In order to achieve increased efficiency, life, and performance, rocket engines require operation at higher and higher temperatures. in order to obtain sufficient strength at these temperatures, the refractory metals such as molybdenun, tungsten, tantalum, niobium, and rhenium mustbe used to… More

In order to achieve increased efficiency, life, and performance, rocket engines require operation at higher and higher temperatures. in order to obtain sufficient strength at these temperatures, the refractory metals such as molybdenum, tungsten, tantalum, niobium, and rhenium must be used to… More

One of the mechanisms which hardens a material against hel radiation is the presence of a surface reflecting layer. a promising candidate in this regard is carbon felt loaded with a refractory metal or compound whose surface melts under hel melts under hel radiation. we have successfully infiltrated… More

An innovative application of chemical vapor deposition to prevent arc damage to rail gun components is proposed. such a tungsten coated copper rail gun conductor has been shown to suffer no surface degradation in arc tests performed at the university of texas center for electromechanics (cem) in… More

An innovative application of chemical vapor deposition to to prevent arc damage to rail gun components is proposed. such a tungsten coated copper rail gun conductor has been shown to suffer no surface degradation in arc tests perform-ed at the university of texas center for electromechanics (cem) in… More

Sic coatings can protect carbon composites from oxidation up to about 3000f. zro2 and hfo2 have been applied as overcoatings to extend oxidation protection to 3500f, but these layers tend to spall. we propose here an innovative method of grading the coating from pure sic at the c/c inside surface to… More

Present magnetic fusion confinement experiments and all reactor designs incorporate a first wall and have limiters either close to or direct contact with the plasma. these components have different functions, but each is exposed to a "first surface" environment with high thermal loads, intense… More

Tungsten is an important material for a wide variety of ordnance items. present commercially available tungsten and tungsten alloys are brittle which limits the usefulness of this material. if ductile tungsten were available the effectiveness of ordnance items such as explosively formed penitrators,… More

Chemical vapor deposition (cvd) is a unique technology for fabricating materials which can provide external protection from laser and other directed energy sources as well as kinetic energy hardening and nuclear radiation protection for electronics. it has already been demonstrated that ultramet's… More

Chemical vapor deposition (cvd) is a unique technology for fabricating materials which can provide external protection from laser and other directed energy sources as well as kinetic energy hardening and nuclear radiation protection for electronics. it has already been demonstrated that ultramet's… More

Chemical vapor deposition (cvd) is a unique technology for fabricating materials which can provide external protection from laser and other directed energy sources as well as kinetic energy hardening and nuclear radiation protection for electronics. it has already been demonstrated that ultramet's… More

Chemical vapor deposition (cvd) is a unique technology for fabricating materials which can provide external protection from laser and other directed energy sources as well as kinetic energy hardening and nuclear radiation protection for electronics. it has already been demonstrated that ultramet's… More

Candidate materials and processes compatible with radiatively cooled thrusters utilizing hydrogen/oxygen and state-of-the-art oxidizing propellants at temperatures of atleast 2480 degrees k and able to withstand at least 1000 temperature cycles are severly limited. no single material exists today… More

Zirconia (zro(2) and hafnia hfo(2)) have been identified as major elements in the development of components which can operate at ultra high temperatures (3000 - 4000f and above). both materials are very refractory (melting temperature above 4800f), stable compoungs, that have high chemical inertness… More

Combined effects bomblets (ceb) are currently fabricated of steel. studies have indicated that an increase in lethality would be achieved if the ceb were redesigned to have a tungsten body. previous investigations using power metallurgy (p.m.) tungsten ceb's were unsuccessful due to material control… More

Chemical vapor desposition (cvd) is the only deposition process which has the speed necessary for building up structures. deposits tend to be epitaxial. both these characteristics are essential for fabricating nanometer composites, which promise to combine the mechanical advantages of metals with… More

The ability to control unwanted impurity levels during electronic device fabrication is essential to establishing the desired properties for device reliability. in phase i ultramet will demonstrate the feasibility of depositing thin, ultra-high purity films of bn, tib2, nbn and sic on fused sio2… More

Kinetic energy weapons employ tungsten projectiles. for maximum effectiveness the tungsten must posses high density, strength and ductility. liquid phase sintering of tungsten powder in a matrix of iron and nickel powder has been employed for this purpose. problems still exist. as density approaches… More

A real need exists in both the military and commercial arenas for a reliable oxidation protective material for carbon composites to 3500f. leading researchers have predicted that a mixture of sic and hfc or zrc should be good candidate material. but their experimental efforts have produced mixed… More

A reliable, efficient means for moving large amounts of heat from the source to a heat sink will be required for thermal management systems in future aerospace applications, such as transatmospheric vehicles. the heat pipe is just such a device, and through proper selection of the case material and… More

Components for aeropropulsion systems will require structural, minimum-weight, reusable thermal protection materials. the limitations of currently available materialsare temperature, thermal shock resistance, and fracture toughness. by an innovative application of chemical vapor deposition, ultramet… More

Over the past decade there has been an ever increasing need for large, lightweight, stiff optical structures for space application. resin matrix composite which seemed the ideal candidate material has poor dimensional stability due to itspropensity to absorb water vapor on earth and lose it in… More

Iridium-coated rhenium thrusters have been fabricated to netinternal shape by chemical vapor deposition (cvd) from the inside out. this program proposes to fabricate coated hollow niobium turbine blades to net external dimensions by cvd on the inside of a hollow mandrel conforming to the net… More

The chemically-boosted kinetic kill vehicle (kkv) weapon is a necessary component of strategic defense. new systems based on advanced solid propulsion concepts are currently being investigated. their ultimate potential can be realized only by the development of ultralightweight, high temperature,… More

Chemically vapor deposited (cvd) tungsten is potentially a costeffective material for high strain rate applications. the effects of process variables on the mechanical properties of currently available cvd tungsten are not understood sufficiently for its properties to be optimized for a variety of… More

In this phase i program, ultramet proposes to demonstrate the feasibility of depositing the boron-boron nitride couple, produced by microwave plasma-enhanced chemical vapor deposition (cvd). it will demonstrate that an ultrastructure composed of alternating nanometer-thick layers of boron, a good… More

