TECHNOLOGY AREAS: Air Platform, Materials/Processes, Sensors

ACQUISITION PROGRAM: Navy Unmanned Combat Air System (N-UCAS); ACAT I

The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), which controls the export and import of defense-related material and services. Offerors must disclose any proposed use of foreign nationals, their country of origin, and what tasks each would accomplish in the statement of work in accordance with section 3.5.b.(7) of the solicitation.

OBJECTIVE: Develop edge bonding technology to make large, strong windows out of smaller plates of spinel, aluminum oxynitride (ALON), or sapphire.

DESCRIPTION: The ultimate size of infrared windows is presently limited by the size of available hot isostatic pressing equipment for spinel and ALON, and by crystal growing equipment used to make sapphire plates. Larger windows for future systems could be fabricated from available plates if strong, thin bonds can be made between plates along their edges. Ideally, the bond line should be as strong as the window material and transparent to infrared and visible radiation to the same degree as the window material. The bond line should be as thin as possible and, ideally, transmit over the same range of infrared and visible wavelengths as the window material. Transparency of the bond line is not a requirement, but it is highly desirable. Strength is a requirement.

PHASE I: Demonstrate a method of edge bonding spinel or ALON or sapphire coupons to achieve a flexure strength comparable to that of the window material. Demonstrate the strength and transparency of the bond using bonded, polished, test specimens.

PHASE II: Demonstrate the flexure strength of the bond with optically polished equibiaxial flexure disks. Design a method capable of implementing the bonding process on large windows. Fabricate a 76 x 76 x 2 cm flat window blank by edge bonding two or four panes. After bonding, demonstrate that the blank is capable of withstanding grinding and polishing and will allow visual and microscopic inspection of the bond line.

PHASE III: Transition the technology to a Navy airborne system or a Navy ship such as the DDX.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: Although the technology is primarily of military value, large, bullet-proof windows for commercial vehicles could be fabricated by the bonding technology developed under this topic.

REFERENCES:
1. Gentilman, R.; McGuire, P.; Fiore, D.; Ostreicher, K.; and Askinazi, J., "Large-Area Sapphire Windows," Proceedings of SPIE. 2003, 5078, 54-60.

KEYWORDS: Ceramic Bonding; Ceramic Joining; Infrared Window; Spinel; Aluminum Oxynitride (ALON); Sapphire.

** TOPIC AUTHOR (TPOC) **

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