SBIR-STTR Award

This proposal addresses the requirement to significantly improve the affordability, maintainability and performance of KKV DACS components. Exothermics and their Phase 1 partner Southern Research Institute will endeavor to increase the performance, lower the cost and enhance the technical property characteristics of SDACS and hypersonic components by examining the use of a new class of ultrahigh temperature capable materials based on the concept of hafnium alloy coating of C/SiC substrates. The coatings will be applied to the substrates by directed magnetron sputter deposition methods, and, once optimized, these methods and materials will offer outstanding possibilities for fabricating SDACS components such as hot gas valves and hypersonic nosetips having superior technical properties at much reduced cost relative to rhenium, the present material of choice for SDACS hardware. Phase 1 development efforts will focus on producing limited numbers of test articles for simulated SDACS propellant testing at ATK-Elkton in Elkton, MD, and for thermomechanical properties characterization at Southern Research Institute (SoRI) in Birgmingham, AL.

Keywords:
Ultrahigh Temperature, Magnetron Sputtering, Hafnium Alloys, Sdacs, Hypersonic Nosetips

The notional performance parameters and kinematic requirements for the SM3 Blk IIB mission would benefit from the availability of advanced materials manufacturing methods that could enhance the technical properties and lower the cost of TDACS components. This Phase 2 STTR proposal addresses the requirement to significantly improve the affordability and performance of ultrahigh temperature capable throttling or solid divert and attitude control system TDACS or componentsof the type that may be found in missile defense interceptors such as SM3 Blk IIB. Exothermics and their Phase 2 partners Aerojet, Materials Research & Design (MR&D) and the Southern Research Institute (SoRI) will endeavor to increase the performance, lower the cost and enhance the property reproducibility of selected TDACS components via the use of tailorable yet cost-effective gas phase nitridation and hot isostatic pressing (HIP) methods. These methods will be used for the cost-effective fabrication of > 4000F-capable HfxN1-x refractory compounds into a variety of components using either bulk or diffusion-bonded HfxN1-x clad onto refractory metal substrates. The program will also conduct an ongoing series of PETM TDACS motor firing tests at Aerojet facilities in Sacramento, CA, in order to validate materials development and optimization work conducted in this program.

Keywords:
Ultrahigh Temperature Materials, Hafnium Nitride, Tdacs, Nitridation, Hip