Platinum group metal (pgm) coatings have been shown to provide oxidation protection for rocket engine components operating to 2200 degrees centigrade. these coatings are not inert to oxygen; rather, they form volatile oxides whicherode at a measurable rate. platinum, rhodium, and iridium form… More

Improved materials having a high damping capacity, combined with good mechanical properties and suitable for structural uses, are needed in a variety of applications. among the areas in which acoustic damping is desirable are improving the response and accuracy of tracking, pointing, and guidance… More

As spacecraft performance requirements become more rigorous, materials and parts specifications become more difficult to meet. high performance must be combined with lightweight to derive the maxium benefit from spacecraft components. simplicity is also essential in avoiding major redesign and… More

As spacecraft performance requirements become more rigorous,materials and parts specifications become more difficult to meet. high performance must be combined with light weight to derive the maximum benefit from spacecraft components. simplicity is also essential in avoiding major redesign and… More

Intermetallic composites, most notably the aluminides, have been identified as potential engine and structural materials offering properties superior to those of the present nickeland cobalt-based superalloys. unfortunately, currently available reinforcements are not compatible with the aluminide… More

New designs and innovations for improving the operating efficiencies of spacecraft, aircraft, and commercial applications are requiring greater operating temperatures. extreme demands are thus being placed on all involved materials, among which are the lubricants, and in many casesrequirements… More

Extraordinary increases in rocket combustion chamber operating temperature have been achieved with iridium-coated rhenium rocket thrusters. this has resulted in a greater than 20-second improvement in specific impulse with no sacrifice in lifetime. three of the platinum group metals, platinum,… More

Ever-increasing design and performance requirements are placing increasingly severe demands on materials properties for gas turbine applications. the operational capabilities of the superalloys have achieved dramatic increases in the last decade, but further increases can be achieved only through… More

The ability to operate gas turbine engine components at temperatures of 1600-2000 deg c represents a considerable increase in both thrust and fuel efficiency for these engines, and is critical to meeting ihptet performance goals. the strength of carbon-carbon composites (c-c), particularly at… More

In response to the need for improved engineered materials for advanced elevated temperature applications, ultramet proposes to apply the extensive composite processing experience, knowledge base, and understanding acquired in several ceramic and composite development programs to improving the… More

In response to the need for improved engineered materials for advanced elevated temperature applications, ultramet proposes to apply the extensive composite processing experience, knowledge base, and understanding acquired in several ceramic and composite development programs to improving the… More

Heat engines based on various thermodynamic cycles are being developed for space power applications. a need clearly exists to minimize weight while maximizing the thermal efficiency of such power systems. high temperature heat pipes are a versatile, efficient means of transporting and managing… More

Current chemical rocket-thrust chambers have limited lives due to the limited oxidation protection currently available. this is true not only at temperatures of 2200 degrees centigrade (4000 degrees fahrenheit), but at 1100 degrees centigrade (2000 degrees fahrenheit) as well. a prime example is the… More

A major barrier to the development of emergency crew escape systems for hypersonic space-capable vehicles (i.e. nasp) is the excessive weight associated with the required thermal protection heat shield. in this phase i program, ultramet proposes to utilize its extensive experience and expertise in… More

The high total heat fluxes associated with high l/d reentry vehicles and boost-glide trajectories require the development of improved heatshields and insulators. in this phase i program, ultramet proposes to design a reentry heatshield based on a ceramic foam core composite sandwich panel… More

Solar-heated hydrogen can yield more than three times the specific impulse of chemical reactions for rocket propulsion. the development of a solar-heated hydrogen engine depends on breakthroughs in high temperature materials. a key component is the solar absorber, which is heated by focused solar… More

Advanced solid rocket propellants are currently available today that would provide a substantial increase in performance and/or reduction in launch cost. they cannot be used, however, because the technology of containment materials is not sufficiently advanced. in this phase i program, ultramet… More

Reusable hypersonic vehicles, operating well beyond the performance envelope of conventional aircraft, will encounter extremely high temperatures; during reentry, the nose will experience in excess of 5000 degrees fahrenheit, and leading-edge surfaces will feel nearly 3500 degrees fahrenheit.… More

Few materials exist that posses useful properties in hydrogen at 2,750 k and are compatible with the environment of a nuclear reactor. bulk fabrication and processing of those that do exist, the ceramics niobium carbide and zirconium carbide, have not yet reached the maturity required for… More

Few materials exist that possess useful properties in hydrogen at 2750K and are compatible with the environment of a nuclear reactor. Bulk fabrication and processing of those that do exist, the ceramics niobium carbide (NbC) and zirconium carbide (ZrC), have not yet reached the maturity required for… More

The Navy is developing liquid metal combustion as the power source for the propulsion systems of several advanced underwater vehicles. Parts made from Hastelloy alloy are used to contain the liquid metal reaction. This environment is extremely hostile: molten lithium at 2OOO-3OOOF causing corrosion,… More

JET VANE THRUST VECTOR CONTROL IS ONE OF THE LEAST EXPENSIVE AND LEAST PERFORMANCE-IMPACTING METHODS FOR THRUST VECTOR CONTROL. THIS METHOD UTILIZES VANES SET IN THE MOTOR PLUME TO DEFLECT EXHAUST GASES, CREATING LATERAL THRUST. HOWEVER, THE USE OF HIGH-IMPULSE, HIGH SOLID CONTENT PROPELLANTS… More

CURRENT FIELD EMITTER ARRAYS HAVE ACHIEVED VALUES OF NORMALIZED TRANSCONDUCTANCE (97 S/cm2) AND AVERAGE ELECTRON CURRENT DENSITY (1 kA/cm2) THAT EXCEED THE LIMITS OF GRIDDED THERMIONIC CATHODES BY ORDERS OF MAGNITUDE. THE POTENTIAL APPLICATION OF FIELD EMETTERS TO TERAHERTZ, MICROWAVE, AND… More

Iridium/Rhenium (Ir/Re) technology developed at Ultramet has demonstrated the ability of liquid rocket engines to operate above 2200C for tens of hours. 22-N (5-lbf) and 445-N (100-lbf) units have been built and tested, and have demonstrated an improvement in specific impulse (Isp) of some 20… More

Current superalloy tururbopump rotor materials are limited in both maximum use temperature and environmental stability. Extended use at elevated temperatures leads to stress corrosion cracking, followed by turbine blade separation. Ultramet previously fabricated an iridium coating on a forged… More

