Near Net Shape and Cost Effective Rapid Powder Consolidation Manufacturing of Advanced Microwave Tube Materials/Components Navy STTR FY2014.A Sol No.: Navy STTR FY2014.A Topic No.: N14A-T010 Topic Title: Near Net Shape and Cost Effective Rapid Powder Consolidation Manufacturing of Advanced Microwave Tube Materials/Components Proposal No.: N14A-010-0096 Firm: Utron Kinetics, LLC 9441 Innovation Drive Manassas, Virginia 20110-2215 Contact: Karthik Nagarthnam Phone: (703) 369-5552 Web Site: www.utronkinetics.com Abstract: 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. Benefits: RF Microwave Components, Accelerator Parts for Normal and Superconducting Uses, Vacuum System Components, Rocket Motor Components Using Refractory Materials for the SM3-Missile Defense DACS Systems, Reactive Fragments, Refractory Liners, Higher Threat Resistance/Lightweight Vehicle Armor Tiles, Advanced Superalloy Parts for an Aerospace Uses, Higher Performance Permanent (NdFeB, SmCo-NanoFe) and Soft Magnets with Improved Magnetic Properties Compared to TYraditional Magnets, Ammunition Related Defense Parts, Transmission and Rotorcraft Parts, Bearings, Microwave Absorbing Ceramics, Electrically and Thermally Conductive Materials/Components for heat Sinks, Optical Mirror Substrates, Higher Strength/Corrosion Resistant Stainless Steel Parts (Upto 250 ksi strength levels with improved ductility hence toughness) Corrosion Resistant Stainless Steels, Tungsten and Tantalum-Tungsten Based Materials for Complex Shaped Warhead Components. Return