K. Nagarathnam, D. Trostle, D. Massey, UTRON Inc, Manassas, VA
An overview of the scientific and technological aspects in the materials development and manufacturing strategies of UTRON’s High Pressure Combustion Driven Powder Compaction (CDC) technology (Fig. 1) will be provided. Key results of the CDC processed ferrous alloys (e.g., Pyrowear 53) and nanocomposite alloys (Figs. 2 and 3) for potential power transmission rotorcraft component materials development and applications will be discussed. Examples of other materials developed by CDC at UTRON such as copper, stainless steel, refractory materials (W, Mo and TZM), niobium, NanoSiC, Nano BoronCarbide will be presented and the significant processing, materials performance and cost-effective manufacturing advantages will be highlighted. Some of the unique advantages of CDC include high densities,(Fig. 4) near net or net-shaping, (Fig. 3) improved surface finish/quality, suitability for simple/complex geometries, synthesis of single as well as multilayered micro/nano materials, milliseconds of compaction process time, little or no post-machining, and process flexibility. The materials characterization strategies include geometry control, process optimization, sintering/heat treatment responses, structure/property characteristics such as geometrical, physical properties, select microstructures and mechanical properties will be presented. Under optimum conditions, the CDC ferrous alloy samples processed at much higher compaction pressures responded well for vacuum carburization with the result of wear resistant surface hardened fine microstructures (Fig. 5) and surface hardnesses as high as Rc 66-69 with deeper case depths (20 to 25 mils). Anticipated applications of CDC compaction include power train components, high temperature propulsion components, refractory x-ray targets, laser optical mirrors, vacuum seals, accelerator/RF microwave components, high temperature nozzle liner parts/heat sinks, advanced propulsion system components for missile defense, advanced high density magnets and high performance engine parts.
Summary: An overview of the scientific and technological aspects in the materials development and manufacturing strategies of UTRON's High Pressure Combustion Driven Powder Compaction (CDC) technology will be provided. Key results of the CDC processed ferrous alloys and their composites will be discussed.
