High-Throughput Manufacturing of Rhenium SDACS Components, Phase II

Award Information
Agency: Department of Defense
Branch: Missile Defense Agency
Contract: N00167-04-C-0054
Agency Tracking Number: 022-0898
Amount: $712,297.00
Phase: Phase II
Program: SBIR
Awards Year: 2004
Solicitation Year: 2002
Solicitation Topic Code: MDA02-021c
Solicitation Number: 2002.2
Small Business Information
12173 Montague Street, Pacoima, CA, 91331
DUNS: 052405867
HUBZone Owned: N
Woman Owned: N
Socially and Economically Disadvantaged: N
Principal Investigator
 Arthur Fortini
 Director of Science and T
 (818) 899-0236
Business Contact
 Craig Ward
Title: Engineering Administrativ
Phone: (818) 899-0236
Email: craig.ward@ultramet.com
Research Institution
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 CVD offers the most cost-effective manufacturing approach for these components, further improvements in production throughput and cost are desired. In Phase I, Ultramet demonstrated that seven main thruster assembly (MTA) thrusters, instead of one, could be simultaneously coated in a single CVD reactor without increasing the deposition time. It was further demonstrated that the rhenium usage efficiency could be increased by 20% relative to the current process, and that the time required to machine MTA thrusters could be reduced by 40% relative to the wire electrical discharge machining (EDM) process currently used. In Phase II, Ultramet will continue to increase the production efficiency of MTA thrusters by further developing the CVD process to include nine thrusters, further developing the machining process to increase its efficiency, and developing/applying innovative quality assurance techniques to increase confidence in the product. The efficacy of the new processes will be demonstrated by several techniques, including hot-fire testing of several thrusters. The result will be a dramatic increase in process throughput and production capacity, an increase in product reliability, a decrease in the number of CVD reactors required for a given job, and a commensurate decrease in the unit production cost.

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

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