Low Cost Machining of Nickel Alloys for Aerospace Components

Award Information
Agency: Department of Defense
Branch: Defense Logistics Agency
Contract: W9113M-09-C-0118
Agency Tracking Number: L083-001-0039
Amount: $100,000.00
Phase: Phase I
Program: SBIR
Awards Year: 2009
Solicitation Year: 2008
Solicitation Topic Code: DLA08-001
Solicitation Number: 2008.3
Small Business Information
Third Wave Systems, Inc.
7900 West 78th St., Suite 300, Minneapolis, MN, 55439
DUNS: 938966090
HUBZone Owned: N
Woman Owned: N
Socially and Economically Disadvantaged: N
Principal Investigator
 Cory Arthur
 Sr. Applications Engineer
 (952) 832-5515
 cory.arthur@thirdwavesys.com
Business Contact
 Troy Marusich
Title: Chief Technical Officer
Phone: (952) 832-5515
Email: troym@thirdwavesys.com
Research Institution
N/A
Abstract
The use of nickel alloys is pervasive in jet engine components and includes cases and fatigue critical rotating parts in the compressor and turbine sections. Machining nickel alloys represents a singular challenge due to the alloys¡¦ exceptional high temperature strength characteristics. This is marked by low material removal rates (MRR), long cycle times and high tooling costs. Our program will demonstrate the feasibility of innovative high-performance machining (HPM) enabled by physics-based modeling for low-cost fabrication of nickel-based aerospace engine components required for fixed wing and rotorcraft fleet sustainment. HPM will reduce costs of nickel aerospace components through a 100% increase in (MRR) while maintaining tool life. This unique approach will allow the use of conventional machine tools and eliminate the need for expensive capital equipment investment, leading to improved fleet sustainment through shorter cycle times, reduced costs, and increased supplier base. Our technical objectives include: (1) advancing physics-based modeling of nickel alloys, (2) demonstrating increased MRR via HPM for fundamental operations, and (3) demonstrating increased MRR via HPM for feature machining. The anticipated results include the demonstration of the feasibility of enabling physics-based modeling approach to analyze and dramatically improve machining of nickel alloys via the application of HPM.

* information listed above is at the time of submission.

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