In this Phase I program, Ultramet proposes to demonstrate the feasibility of using a modified solid rocket booster (SRB) to provide the hot gas cranking and ignition source for starting a small turbojet sustainer engine, in addition to boost propulsion. This SRB-based starting system would replace… More

Continuous silicon carbide (SiC) fiber-reinforced ordered titanium intermetallic alloy (Ti3Al) matrix composites are enabling materials for next-generation turbojet compressor and hypervelocity vehicle airframe applications. They possess unique combinations of several attractive properties such as… More

Fiber-reinforced and whisker-reinforced molybdenum disilicide (mosi2) matrix composites have been indentified as excellent candidates for high temperature structural applications in oxidizing environments. however, the room temperature fracture toughness and high temperature yield and creep strength… More

Wide-bandgap semiconductors such as beta-silicon carbide (beta-sic) have the potential to be useful in the fabrication of electronic devices that can operate at high temperatures and high power levels in corrosive environments. such devices currently under consideration include mesfet, impatt diode,… More

This project will demonstrate the feasibility of a unique new method for producing dispersion-hardened alloys. dispersed, stable, second-phase particles having a controlled morphology will be incorporated into matrices of aluminum and titanium alloys. this will be accomplished by coating each… More

Micrograin carbides are small grain size (1-5 micron diameter) particles of tungsten carbide (wc) that have been "cemented" together with a predominantly cobalt matrix, using liquid phase sintering. they are an excellent material for carbide cutting tools and other wear- and/or corrosion-resistant… More

Nickel/metal hydride (Ni/MH) batteries have received great attention recently in both government and private industry sectors. The most attractive characteristics of Ni/MH batteries are their much higher energy density over other types of batteries, such as lead-acid and nickel/cadmium, and the fact… More

In previous work, Ultramet has demonstrated an innovative variation of chemical vapor infiltration (CVI) in which two or more carbide coatings are applied in fine, alternating layers. The interfaces between these layers act as highly effective toughening mechanisms by inhibiting crack propagation.… More

Researchers are investigating an innovative new class of materials which provide dramatically increased strength, modulus, and wear resistance while maintaining mechanical properties to high temperature. the concept utilizes ceramic foams, fabricated by chemical vapor deposition (cvd) as… More

The introduction of non-azide generants for automobile airbag systems presents new challenges in the use of materials for internal airbag components such as primary and slag filters. because non-azides are much hotter (2130 degrees centigrade vs. 1090 degrees centigrade) and contain more metallic… More

Fluidized beds are an ideal tool for producing or modifying powder materials. unfortunately, the most desirable powders for producing engineering materials are of such a fine size (

The need for a cancellous bone substitute, in the form of an artificial biocompatible implant, is significant. research has demonstrated that an implant ideally should serve as a porous framework for bone regeneration. in this program, we will use a novel biomedical application of a material… More

THE STATE OF THE ART IN HIGH TEMPERATURE MATERIALS FOR LIQUID ROCKET COMBUSION CHAMBERS IS IRIDIUM/RHENIUM (Ir/Re), WHICH PERMITS OPERATION TO 2200C. MATERIALS THAT WOULD PERMIT A SIGNIFICANT INCREASE IN OPERATING TEMPERATURE WOULD ALLOW INCREASED PERFORMANCE, DECREASED WEIGHT, AND A SIGNIFICANT… More

High rate of fire, high velocity, medium-caliber (20-, 25-, and 30-mm) gun barrels have been used extensively by U.S. armed forces over the past 20 years. A major problem with such systems is that the barrel must be replaced far too often due to excessive wear and corrosion at the breech end, which… More

Noise generated by general aviation aircraft has a negative impact on the aviation community, and strict adherence to FAR Part 36 regulations requires noise reductions on the majority of these aircraft. Any new aircraft certified or any modification to an existing aircraft must show compliance with… More

Depleted uranium (du) is the state-of-the-art material for kinetic energy penetrators used to defeat steel and composite armors. du alloys, however, are costly to fabricate, handle, and store because of an extremely complex metallurgy and the obvious health factor associated with the use of uranium.… More

Fragmenting warheads offer a high kill radius and lethality against lightly armored targets such as aircraft, personnel carriers, entrenched personnel, missiles, and spacecraft. Increasing the density and controlling the size, shape, and velocity of the fragments can greatly increase warhead… More

40429 November 18, 1996 Ultramet To promote substantial improvements in energy and cost efficiency in fiberglass manufacturing, new component materials and coatings must be developed that allow glass forming at higher temperatures than currently… More

Fragmenting warheads offer a high kill radius and lethality against lightly armored targets such as aircraft, personnel carriers, entrenched personnel, missiles, and spacecraft. One of the easiest ways to increase the penetration capability of a kinetic energy penetrator, shaped charge liner,… More

Continuous fiber-reinforced ceramic matrix composites represent an enabling technology for the next generation of aircraft engines and power generating equipment. The current state-of-the-art in ceramic matrix composites (CMC) for use in oxidizing environments is a silicon carbide (SiC) matrix… More

128 High-Efficiency Muzzle Flash Suppressor--Ultramet, 12173 Montague Street, , Pacoima, CA 91331-2210; (818) 899-0236 Mr. Brian E. Williams, Principal Investigator Mr. Craig N. Ward, Business Official DOE Grant No. DE-FG03-97ER82504 Amount: $75,000 In the event of a hostile act,… More

Even with new advances in high temperature materials, large (>1000 lb. thrust) liquid propellant combustion chambers require cooling to prevent temperatures from reaching levels at which chamber strength is no longer adequate to support the chamber pressure. This cooling requirement imposes severe… More

Turbine engine component life is currently limited by creep, creep-rupture, oxidation/corrosion, and thermomechanical fatigue. The use of protective coatings, such as nickel-chromium-aluminum-yttrium (NiCrAlY) and more recently platinum aluminides and various thermal barrier coatings (TBCs), has… More

Missile defense systems will never be practical unless they are affordable. In some cases, backing off on the technology can result in an equivalent unit at considerably lower cost. Such a case exists with regard to the divert thrusters used in liquid propellant propulsion systems. These thrusters… More

