DLA26BZ02-NV001 — Domestic Production of Refractory Powders for Ultra-High Temperature Ceramics and Aerospace Alloys

Award Maximum: $100,000 Period of Performance: 12 months Phase Type: Phase I

OBJECTIVE: The Defense Logistics Agency (DLA) seeks to provide responsive, best value supplies of related materials consistently to our Department of War (DoW) customers and other DoW stakeholders. DLA continually investigates a variety of critical minerals for more efficient means of their production, opportunities for recycling, and more competitive domestic supply chains which would lead to higher levels of innovation in current and future systems combined with benefits to other commercial and government technology applications. In an effort to reduce costly foreign reliance and/or single points of failure, DLA is looking to establish domestic capabilities to produce high purity refractory powders for applications in aerospace alloys and ultra-high temperature ceramics (UHTC) used in hypersonic and other defense platforms. The end goal of the project would be for the development of domestic suppliers that would produce industrial quantities of high purity, low oxygen refractory powders to include carbides, borides, and metals containing Hf, Zr, V, Nb, Ta, Cr, Mo, W, etc. The powders should be well characterized for metals purity, oxygen content, morphology, particle size, and sintering characteristics. New and novel ideas that would allow for competitive pricing compared to imported raw materials will have preference. Ideally, the production process would be modular and scalable. These areas of materials and manufacturing technology provide potential opportunities toward achieving breakthrough advances for national defense. Proposed efforts funded under this topic may encompass diverse feedstock and processing at any level that will result in increasing production capacity, affordability, and supply chain resiliency. Research and Development (R&D) efforts selected under this topic shall demonstrate and involve a degree of risk where the technical feasibility of the proposed work has not been fully established. Further, proposed efforts must be judged to be at a Technology and/or Manufacturing Readiness Level (TRL/MRL) 6 or less, but greater than TRL/MRL 3 to receive funding consideration. TRL 3. (Analytical and Experimental Critical Function and/or Characteristic Proof of Concept) TRL 6. (System/Subsystem Model or Prototype Demonstration in a Relevant Environment)

DESCRIPTION: Refractory powders are a critical feedstock for many high-temperature defense applications, and the US is strongly reliant on imported materials to meet production needs. Varying powder qualities and increasing procurement costs/lead times upstream limit domestic production capabilities downstream. To this end, DLA is looking for wholly domestic capabilities to recycle and produce refractory metals, carbides, and borides that meet or exceed defense specifications. Novel techniques that increase the domestic availability and supply chain resiliency of refractory materials will have preference. The ideal production process will be both modular and easily scalable.

PHASE I: Not to exceed a duration of 12 months and cost of $100,000.

Phase I will deliver a proof-of-concept demonstration of a refractory powder production process and preliminary materials characterization. A technology development and commercialization roadmap will be produced along with a preliminary technoeconomic analysis. An alignment or collaboration with a relevant DoW Component organization/supplier (e.g., DoW lab, defense system program office or prime contractor) and one or more relevant DoW weapon system supply chain participants or other suitable organization is highly desirable.

PHASE II: Phase II will consist of establishing a pilot scale process to produce refractory powders. Produced materials will be fully characterized for purity, phase, morphology, and other relevant properties. A business case will be generated using both DoW and commercial markets. Collaboration with a relevant DoW Component organization/supplier (e.g., DoW lab and/or prime contractor) and one or more relevant DoW weapon system supply chain participants or other suitable organization is highly desirable. Performers will identify commercial benefit or application opportunities of the innovative processes should be developed with the intent to readily transition to production in support of DoW and its supply chains.

PHASE III DUAL USE APPLICATIONS: At this point, no specific funding is associated with Phase III. Relationships developed and progress made in Phase I and Phase II projects should result in the ability to produce to DoW orders and organic growth of business from there.