Tungsten 3% Rhenium wire manufacturing

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: Develop tungsten 3% rhenium wire manufacturing capability using existing feedstock owned by DLA. DESCRIPTION: The Defense Logistics Agency (DLA) is looking for a domestic capability to manufacture tungsten 3% rhenium wire. Global Tungsten and Powders (GTP), a subsidiary of the Plansee Group, discontinued the manufacture of its tungsten and rhenium wire products in February 2013. Specifically, tungsten 3% rhenium wire is used in multiple vacuum electronic devices (VEDs) that support Department of Defense requirements. Traveling wave tubes (TWTs) make up the largest population of VEDs that use tungsten 3% rhenium wire. TWTs are used as RF amplifiers in radar, electronic warfare, communications, and other military systems. A Title III program was initiated in late 2013 with the goal of establishing a new US source to replace GTP as a tungsten 3% rhenium wire supplier. As of the end of fiscal year 2021, this program has been unsuccessful achieving the end goal of creating split free tungsten rhenium wire in the sizes required to meet all DoD applications. During the time the program was in operation GTP manufactured tungsten rhenium wire ingots to be used as feedstock for the tungsten rhenium wire manufacturing process. The Defense Logistics Agency owns a significant amount of this feedstock. DLA is looking to execute an SBIR program to attempt to analyze a way forward in supporting the manufacturing of tungsten 3% rhenium wire in the United States. PHASE I: Direct To Phase II must provide a proof of concept. The successful proposal will submit documetation demonstrating the projet proposal is at the (Analytical and Experimental Critical Function and/or Characteristic Proof of Concept level (TRL 3). Develop applicable and feasible process demonstration for the approach described, and demonstrate a degree of commercial viability. PHASE II: Not to exceed a duration of 24 months and cost of $1,800,000. Based on the previously work done by the industry, the research and development goals of PHASE II will demonstrate commercial viability by successfully producing multiple diameters of tungsten 3% rhenium wire. Tasks to be accomplished include process design, development of ingot processing and wire drawing schedules to manage the manufacturing process and meet the wire specifications provided by the VED industrial base. These processes will be used to produce the target wire sizes. Sufficient validation trials will be conducted to support analyses of manufacturing at commercial scale, including cost, cycle time and commercial benefit of the innovation. Remaining technical and manufacturing gaps will be identified. Manufactured wire shall be used for eddy current testing. Innovative processes should be developed with the intent to readily transition to production in support of DoD needs. A partnership with a current or potential DoD supplier, OEM, or other suitable partner is highly desirable. PHASE III DUAL USE APPLICATIONS: At this time, no specific funding is associated with PHASE III. Progress documented from a direct PHASE II should result in a vendor's qualification as an approved source for tungsten 3% rhenium wire manufacturing for civil or commercial applications, enabling participation in future procurements. COMMERCIALIZATION: The vendor will pursue commercialization of the tungsten 3% rhenium wire developed in prior phases, as well as potential commercial sales of any parts or other items. REFERENCES: 1. https://www.dodmantech.com/ 2. 2015 Strategic and Critical Materials Report on Stockpile Requirements 3. National Defense Authorization Act For Fiscal Year 2014 KEYWORDS: tungsten 3% rhenium wire