51045-98-I Novel Electrochemical Reactor for Separation of Metals--Ultramet, 12173 Montague Street, Pacoima, CA 91331-2210; (818) 899-0236 Dr. Arthur J. Fortini, Principal Investigator Dr. Craig N. Ward, Business Official DOE Grant No. DE-FG03-98ER82703 Amount: $74,996 Removal of contaminants… More

The temperature constraints of current thermal protection system (TPS) materials limit the flight path and thus the mission flexibility of existing and new hypersonic and spacecraft reentry vehicles, such as the Military Space Plane (MSP). Lightweight materials with increased TPS operational… More

Solid rocket motors are used extensively in commercial, government, and military applications. The flame temperatures produced by these motors can exceed 3315¿C (6000¿F). Unfortunately, this temperature is well above the melting point of most materials, leaving only a select few from which… More

Not Available Most commercial of-the-shelf (COTS) headset systems utilize a combination of Passive and analog active noise reduction (AANR) to improve voice communication reception and intelligibility in high noise aircraft environments. These system do not satisfy USAF needs. The USAF has defined… More

Not Available A low cost, high performance, 1300nm VCSEL will be a very desirable device for telecommunications as well as data communications applications. However, there is no low cost process for manufacturing of the 1300 or 1550nm devices at present because of the smaller refractive index… More

Not Available Materials used in the construction of aircraft hydraulic and fuel systems o-rings must provide long term performance in aggressive chemical environments over a wide range of temperatures and loads. Current o-ring materials, while chemically compatible with existing aircraft fuels and… More

Not Available Technology in Blacksburg, Inc. proposes to improve gas turbine compressor stability and reduce losses by employing flow control on the rotor blades. The suction-side boundary layer on the rotor blade will be bled off, the air will be re-energized using a

The ever-growing concern over air quality has led to considerable legislation to control atmospheric concentrations of ozone, nitrogen oxides, sulfur oxides, and volatile organic compounds (VOCs). However, much work remains before an acceptable measure ofindoor air quality is adopted. This is due… More

Both failure analysis and reconditioning of nickel superalloy gas turbine and rocket engine components are plagued by a major problem: the thin oxide films that form on unprotected fracture surfaces during field operation obscure the surfaces intended foranalysis and interfere with repair… More

The well-established high temperature strength, low density, and mechanical and thermal shock-resistance of carbon/carbon composites represent perhaps the most appealing combination of properties exhibited by any ceramic or metallic material currentlyunder consideration for advanced aircraft engine… More

The use of reduced-toxicity monopropellants such as dimethylaminoethyl azide (CINCH) or those based on energetic liquid salts such as hydroxylammonium nitrate (HAN) promises a number of improvements over conventional hydrazine propellant. Chief amongthese is improved safety, which will… More

Brayton and combined-cycle (turbine) engines are widely used for a variety of applications, including aeropropulsion and power generation. The performance of turbine engines is limited by the allowable use temperature of their hot-section components. Dueto increasingly complex cooling passages and… More

Current and developmental thermal protection system (TPS) materials severely limit the flight path and thus the mission flexibility of existing and future space transportation vehicles (STV), including reusable launch vehicles (RLV). TPS are essential, but also add parasitic weight rather than… More

"The use of reduced-toxicity monopropellants such as dimethylaminoethyl azide (CINCH) or those based on energetic liquid salts such as hydroxylammonium nitrate (HAN) promises a number of improvements over conventional hydrazine propellant. Chief amongthese is improved safety, which will… More

The use of gaseous oxygen/hydrogen (O2/H2) propellant for satellite maneuvering, attitude control, and station keeping offers many advantages over the use of storable propellants such as nitrogen tetroxide/monomethyl hydrazine (NTO/MMH) or nitrogen tetroxide/hydrazine (NTO/N2H4). Primary among these… More

No timely and cost-effective methods now exist for fabrication of thick-section (>=2), continuous fiber-reinforced ceramic matrix composites (CMCs). Application of such CMCs can enhance the efficiency and performance, reduce the weight, improve the durability, and lower the cost of aerospace… More

No timely and cost-effective methods now exist for fabrication of thick-section (>=2), continuous fiber-reinforced ceramic matrix composites (CMCs). Application of such CMCs can enhance the efficiency and performance, reduce the weight, improve the durability, and lower the cost of aerospace… More

"A large number of the rhenium components used in the MDA/Navy solid divert and attitude control system (SDACS) kinetic kill vehicle are fabricated by chemical vapor deposition (CVD). While CVD offers the most cost-effective manufacturing approach forthese components, further improvements in… More

"Future Air Force space, missile, and aircraft systems require advanced high temperature materials to meet projected performance requirements. Rocket engine and turbine engine programs such as the IHPRPT and IHPTET initiatives, respectively, are intendedto double next-generation propulsion… More

The use of gaseous oxygen/hydrogen (O2/H2) propellant for satellite maneuvering, attitude control, and station keeping offers many advantages over the use of storable propellants such as nitrogen tetroxide/monomethyl hydrazine (NTO/MMH) or nitrogen tetroxide/hydrazine (NTO/N2H4). Primary among these… More

"A key design limitation of many current electronic systems is heat rejection. As microchips become ever more densely packed with greater quantities of components, the amount of heat generated per unit area likewise increases rapidly. As the junctiontemperatures within an electronic component… More

73078S03-I The potential economic, environmental, and strategic benefits associated with the development of inertial fusion energy (IFE) are numerous. However, the application of fusion technology for cost-competitive electric energy generation cannot be realized without advanced firstwall… More

Current thermal protection systems (TPS) severely limit the flight path and the mission flexibility of space transportation vehicles, including reusable launch vehicles. TPS are essential, but add parasitic weight rather than providing both structural functionality and thermal protection.… More

Application of ceramic matrix composites (CMC) reinforced with carbon fibers can potentially enhance the efficiency and performance, reduce the weight, improve the durability, and lower the cost of rocket engine combustion devices and turbomachinery components used in high temperature, high-stress… More

One of the primary factors inhibiting the practical use of next-generation electromagnetic electric propulsion (EP) engines at high power levels (50-100 kW) is the current lack of thermally and mechanically stable insulators. Insulator materials for high-power Hall thrusters can erode rapidly as a… More

