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Tooling-Free On-Demand Repeatable Ceramic Engineered Components

Award Information
Agency: Department of Defense
Branch: Defense Logistics Agency
Contract: SP4701-15-C-0073
Agency Tracking Number: L152-003-0005
Amount: $148,812.59
Phase: Phase I
Program: SBIR
Solicitation Topic Code: DLA152-003
Solicitation Number: 2015.2
Solicitation Year: 2015
Award Year: 2015
Award Start Date (Proposal Award Date): 2015-09-30
Award End Date (Contract End Date): 2016-09-29
Small Business Information
1825 Corporate Center Blvd
Fairborn, OH 45324
United States
DUNS: 132336426
HUBZone Owned: No
Woman Owned: No
Socially and Economically Disadvantaged: No
Principal Investigator
 DZ Sokol
 (937) 322-3227
Business Contact
 Teffan Moler
Phone: (937) 322-3227
Research Institution

This Phase I SBIR project demonstrates how CAD as tooling, coupled with additive manufacturing, will ultimately prove the viability of on-demand ceramic process aids for all legacy turbine airfoil investment castings.This in turn, will reduce the leadtime for ceramic process aids by 95% and save up to $750,000 per casting part number in tooling costs.This capability is driven by the need to support legacy aircraft and engines critical to warfighter readiness.Acquisition of complex legacy jet engine turbine airfoils is characterized by high cost, long leadtimes, and a limited number of sources.These airfoils start as investment castings, using high temperature nickel-based alloys.Their production requires essential process aids in the form of ceramic cores and molds that are formed using sophisticated machined tooling for injection of the ceramic materials required for the investment casting process.A key stumbling block in providing cast turbine airfoils is availability of tooling to produce ceramic cores and molds.Additive manufacturing for these componentseliminates hard tooling, including machined core dies.Digital data effectively replaces conventional core die injection tooling; ceramic cores and molds for investment castings can be designed and produced without the need for machined steel dies and related fixtures.

* Information listed above is at the time of submission. *

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