SBIR-STTR Award

In the Phase-I project Bhawin LLC will establish a production technique for ceramic windows and domes using a Calcium Lanthanum Sulphide nanopowders that will eliminate use of H2S that requires special safety precautions in CVD. The high cost and low mechanical strength of windows and domes that protect the multimode sensors on missiles and maximize their mode of operation have been a concern for a long time for the Department of Defense. Crucial requirements for this application are: a) excellent infrared transmission, b) very good mechanical properties and c) ability to withstand harsh environmental conditions. Multispectral Calcium Lanthanum Sulphide is well suited for high performance aperture systems that function across abroad wavelength spectrum (0.4 to 12 microns). Bhawin LLC will develop and implement an economical combustion method and Microwave- Hydrothermal process for large scale production of mono dispersed pure Calcium Lanthanum Sulphide nanopowders for use in ceramic IR transparent missile domes. This process will generate large quantities of metal sulfide nanoparticles to meeting the ARMY specifications. This process will be achieved utilizing the BHAWIN proprietary combustion and microwave technologies, which allows for precise control over the nanoparticle size and size distribution and can be readily scaled in the manufacturing environment.

Military LWIR sensor windows and domes have been traditionally plagued by high maintenance and replacement costs due to soft, erosion prone ZnS and ZnSe materials. The high replacement cost of 100 units per year at $50,000 plus/unit for the Forward Looking Infrared (ATFLIR) ZnS window assembly on F-18s is a prime example. Transparent Ca2La2S4(CLS) with a broad 2–16 micron transmission window, higher hardness and potential strength more than twice that of ZnS has long been a highly desirable replacement. Until this Phase 1, despite numerous research and development projects, no CLS powder processing effort produced cost effective, high purity CLS nanopowders capable of consolidated optical ceramics with 60% transmission from 6-16 microns and strengths twice that of previous CLS materials. The Phase-II proposal details systematic steps for optimizing the attractive Phase 1 synthesis process, scaling up to multi-kilogram quantities, and demonstrating consolidation methods capable of achieving 60% or greater transmission, superior strength and rain erosion resistance in scaling to realistic size samples. With follow on Phase 3 and/or Manufacturing Technology program funding, a sound commercialization strategy with a high probability of success is outlined.