73077S03-I The potential economic and strategic benefits associated with the development of nuclear energy are numerous. However, greater application of nuclear technology cannot be realized until advanced materials are developed that allow operation under the high heat flux conditions necessary… More

No timely and cost-effective methods now exist for the fabrication of continuous fiber-reinforced ceramic matrix composites (CMCs) of complex geometries. Application of such CMCs can potentially enhance the efficiency and performance, reduce the weight,improve the durability, and lower the cost of… More

Low-density, high specific stiffness ceramic and metal open-cell foam materials may be utilized for creation of an innovative fuel matrix for use in space nuclear reactors. Highly porous structural foam may be developed for high thermal efficiency, high temperature fuel elements for both propulsion… More

No timely and cost-effective methods now exist for the fabrication of continuous fiber-reinforced ceramic matrix composites (CMCs) of complex geometries. Application of such CMCs can potentially enhance the efficiency and performance, reduce the weight,improve the durability, and lower the cost of… More

This Small Business Innovation Research Phase I project will demonstrate the feasibility of producing thermal barrier coatings (TBCs), along with sealcoats engineered to minimize oxygen ingress through the TBC to the bondcoat, by a novel chemical vapor deposition (CVD) route. Success will largely be… More

A key design limitation of many current electronic systems is heat rejection. As microchips become ever more densely packed with greater quantities of components, the amount of heat generated per unit area likewise increases rapidly. As the junctiontemperatures within an electronic component… More

A key design limitation of many current electronic systems is heat rejection. As microchips become ever more densely packed with greater quantities of components, the amount of heat generated per unit area likewise increases rapidly. As the junctiontemperatures within an electronic component… More

Phase III IHPRPT goals call for a 70% increase in density Isp for monopropellant systems. Advanced HAN-based monopropellants such as AF-m315 have the potential not only to exceed this goal, but also to exceed the density Isp of NTO/MMH. But before suchpropellants can be commercialized, a reliable… More

Large liquid rocket engine combustion chambers suffer from two key constraints: they incorporate relatively low temperature capability alloys to minimize cost, and require active cooling to prevent excessively high temperatures from weakening the chambermaterials such that they can no longer sustain… More

The Air Force is seeking a highly operable aerospace vehicle that can be ready to launch on demand. Hydrocarbon-fueled vehicles offer certain benefits over other propulsion systems. The vehicle is heavier when fueled with kerosene, but because of thenature of the propellant, it is lighter when… More

A large number of the rhenium components used in the solid divert and attitude control system (SDACS) of the Standard Missile 3 (SM-3) LEAP kinetic kill vehicle, being developed for missile defense in the Aegis LEAP Intercept (ALI) program, are fabricated by chemical vapor deposition (CVD). While… More

Future Air Force space, missile, and aircraft systems require advanced high temperature materials to meet projected performance requirements. Rocket engine and turbine engine programs such as the IHPRPT and IHPTET initiatives, respectively, are intended to double next-generation propulsion… More

Application of fiber-reinforced ceramic matrix composites (CMC) can enhance the efficiency and performance, reduce the weight, improve the durability, and lower the cost of rocket engine combustion devices and turbomachinery components used in high temperature, high-stress environments. Meeting… More

Low-density, high specific stiffness ceramic and metal open-cell foams may be utilized for creation of an innovative fuel element for use in space nuclear reactors. Highly porous structural foam may be developed for high thermal efficiency, high temperature fuel elements for both propulsion and… More

This Small Business Innovation Research (SBIR) Phase II project will seek to develop a novel technique for applying thermal barrier coatings (TBCs) to turbine (jet) engine components. The use of low thermal conductivity TBCs has enabled higher temperatures and longer component life to be achieved,… More

Silicided niobium alloy (C103) combustion chambers have been used extensively in both NASA and DoD liquid rocket propulsion systems. Niobium alloys offer a good combination of temperature capability, density, and cost, while the silicide coating has been successful in providing moderate oxidation… More

76266-Hydrogen use would increase dramatically if plans to employ it as an environmentally friendly, zero-emission fuel source come to fruition. However, before the widespread use of hydrogen becomes commercially viable, several alternative means of production must be developed, some of which will… More

The Air Force is seeking a highly operable aerospace vehicle that can be ready to launch on demand. Hydrocarbon-fueled vehicles offer certain benefits over other propulsion systems. The vehicle is heavier when fueled with kerosene, but because of the nature of the propellant, it is lighter when… More

The massive acoustic loads produced by launch vehicles can detrimentally affect the proper functioning of vehicle components, payloads, and launch support structures. The high-velocity and high temperature rocket engine exhaust stream mixes with ambient atmosphere to generate intense acoustic loads,… More

The current push to develop small satellites, referred to as microsatellites (

79175S The International Thermonuclear Experimental Reactor (ITER) is an international effort to build the first power-producing, magnetically-confined fusion reactor within the next decade. The reactor design requires the development of advanced materials for flow channel inserts that will allow… More

Silicided niobium alloy (C103) combustion chambers have been used extensively in both NASA and DoD liquid rocket propulsion systems. Niobium alloys offer a good combination of temperature capability, density, and cost, while the silicide coating has been successful in providing moderate oxidation… More

79191S The potential economic, environmental, and strategic benefits associated with the development of magnetic fusion energy (MFE) are numerous. However, fusion technology cannot be realized until advanced materials are developed that allow operation under the high heat flux conditions necessary… More

Aerothermal heating of leading edges and nose tips on reentry vehicles creates stagnation-point temperatures that are beyond the limits of most materials. For systems that have reusability requirements, the challenge is even greater. Heat pipes offer a solution to this problem by providing a… More

The current push to develop small satellites, the need for formation flying constellations, and the desire to replace reaction control wheels have resulted in the need for thrusters that can deliver very small impulse bits. The required thrusters are much smaller than those available today, so new… More

The use of ceramic matrix composites (CMCs) has the potential to increase the life and operating envelope of turbine engines. While great strides have been made in mechanical properties, CMCs still suffer from limitations in terms of shape capability, especially with complex-shaped parts such as… More

Conventional fiber-matrix interface coatings applied by chemical vapor infiltration (CVI) are expensive because they require costly, high-temperature equipment and must be applied at a slow rate in order to achieve uniform infiltration across large thermal gradients. In previous work for DoD and… More

