Iron Powder Advancements

OUSD (R&E) CRITICAL TECHNOLOGY AREA(S): Advanced Materials The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), 22 CFR Parts 120-130, which controls the export and import of defense-related material and services, including export of sensitive technical data, or the Export Administration Regulation (EAR), 15 CFR Parts 730-774, which controls dual use items. Offerors must disclose any proposed use of foreign nationals (FNs), their country(ies) of origin, the type of visa or work permit possessed, and the statement of work (SOW) tasks intended for accomplishment by the FN(s) in accordance with the Announcement. Offerors are advised foreign nationals proposed to perform on this topic may be restricted due to the technical data under US Export Control Laws. OBJECTIVE: The objective of this project is to improve iron based powder manufacturing processes such as carbonyl iron (CIP), iron silicide (FeSi), and ferro chromium (FeCr) with a focus on increasing corrosion resistance, reducing cost, and/or strengthening domestic industrial base powder production. DESCRIPTION: The awardee(s) shall perform a series Design of Experiments (DOE), building on their previous manufacturing development efforts, to mature iron powder production. This work may include but is not limited to, producing small batches of varying formulations of encapsulated CIP for government testing to prove out the manufacturing processes, exploring powder atomization processes for powder production at large scale, and process optimization to reduce cost. PHASE I: As this is a Direct-to-Phase-II (D2P2) topic, no Phase I awards will be made as a result of this topic. To qualify for this D2P2 topic, the Government expects the applicant(s) to demonstrate feasibility by means of a prior Phase I-type effort that does not constitute work undertaken as part of a prior SBIR/STTR funding agreement. The feasibility study shall address manufacturing process improvements for iron powder production. This study will include the scientific and technical merit and feasibility of ideas appearing to have commercial potential, a process flow diagram with assigned Manufacturing Readiness Levels (MRL) for each step of the process, and a manufacturing maturation plan to identify where and how the company will make improvements to increase the MRL of the process steps. The study must have validated the product-market fit between the proposed solution and a potential AF stakeholder. The feasibility study should have; -Identified the prime potential AF end user(s) for the non-Defense commercial offering to solve the AF need, i.e., how it has been modified; -Described integration cost and feasibility with current mission-specific products; -Described if/how the demonstration can be used by other DoD or Governmental customers. PHASE II: During the Phase II effort, the awardee(s) shall implement its version of the manufacturing maturation plan previously developed under their "Phase I-type" effort. Through a series of design of experiments campaigns, the awardee(s) shall perform manufacturing process verification postulated in Phase I and process scale-up with a goal of being to be able to achieve quantities of metric tons/year. Quantities on the order of 50 grams of the material shall be delivered to the government for independent testing. The goal of Phase II is manufacturing readiness level (MRL) 6 as an objective and level 5 as a threshold. PHASE III DUAL USE APPLICATIONS: The awardee(s) can expect to pursue commercialization of the technology developed in Phase II for transitioning expanded mission capability to a broad range of potential government and civilian users and alternate mission applications. The entry technology readiness level (TRL) into a Phase III project will be TRL 6 and the MRL will be at a minimum of MRL 5. In order for potential transition into a DoD or government program, production cost will play a critical role. Therefore, during the Phase III effort, the awardee(s) shall focus on manufacturing improvements to reduce the cost of their material by addressing areas such as, but not limited to, yield improvements, cycle time reduction and process optimization. In addition, the awardee(s) shall also address production capacity scale-up by exercising their production process to produce at least 5 batches of material and subsequent mechanical and electrical testing will be performed to ensure material uniformity from batch to batch. Direct access with end users and government customers will be provided with opportunities to receive Phase III awards for providing the government additional research & development, or direct procurement of products and services developed in coordination with the program. REFERENCES: 1. Third-Stage Sintering of Carbonyl Iron Powder, Modern Developments in Powder Metallurgy, p1-19. 2. AN OVERVIEW OF POWDER ATOMIZATION PROCESSES AND FUNDAMENTALS, International Journal of Powder Metallurgy and Powder Technology, Vol. 13:3 Jul 77 pp. 169-173, 175-178, 180-182, and 184-188. 3. Production of Al-4.5%Cu Powder by the Rotating-Water-Atomization Process, Journal of the Japan Institute of Metals, Vol. 47:11 Nov 83 pp. 1016-1021 KEYWORDS: Carbonyl Iron Powder; Metal Water Atomization; Fine Metal Powder Production