Net Shape Manufacturing of Functionally Grading Nano-Composite Materials for Gears Using High Pressure Combustion Driven Powder Compaction (CDC) Navy STTR FY2005 Sol No.: Navy STTR FY2005 Topic No.: N05-T006 Topic Title: Net Shape Manufacturing of Functionally Grading Nano-Composite Materials for Gears Using High Pressure Combustion Driven Powder Compaction (CDC) Proposal No.: N054-006-0071 Firm: UTRON, inc. 8506 Wellington Road, Suite 200 Manassas, Virginia 20109-3988 Contact: Karthik Nagarathnam Phone: (703) 369-5552 Web Site: www.utroninc.com Abstract: In response to Navy's needs for functional gradient gear materials development for applications such as V22-Aircraft/Helicopter, UTRON proposes an innovative manufacturing technology called the high pressure Combustion Driven Powder Compaction (CDC) to manufacture net shape quality, high density, mechanically durable and wear resistant ferrous based nanocomposite gear components with 9310 alloy, pyrowear 53, and CBS 600 as base materials and select dispersion of wear resistant nanocarbides such as boron carbide, silicon carbide and solid lubricants (e.g., molybdenum sulfide) by optimal sintering and heat treatment. Process advantages include superior sub-micron surface finish, synthesis/process flexibility of novel nanocomposites with ferrous alloys, less materials wastage, net shapes of simple to complex geometry at competitively lower manufacturing costs compared to the traditional wrought gear fabrication methods. The major focus of Phase I is to demonstrate the proof of concept to fabricate the proposed materials in various geometries such as 1 or 0.5 inch diameter disks, dogbones and contact fatigue test rings at high pressures (150 tsi) and scientifically evaluate the physical, geometrical, microstructural, mechanical and select rotating contact fatigue wear properties with optimal sintering/heat treatments. This will be done in collaboration with Penn State's Applied Research Laboratory and Bell Helicopter-Textron. Benefits: The potential military and commercial uses of UTRON's CDC processing are anticipated in the power train system parts (gears/bearings)and advanced Solid Rocket Motor components/spacecraft/missile (THAAD missiles, SM3-SDACS system for Navy and other high performance rocket propulsion technologies such as IHPRPT) nozzle liner subsystems. Other high temperature applications include thrusters for satellite station keeping, high temperature engine components, advanced heat pipes, valves, solid lubricant composite bearings, heat shields in spacecraft, and reentry /reusable vehicles, high performance engine parts such as pistons, rings, & liners, welding electrodes, valves/valve seats/connecting rods, nose cone caps for military systems, x-ray targets, permanent/superconducting magnets, accelerator components, and RF microwave parts. Return