78163S Superconducting radio frequency (RF) accelerating cavities provide high continuous wave operating fields while offering higher beam quality and reduced beam-cavity interaction for high-energy physics research. An efficient and cost-effective fabrication methodology for the large-scale… More

The Air Force is seeking advanced cooling concepts for scramjet engines for use in hypersonic cruise missiles, Mach 8-10 strike/reconnaissance aircraft, and affordable, on-demand access to space. In current work for the Air Force, Ultramet and Boeing/Rocketdyne are demonstrating the performance and… More

Polybenzoxazole polymers, including polyphenylenebenzobisoxazole (PBO) in particular, are under development for use in a wide variety of aerospace applications due to their remarkable tensile strength, modulus, and flame resistance. These materials are of particular interest due to their high… More

The reentry spacecraft and hypersonic cruisers of the future will require advanced lightweight thermal protection systems that can provide the dual functionality of thermal protection and structural capability. In the proposed project, Ultramet will fabricate a lightweight, reusable, highly… More

The International Thermonuclear Experimental Reactor (ITER) is an international effort to build the first power-producing, agnetically-confined fusion reactor within the next decade. The reactor design requires the development of advanced materials for flow channel inserts that will accomodate a… More

The potential economic, environmental, and strategic benefits associated with the development of magnetic fusion energy are enormous. However, fusion technology cannot be realized without the development of advanced materials that allow operation under the high heat flux and radiation conditions… More

Aerothermal heating on the nose tip and leading edges of the Falcon hypersonic vehicle will create stagnation point temperatures that are beyond the limits of most materials. Furthermore, because Falcon has the requirement of being reusable, the challenges are even greater. Heat pipes offer a… More

NASA and DoD are seeking economical and high-performance bipropellant thrusters for various applications. These goals cannot be achieved using the silicided C103 chambers in current use. Ultramet has developed and successfully demonstrated carbon fiber-reinforced zirconium carbide (C/ZrC) and carbon… More

New and innovative lightweight radiation shielding materials are needed to protect humans in future manned exploration vehicles. Radiation shielding materials are needed for large structures such as the space station, orbiters, landers, rovers, habitats, and spacesuits. Materials currently used are… More

Future reentry and hypersonic vehicles require advanced lightweight leading edge thermal protection systems that can provide the dual functionality of thermal/oxidation protection and structural capability. In Phase I, Ultramet demonstrated the feasibility of combining the light weight of… More

The Air Force is establishing a long-term investment in advanced thermal protection systems (TPS). The goal of this effort is to provide design, materials, and fabrication solutions that meet airframe requirements of aircraft-like operability, responsiveness, and mission flexibility in contrast to… More

Hypersonic flight requires the development of insulating materials with a combination of thermal conductivity, density, and structural integrity that is beyond the capability of materials currently in use. In previous thermal protection system work for DoD and NASA, Ultramet developed a highly… More

The thermal, mechanical, and chemical environment generated during launch and flight of hypersonic missiles is severe. Ultramet has developed a melt infiltration process for rapid fabrication of refractory ceramic matrix composites (CMCs) including matrices of zirconium carbide, hafnium carbide,… More

Rhenium has been successfully demonstrated in solid rocket motor applications because of its high melting point and excellent strength at elevated temperatures. However, rhenium comes with a significant weight and cost penalty when used in monolithic form. Refractory ceramics such as hafnium carbide… More

To reduce combustion instability and noise in turbine engines, Ultramet will team with the University of Alabama to design, model, fabricate, and test refractory hafnium carbide/silicon carbide open-cell ceramic foam to be used in the combustion chamber as a passive control device. Previous work at… More

The thermal, mechanical, and chemical environment generated during launch and flight of hypersonic projectiles is severe. Ultramet has developed a melt infiltration process for rapid fabrication of refractory ceramic matrix composites (CMCs) including matrices of zirconium carbide, hafnium carbide, … More

Corrosion-related maintenance of metal alloy components such as hydraulic wing and blade fold actuation systems for carrier-based aircraft and rotary gear assemblies costs the Navy approximately $1 billion per year. Innovative and low-cost surface modifications that do not compromise mechanical… More

The reactor design proposed by the United States for the International Thermonuclear Experimental Reactor (ITER) requires the development of advanced materials for breeder blankets. Although recently developed aluminide coatings for tritium permeation barriers work well in the laboratory, they fail… More

NASA and DoD are seeking high-performance, lightweight liquid rocket combustion chambers with future performance goals that cannot be achieved using state-of-the-art actively cooled metallic liners, silicided C103, or even carbon fiber-reinforced silicon carbide (C/SiC) ceramic matrix composites… More

The use of ceramic matrix composites (CMCs) has the potential to increase the life and operating envelope of turbine engines. While great strides have been made in mechanical properties, CMCs still suffer from limitations in terms of shape capability, especially with complex-shaped parts such as… More

In previous work, Ultramet has developed and demonstrated a rapid, low-cost method of applying oxide, carbide, and nitride interface coatings to carbon, oxide, and silicon carbide (SiC) fibers at low temperature (as low as 100 degrees C) via ultraviolet-enhanced chemical vapor deposition (UVCVD).… More

In recent decades, advancements in electronic components have led to devices that generate significantly more heat per unit area. The processes by which waste heat is removed are less efficient, and the system must operate at higher temperatures. Magnet wire is a key component in many of these… More

Launch-on-demand satellites require both high thrust and high specific impulse (Isp). In this project, Ultramet will develop a multi-mode propulsion system that is capable of delivering an Isp of 291 seconds (density Isp of 453 s) in high-thrust mode using HAN/HEHN monopropellant. The propellant… More

Open-cell foams offer several unique mechanisms that can be used to defeat the threat posed by mine blast effects. The initial shock wave reaching the armor is by far the greatest threat, and dissipating the energy of this shock wave is the goal of the proposed work. The first mechanism relies on… More

Advanced missile defense interceptors require lightweight thermal protection systems (TPS) and aerostructures designed to minimize internal temperature rise and ensure missile airframe structural integrity during flight, including operation in adverse weather. These material systems must meet… More

Fission-based power systems are anticipated for various planetary surface human base applications with power levels of 30ýý100+ kWe. The development of high temperature, high efficiency heat exchangers, turbines, and pumps is critical for next-generation nuclear power and space propulsion… More

