SBIR-STTR Award

Grid Logic proposes to develop a fieldable solid state welding process that can join and repair 2000 and 7000 series aluminum alloy components. This solution will be based on a new magnetic pulse welding technology from Grid Logic that permits the cold welding of these alloys without the material degradation problems common in arc fusion welding processes. The efforts primary objective will be to design and demonstrate the feasibility of this welding process on DOD approved target repair geometries. Grid Logic develops advanced manufacturing systems for production and repair of high-performance metallic components. It leverages its strong R&D capabilities to create turnkey manufacturing solutions for DOD and industrial manufacturers.

The U.S. Army wishes to use new aluminum alloy components in next generation vehicles to reduce weight and improve ballistic protection performance. While such components can be fabricated, the Army has not adopted their use because adequate welding technology does not exist for repair in the field. The objective of the R&D in this SBIR is to develop a new type of portable welder capable of performing the repairs for these components. Grid Logic’s approach is to create a small version of Magnetic Pulse Welding technology that will propel filler material at extremely high velocity toward the part to be repaired; forming a solid state cold weld. This device will be made possible by a novel pulsed magnetic field transducer, developed by Grid Logic, capable of accelerating the filler material to the necessary velocities. Grid Logic demonstrated the feasibility of this pulsed magnetic field transducer in Phase I. In the proposed Phase II project, Grid Logic will develop a pre-commercial, prototype of the new welding system that can be used for in-field repair of non-weldable aluminum alloy parts. The system will be internally tested and delivered to the Army for further evaluation at the end of the project.