SBIR-STTR Award

Additive Manufacturing of TZM Refractory Metals for Hypersonic Thermal Management Structures
Award last edited on: 9/26/2022

Sponsored Program
SBIR
Awarding Agency
DOD : MDA
Total Award Amount
$1,649,965
Award Phase
2
Solicitation Topic Code
MDA19-013
Principal Investigator
Jesse M Blacker

Company Information

The ExOne Company (AKA: ExOne)

127 Industry Boulevard
North Huntingdon, PA 15642
   (877) 773-9663
   info@exone.com
   www.exone.com
Location: Multiple
Congr. District: 12
County: Westmoreland

Phase I

Contract Number: HQ0860-20-C-7033
Start Date: 11/22/2019    Completed: 3/21/2021
Phase I year
2020
Phase I Amount
$149,974
ExOne will demonstrate technical feasibility of an additive manufacturing process for making Titanium Zirconium Molybdenum alloy (TZM) materials for hypersonic applications by building a small TZM subcomponent. Effort will establish a foundational understanding of the powder feed stocks, the printing process parameters, and the densification process requirements at the coupon and small component level and a small, initial material property data set will be developed. Approved for Public Release | 19-MDA-10270 (18 Nov 19)

Phase II

Contract Number: HQ0860-21-C-7122
Start Date: 1/11/2021    Completed: 1/10/2023
Phase II year
2021
Phase II Amount
$1,499,991
ExOne successfully demonstrated the feasibility of using additive manufacturing to produce TZM refractory alloys at full theoretical density for hypersonic thermal protection / management / structures and met all of the Phase I research objectives. The process was developed beginning with a thorough powder feedstock characterization, followed by printing process parameter development, and finally with sinter and Hot Isostatic Pressing (HIP) densification process development. ExOne was able to achieve theoretical density TZM (10.2 g/cc) material and produced numerous coupons that were used for material characterization. Finally, ExOne designed, printed, and densified a subcomponent, complex, application relevant geometry in TZM alloy to prove feasibility of making complex shaped structures. At the end of the Phase II program – ExOne will deliver a manufacturing demonstration article that is additively manufactured in TZM material in a geometry relevant to hypersonic thermal structures. ExOne will deliver a material property data set that will be used in future design efforts. Optimized printing and sinter / HIP processes will be defined. ExOne will have additively manufactured TZM capabilities ready for consideration in technology insertion /qualification for hypersonic weapon platforms. At the end of the Phase II program – ExOne will deliver a manufacturing demonstration article that is additively manufactured in TZM material in a geometry relevant to hypersonic thermal structures. ExOne will deliver a material property data set that will be used in future design efforts. Optimized printing and sinter / HIP processes will be defined. ExOne will have additively manufactured TZM capabilities ready for consideration in technology insertion /qualification for hypersonic weapon platforms. Approved for Public Release | 20-MDA-10643 (3 Dec 20)