MER is already marketing other strategic materials such as carbon fullerenes, carbon nanotube, carbon-carbon composites, PEM fuel cells, and Li ion fibre batteries through associations with partner companies. Anticipated public benefits derive from every sector requiring transparent, high strength ceramics. Most important applications for the defense sector are windows for armored vehicles, armor, windows for aircraft and spinel domes for missiles.
A spinel market as big as approximately $250 million is forecast for 2015. As mentioned above there are a wide range of applications where transparent materials are required with the following properties: tough (passing rigorous drop tests), scratch resistant, resists thermal shock, hard, high temperature resistant, good transmission qualities from UV to far infrared, lightweight, easy to manufacture, and low cost. In the near term, the military markets represent the primary market opportunity because of the operational needs and relative insensitivity to price. The primary target should be large reconnaissance windows for the Navy, aircraft window application, large ballistic windows for armored vehicles like MRAP, FMTV, HEMTT, tanks, and Humvees. MER intends to commercialize and license the novel spinel window technology developed in this project to primary defense contractors, and commercial users. Capital investment in the order of around $8 million would result in added sales revenue of $15-20 million per year.
MER's intentions are to pursue all possible applications for the development of the proposed large size transparent spinel reconnaissance windows through joint ventures with others like CoorsTek or other ceramic houses who are in the transparent ceramics/armor business, utilizing venture capital opportunities that are available to MER to exploit this development as well as license others, where appropriate, with the developed technology.
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