Hydroxylammonium nitrate (HAN)-based propellant promises many improvements over hydrazine and NTO/MMH propellants. Chief among these is improved safety, which will significantly decrease overall use costs. However, reduced toxicity monopropellants are difficult to ignite. Although this… More

Rhenium has been successfully demonstrated in tactical solid rocket motor applications because of its high melting point and strength at elevated temperatures. However, rhenium comes with a significant weight and cost penalty when used in monolithic form. Low-cost refractory ceramics such as hafnium… More

In the Prompt Global Strike (PGS)-Conventional Strike Missile (CSM) program, the Air Force is seeking a mid-term, land-based conventional weapon system capable of striking targets halfway around the globe within an hour of an order to launch. While candidate long-term systems are likely to include… More

Reduction of combustion-generated noise is one of the most significant challenges in the development of advanced gas turbine engines. Several processes contribute to the noise, but combustion instabilities pose the most serious threat to engine operation and safety. In Phase I, highly porous… More

The reactor design proposed by the United States for the International Thermonuclear Experimental Reactor (ITER) requires development of advanced materials for breeder blankets. Aluminized coatings developed over the last several years for tritium permeation barriers work well in the laboratory but… More

Thermal management is a key design limitation in detector instrumentation and related electronics. The thermal management system typically is designed to cool the entire board and is not well suited to control the increasing number of hot spots found in advanced electronics systems. The problem is… More

The potential economic, environmental, and strategic benefits associated with the development of fusion energy are numerous. However, fusion technology cannot be realized without advanced materials that allow operation under the high heat flux conditions necessary for cost-competitive electric… More

The International Thermonuclear Experimental Reactor (ITER) design requires the development of advanced materials for flow channel inserts, in order to permit the high tritium breeder exit temperature of ~700°C needed to increase overall plant efficiency. The primary requirements for the flow… More

Tungsten is one of the most important candidate materials for the diverter components of fusion energy systems, due to its low erosion and good properties at high temperature. However, the fabrication of complex-shaped tungsten parts by conventional processing techniques is problematic. This project… More

Ultramet will design and fabricate a lightweight, high temperature 5-lbf combustion chamber. The system will be designed for use with the AF-315 family of monopropellants, which have specific impulse values well in excess of 240 sec, and the combustion chamber material will be based on Ultramet's… More

Fission-based power systems with power levels of 30 to ≥100 kWe will be needed for planetary surface bases. Development of high temperature, high efficiency heat exchangers is critical for next-generation nuclear power and space propulsion systems. In Phase I, Ultramet and Sandia National… More

In previous work for NASA and DoD, Ultramet developed lightweight open-cell foam insulators composed of a carbon or ceramic structural foam skeleton filled with a high temperature nanoscale aerogel insulator. The structural integrity and high insulation behavior have been demonstrated when used in… More

The use of fusion technology for cost-competitive electric energy generation cannot be realized until advanced plasma-facing materials and structures are developed that are capable of withstanding the intense pulsed X-rays, energetic ions, and neutrons produced by the periodic explosion of a fusion… More

During the development of the Spallation Neutron Source (SNS) at Oak Ridge National Laboratory, high-energy proton pulses were found to create high-intensity pressure pulses in the liquid mercury. In turn, these pulses damaged the mercury container due to the effect of cavitation damage erosion… More

Tokamak fusion reactors will use plasma facing components made of tungsten because of its excellent physical sputtering characteristics and high temperature capabilities. Boron is also used as a plasma facing material in most tokamaks because of its outstanding plasma-conditioning properties. Both… More

Accurate prediction of coupled transport phenomena is critical to the design of liquid metal blankets used in fusion reactors. While rapid advances are being made in the computer modeling of blanket systems in areas of fluid flow, magnetohydrodynamics (MHD), heat transfer, structural mechanics, and… More

Integrated gasification combined cycle (IGCC) gas turbines are rapidly becoming the choice for current and future power systems because they offer efficient fuel conversion and generate electricity at reduced cost. Practical application of efficient and cost-effective IGCC turbines requires the… More

An efficient, reproducible, and cost-effective fabrication process is needed for the large-scale production of superconducting radio frequency (SRF) cavities, in support of numerous U.S. and international high-energy accelerator projects. In previous work, the use chemical vapor deposition (CVD)… More

In this project, Ultramet will design, build, and hot-fire test a lightweight, low-cost, high-temperature 5-lbf combustion chamber. The system will be designed for the AF-315 family of monopropellants, which have specific impulse values ranging from 263 to 288 sec, and the combustion chamber… More

Future performance goals for ballistic missile defense systems necessitate the development of zero-erosion throat materials for boost and tactical solid rocket motors. Increasing demands imposed by advanced solid propellants used in systems such as throttling diverter and attitude control systems… More

The economic, environmental, and strategic benefits associated with the development of fusion energy are numerous, but they cannot be realized until new technology is developed to allow operation under high heat flux conditions. Bathing the wall of a fusion reactor plasma-facing component in a… More

Rhenium hot gas path components are used extensively in the solid divert and attitude control system (SDACS) of the MDA/Navy Standard Missile-3 Aegis LEAP Interceptor missile defense program, on which Ultramet is a key subcontractor. The mechanical, thermal, and chemical performance of rhenium is… More

In previous work for NASA and DoD, Ultramet developed lightweight open-cell foam insulators composed of a carbon or ceramic structural foam skeleton filled with a high temperature nanoscale aerogel insulator. Structural integrity and high insulation behavior have been demonstrated when used in… More

Current cryogenic insulation materials suffer from various drawbacks including high cost and weight, lack of structural or load-bearing capability, fabrication complexity, and property anisotropy. A need clearly exists for lightweight thermal insulation that is isotropic, structurally capable, and… More

AISI 9310 nickel-chromium-molybdenum alloy steel is used extensively in military helicopter rotor shafts and gears. This reliable alloy provides excellent fatigue life combined with high hardness, elastic modulus, and tensile strength. However, to facilitate rapid speed changes of variable drive… More

Ultramet will design and fabricate a lightweight, high temperature 5-lbf combustion chamber for use with cryogenic liquid oxygen/methane (LOX/CH4) propellant that will deliver a specific impulse of ~355 seconds, an increase over the current 320-sec baseline that will result in a propellant mass… More

