TECHNOLOGY AREAS: Materials/Processes

ACQUISITION PROGRAM: ONR EM Railgun Innovative Naval Prototype, ACAT TBD

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 innovative low density electrical contact materials for high-velocity and high-current linear sliding contact.

DESCRIPTION: Sliding contacts are often found in electrical generators and motors. The Navy is presently developing high-power electrical machinery for advanced power systems. One potential application area is electromagnetic launch. Electromagnetic rail launchers are linear electric motors which utilize large current pulses (1-10 MA) to accelerate payloads through the Lorentz force to high velocities (1-3 km/s). Maintaining electrical contact under these operating parameters is a significant challenge due to armature wear and loss of mechanical strength due to frictional and electrical heating. Loss of electrical contact results in arcing and rail damage. Aluminum alloys in the 6xxx and 7xxx series are presently used in the fabrication of armatures for electromagnetic launch to minimize parasitic mass. The alloys have sufficient mechanical strength to withstand the acceleration at launch and adequate electrical conductivity for effective current collection.

This topic seeks the development of innovative materials with low density, high electrical conductivity, high yield strength, and high toughness compared with existing 6xxx and 7xxx aluminum alloys with -T6 or -T651 tempering.

PHASE I: Develop and test alternative armature materials that can replace the aluminum alloys presently in service.

PHASE II: Build upon the Phase I work to fabricate material at a pilot-scale sufficient for armature testing and development.

PHASE III: The offeror shall work with a DoD prime contractor to transfer the pilot-scale material processing capability to full-scale production.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: These types of lightweight, economic materials can replace existing commercial technologies in high density power systems. Material would be applicable to high current opening and closing switched in the electric power industry. Improved life and performance can dramatically reduce lifetime costs.

REFERENCES:
1. A. Yeoh, G. Prabhu, C. Persad, "Liquation cracking and its effects in aluminum alloy armatures," IEEE Transactions on Magnetics, 33(1), 419-425, JAN 1997

2. D. C. Haugh and G. M. G. Hainsworth, "Why �C� armatures work (and why they don�t!)," IEEE Transactions on Magnetics, 39(1), 419-425, JAN 2003

3. http://www.onr.navy.mil/emrg/electromagnetic-railgun.asp

KEYWORDS: electrical contact; electromagnetic launch; alloy; composite

** TOPIC AUTHOR (TPOC) **

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