Dry Synthesis of Alpha Aluminum Hydride Navy SBIR FY2005.1 Sol No.: Navy SBIR FY2005.1 Topic No.: N05-070 Topic Title: Dry Synthesis of Alpha Aluminum Hydride Proposal No.: N051-070-0119 Firm: Powdermet Inc. 24112 Rockwell Drive Euclid, Ohio 44117 Contact: Andrew Sherman Phone: (216) 404-0053 Web Site: www.powdermetinc.com Abstract: The use of alane in new propellants is projected to yield greater than 10% gain of specific impulse (Isp) over the state of the art solid propellants. This would translate into a 30% increase in range for a single stage tactical missile, a 4,400 lb (10%) payload increase for the Titan Solid Rocket Motor (SRM), or a 1,100 lb (20%) payload increase for the IUS (space shuttle) upper stage. Commercially available materials, however, do not possess adequate stability and compatibility with solid propellant ingredients to allow development of practical propellants, due to low thermal stability and impurities. This proposal will investigate a scalable, dry synthesis approach to producing pure alpha alane wihtout the use of solvents. The approach is based on recent advances int he production of alanes for hydrogen storage, and utilizes catalyst materials and high pressure and temperature to synthesize the alane powders. Additionally, a precision nano-encapsulation technique will be used to stabalize the alane particles to provide long term stability in contact with AN and AP and other proellant ingredients. Benefits: SAlane propellants are estimated to result in a23% increase in payload for the Titan IV launch vehicle sent to LEO and a 19% decrease in missile weight for a typical strategic missile system. If the dry synthesis is succesfully developed, the primary use will be as a propellant ingredient, with some commercial markets for H2 storage and reducing agents, depending on price. Return