ARCTOS Technology Solutions, LLC — Department of Defense SBIR Phase I: AF161-080

Description

ABSTRACT: In this Phase I program Advratech (prime) will work with Resonetics and Wright State University (subs) to improve upon the current state-of-the-art for selective laser melting (SLM) additive manufacturing (AM) of high-Z (high-Z = high atomic mass) materials by developing high- to low-Z graded materials, alloyed in situ, to produce light weight structural ICBM components with integrated radiation shielding.The first step is developing optimal SLM parameters for building high-Z materials, then determining the optimal material combination for high-to-low-Z functionally graded alloys, and finally determining optimal build parameters for several different atomic ratios of the chosen alloy materials.Then we will use the parameters developed to build graded alloys in the build direction.This will involve studying how quickly to change the powder atomic ratio, and over what distance.Next the research team will demonstrate horizontal graded alloy development, thus enabling the fabrication of complex, 3D graded alloys. Finally, at the end of Phase I the research team will produce an ICBM component with integrated radiation shielding, provided by Lockheed Martin, to complete a hardware demo of our functionally graded alloy system on a part relevant to ICBM programs.; BENEFIT: This project will create new additive manufacturing (AM) processes for producing high temperature ICBM components with integrated radiation shielding, via selective laser melting (SLM).Benefits include:1) High-to-low-Z graded alloy AM for the first time, via SLM and in situ alloy development.2) Lightweight materials graded to refractory metals create high-temperature structural parts with integrated radiation shielding.3) Reduced mass and cost of ICBM components through the elimination of added radiation shielding.4) Assemblies normally manufactured as separate components can be built as a single unit.5) Reduced maintenance through lower part count6) Spares can be manufactured in an on-demand basis.7) Cross-cutting technology can be used for other DoD applications, such as shaped-charge liners, and for medical devices.Future research (Phase II) will see the graded alloy AM process automated with a multi-material hopper system for powder delivery to the build point.This process is also easily portable to larger commercial style SLM systems, so commercialization is likely.The graded alloy fabrication developed here may also be useful for reverse-engineering and building improved ICBM components on current platforms. Commercial applications of this technology are very promising.Our current proposal has two letters of support from different commercial partners.First is Lockheed Martin who plans to use this technology for their ICBM systems.The second is Battelle, a prime contractor for the Army who produce shaped-charge liners for explosive munitions.They are highly interested in this technology, they plan to build functionally graded shaped charge liners to improve armor piercing capability, thus improving the capability of the American warfighter on the ground.A third promising application is medical device, here there is significant interest in using functionally graded alloys to improve arterial stent delivery, as well as other uses.Resonetics, a subcontractor on this project intends to commercialize this technology for this purpose.