Hypersonic Infrared Dome Navy SBIR FY2004.3 Sol No.: Navy SBIR FY2004.3 Topic No.: N04-234 Topic Title: Hypersonic Infrared Dome Proposal No.: N043-234-0 Firm: QED Technologies, Inc. 1040 University Ave. Rochester, New York 14607-1239 Contact: Aric Shorey Phone: (585) 256-6540 Web Site: www.qedmrf.com Abstract: In order to enhance missile performance, future missile designs will incorporate domes with a more aerodynamic shape than the traditional hemisphere. Significant additional benefits in areas of performance and cost reduction would be realized if a new material with more robust properties and the ability to be formed to near net shape replaced more common materials, such as sapphire. One promising replacement is polycrystalline alumina (PCA) with sub-micron grain size. It can be made to have improved toughness and nearly the same optical transmission in the mid-wave infrared (MWIR) band as sapphire. There is no established fabrication process suitable for this material or the aerodynamic shapes of interest; conventional finishing processes used to manufacture flat and spherical optics are not appropriate for such complex shapes. A process that utilizes deterministic micro-grinding, Magnetorheological Finishing (MRF) and newly developed MR Jet provides significant and unique advantages for finishing both the convex and concave surfaces of such conformal shapes. Work in Phase I will demonstrate: 1) a full manufacturing process on PCA flats from material blank through final polishing that meets transmission specifications and 2) the ability to fabricate precision domes with the proposed process. Successful completion of Phase I activities will enable the manufacture of PCA ogives during Phase II. Benefits: Today's hemispheric infrared transmitting domes are not capable of surviving the thermal shock associated hypersonic flight. Conformal optics, however, blend smoothly into reduced signature platforms, optimize electro-optic sensor fields-of-regard, and increase weapon effectiveness. One of the greatest areas of impact of conformal optics, such as ogive missile domes, was determined to be the reduction of aerodynamic drag at high missile speeds. It was shown that reduced drag translates to increased weapon range, higher weapon velocities and reduced time-to-target. Analyses also indicated that aerodynamic shapes substantially increase weapon lethality. The manufacturing process development proposed here would provide a solution for producing conformal, aerodynamically-shaped domes capable of surviving thermal shock while providing system-wide cost and performance benefits. The ogive shape and polycrystalline alumina would improve resistance to rain and sand erosion and make the dome less susceptible to brittle fracture. The performance advances that conformal optics enable include greater standoff engagement and low observability (stealth) capability for systems across the DoD. Numerous missile applications would directly benefit from a conformal manufacturing technology and would see substantial systems improvement, including the missile seeker domes of the Common Missile, the Precision Attack Munition (PAM), Loitering Attack Munition (LAM), and the new Low Cost Precision Kill (LCPK) missile (MRDEC). Complementary applications also include laser windows in lower cost materials for the Compact Kinetic Energy Missiles (CKEM) (MRDEC) and infrared windows for use as components of high energy lasers and infrared imaging systems, specifically benefiting systems defense-wide, such as the Navy's High Energy Laser Program and the Air Force's Airborne Laser Program. A conformal optics manufacturing technology is essential to all DoD services and will benefit programs defense-wide. Applications in the civilian realm would likewise benefit from a commercial manufacturing process. Polycrystalline alumina development, for example, would directly benefit civilian markets such as high-pressure sodium lamps. A general conformal manufacturing technology would likely benefit current applications include high precision molds, (e.g., used for car headlights which are currently hand polished) and aspheric toroids used for scanning optics (e.g., in a supermarket scanner). Additionally, civil police forces will benefit from improved sensors and facemask applications. Return