Future performance goals for ballistic missile defense systems necessitate the development of zero-erosion throat materials for boost and tactical solid rocket motors. Increasing demands imposed by advanced solid propellants used in systems such as throttling divert and attitude control systems… More

Hydroxylammonium nitrate (HAN)-based monopropellants promise many improvements over monopropellant hydrazine and bipropellant nitrogen tetroxide/monomethyl hydrazine (NTO/MMH). But before HAN-based monopropellants can be commercialized, a reliable ignition system must be implemented. In this Phase… More

Current Enhanced Small Arms Protective Insert (E-SAPI) plates are made from hot-pressed boron carbide (B4C), which offers a favorable combination of high hardness and light weight. As threats continue to evolve, however, armor systems must also evolve to defeat the threats. Unfortunately, this… More

In this project, Ultramet is designing and fabricating a lightweight, high temperature combustion chamber for use with cryogenic liquid oxygen/methane (LOX/CH4) propellant that will deliver a specific impulse of ~355 seconds, an increase over the current 320-sec baseline that will result in a… More

Current cryogenic insulation materials suffer from various drawbacks including high cost and weight, lack of structural or load-bearing capability, fabrication complexity, and property anisotropy. A need clearly exists for lightweight thermal insulation that is isotropic and structurally capable… More

The state-of-the-art material system for high-performance radiation-cooled liquid rocket engines is iridium/rhenium manufactured by chemical vapor deposition (CVD). As it has been produced for the past several years, Ultramet's CVD rhenium has a yield strength of 43 ksi and an elongation of… More

In conjunction with Sandia National Laboratories, Ultramet previously demonstrated the feasibility of using low-density, high specific stiffness open-cell foams for creation of innovative fuel elements for use in space nuclear reactors. Highly porous and structural foam material was produced by… More

During development of the Spallation Neutron Source (SNS) at Oak Ridge National Laboratory (ORNL), high-energy proton pulses were found to create high-intensity pressure pulses in the liquid mercury. These pulses damaged the mercury container because of cavitation damage erosion, which must be… More

Application of fusion technology for cost-competitive electric energy generation cannot be realized until advanced plasma-facing materials and structures are developed. The specific problem addressed in this project is the mitigation of heat-induced failure and surface blistering of tungsten-based… More

Ultramet recently demonstrated rapid, reliable, and repeated ignition of hydroxylammonium nitrate (HAN)-hydroxyethylhydrazinium nitrate (HEHN) monopropellant mixtures. HAN-HEHN green monopropellants offer many improvements over monopropellant hydrazine and NTO/MMH bipropellant, including increased… More

The decomposition of hydroxylammonium nitrate (HAN)-based monopropellants is a complex process that involves numerous unimolecular and bimolecular reaction steps. During the decomposition sequence, numerous intermediate reaction products form and are then later consumed. Chemical reactions between… More

In recent decades, advances in electronic components have led to smaller devices that generate significantly more heat per unit area. The processes by which waste heat is removed are less efficient, and the system must operate at higher temperatures. Magnet wire is a key component of many of these… More

Advanced missile defense interceptors require lightweight thermal protection systems (TPS) and aerostructures designed to minimize internal temperature rise and ensure missile airframe structural integrity during flight, including operation in adverse weather. These material systems must meet… More

Rhenium hot gas path components are used extensively in the solid divert and attitude control system (SDACS) of the Standard Missile-3 (SM-3) Block 1A Aegis ballistic missile defense system, on which Ultramet is a key subcontractor. The mechanical, thermal, and chemical performance of rhenium is… More

ABSTRACT: Future Air Force as well as other DoD and NASA missions require structural composites capable of enduring peak hot surface temperatures of 3000 degrees F or higher while providing cold face temperatures of 600 degrees F or lower to prevent damage to underlying structures and components.… More

Ultramet recently demonstrated rapid, reliable, and repeated ignition of hydroxylammonium nitrate (HAN)-hydroxyethylhydrazinium nitrate (HEHN) monopropellant mixtures. Before this milestone was achieved, the feasibility of using this advanced ionic liquid monopropellant was distant. In this project,… More

Low-cost access to space demands durable, cost-effective, efficient, and low-weight propulsion systems. Key components include rocket engine nozzles and nozzle extensions for boost and upper stages. Options for such nozzles include actively cooled alloys, ablatives, and radiation-cooled composites… More

In a fusion reactor solid tritium breeder blanket, small pebbles of ceramic breeder are packed into a blanket container in order to breed and extract tritium, which is the main fuel of next- generation deuterium-tritium fusion reactors. The current sphere-pack technology imposes… More

Niobium superconducting radio frequency (SRF) cavities provide high continuous wave operating fields while offering high beam quality and low beam-cavity interaction. Extensive research is being conducted worldwide to develop cost-effective processing for large-scale production of niobium SRF… More

New fuel forms are required to enable gas-cooled fast fission reactors to operate using an oncethrough deep-burn fuel cycle. The new reactors will have a core life of 30 years and burn the plutonium-239 created in the core as well as other transuranics. Deep burn rapidly and effectively reduces the… More

For a selected vehicle and jet engine configuration, fuel consumption is to a significant degree dictated by the thermal efficiency of the engine. Achieving optimal thermal efficiency and minimizing fuel consumption requires high temperature operation with minimum cooling of hot gas path components,… More

The Standard Missile-3 (SM-3) Block 2B missile defense system is confronted by needs for higher performance, including enhanced acceleration, extended flight duration, and greater aerothermal heating endurance, all of which lead to requirements for lighter weight and higher performance materials.… More

ABSTRACT: The decomposition of hydroxylammonium nitrate (HAN)-based monopropellants is a complex process that involves scores of unimolecular and bimolecular reaction steps and dozens of species. Chemical reactions between these species and the catalyst, as well as thermal effects, can all have a… More

Future performance goals for ballistic missile defense systems necessitate the development of zero-erosion throat materials for boost and tactical solid rocket motors. Increasing demands imposed by advanced solid propellants used in systems such as throttling divert and attitude control systems… More

Monolithic microwave integrated circuits (MMIC) generate ever-increasing heat loads. Foam-based cooling systems have proven beneficial for high heat dissipation with low pumping and small volume requirements. In previous work, Ultramet fabricated silicon carbide (SiC) foam heat sinks for gallium… More