Enabling Materials Processing Technology for Low-Cost Fabrication of Integral Bladed Rotors (IBR)

Award Information
Agency:
Department of Defense
Branch
Air Force
Amount:
$750,000.00
Award Year:
2005
Program:
SBIR
Phase:
Phase II
Contract:
FA8650-05-C-5301
Award Id:
67613
Agency Tracking Number:
F041-140-1281
Solicitation Year:
n/a
Solicitation Topic Code:
n/a
Solicitation Number:
n/a
Small Business Information
7900 West 78th St., Suite 250, Minneapolis, MN, 55439
Hubzone Owned:
N
Minority Owned:
N
Woman Owned:
N
Duns:
938966090
Principal Investigator:
Troy Marusich
Chief Technical Officer
(952) 832-5515
troym@thirdwavesys.com
Business Contact:
Kerry Marusich
President, CEO
(952) 832-5515
sales@thirdwavesys.com
Research Institute:
n/a
Abstract
Integral bladed rotors (IBR) manufacturing is an essential part of gas turbine fabrication for modern fighter aircraft. Stringent dimensional tolerance and surface finish requirements necessitate precision manufacturing and consequently, resulting in increased cost. Our Phase II proposal will demonstrate innovative high speed machining (HSM) technologies the Air Force needs for affordable fabrication of titanium and nickel IBRs. Our approach meets the program target by providing an immediate 45% cost reduction for F-119 and F-135 engines and requires no capital equipment investment. Our program will ultimately: (a) Achieve dramatic cost and cycle time reductions for titanium and nickel alloy IBRs with no capital equipment investment; (b) Eliminate expensive, environmentally unfriendly electrochemical machining and improve surface finish; (c) Meet program affordability target of 35-50% for IBRs which meet qualification criteria; and (d) Achieve life cycle cost savings for F-135 and F-119 engines of $3 billion. Our disciplined three-phase development program will: (a) Apply innovative HSM technologies to nickel-based alloys to extend the cost savings to these materials; (b) Demonstrate innovative HSM technologies for titanium-based alloys via fabrication of IBR features; and (c) Fabricate full-scale IBR to demonstrate innovative HSM technologies for titanium and nickel based alloys that meet the affordability target.

* information listed above is at the time of submission.

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