Utilizing Oxide Dispersion Strengthening (ODS) to Elevate Mechanical Properties of Current and Next Gen Metallic Alloys

OUSD (R&E) CRITICAL TECHNOLOGY AREA(S): Hypersonics; Space Technology 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: Rapid development of material and process options for high temperature applications via early rigorous screening testing in relevant environments. DESCRIPTION: The Department of the Air Force (DAF) is interested in developing low-cost materials that have high strength at elevated temperatures, excellent oxidation resistance, good ductility, fabricability, and creep resistance. Lower density materials are desired for DAF applications due to weight savings. DAF is primarily interested in oxide dispersion strengthened refractory alloys. Nickel superalloys may be considered if they advance the state of the art relative to NASA's GRX-810 alloy. GRX-810 is a new commercial nickel superalloy coupled with dispersed nanoscale yttria. It has shown success in cost effectively elevating high temperature mechanical performance compared to conventional nickel superalloys. DAF is interested in utilizing cost effective oxide nanoparticles that offer similar performance as yttria. Regardless of the processing route chosen (e.g., additive manufacturing, powder metallurgy, or conventional manufacturing), steps will be taken under this effort to begin to qualify the new material. If the candidate material performs well at the coupon scale, there is DAF interest to scale up and fabricate components such as uncooled or fuel-cooled axisymmetric engine ducts to evaluate material performance in a relevant environment. Components must be designed, fabricated, and integrated into a test facility. Components should be designed to be "plug and play" within a scheduled test or test facility. The company is responsible for supplying subcomponents, subsystems, and instrumentation required for testing. Prior to testing, thermal-structural analysis with material properties would have to be carried out and reviewed via a DAF led preliminary and critical design review process. DAF or external test facilities may be considered for testing in a relevant environment. DAF suggests incorporating cost for testing into the proposal in case an external test facility is utilized. This effort will have ITAR and CUI restrictions. The company must provide a signed DD 2345 Form to TPOCs before critical technical information is shared. Individuals working on the project must be U.S citizens and must not have citizenship with foreign adversaries. PHASE I: This topic is intended for technology proven ready to move directly into Phase II. Therefore, a Phase I is not required. The applicant is required to provide detail and documentation in the Direct to Phase II proposal which demonstrates accomplishment of a Phase-I-like' effort, including a feasibility study and basic research to demonstrate higher TRL research. The applicant should have defined a clear, immediately actionable plan with the proposed solution and the AF customer. Phase I type efforts include having demonstrated feasibility via developed material compositions of interest and basic mechanical properties. Some simple models to simulate microstructure and mechanical properties of these compositions may also be investigated. PHASE II: Eligibility for D2P2 is predicated on the offeror having performed a Phase I-like effort predominantly separate from the SBIR Programs. Under the phase II effort, the offeror shall sufficiently develop the technical approach, product, or process in order to conduct a small number of advanced manufacturing and/or sustainment relevant demonstrations. Identification of manufacturing/production issues and or business model modifications required to further improve product or process, availability, or safety, should be documented. Air Force stakeholder engagement is paramount to successful validation of the technical approach. These Phase II awards are intended to provide a path to commercialization, not the final step for the proposed solution. PHASE III DUAL USE APPLICATIONS: Phase III or Phase II enhancement proposals shall include collaborative efforts with the customers to validate and support the verified workflows. Phase III shall provide businesses workflows that have been verified and validated to an acceptable degree, as deemed by the customer. Expected Manufacturing Readiness Level (MRL): 4; Expected Technology Readiness Level (TRL): 7 REFERENCES: 1. Miller, M. K., et al. "Stability of ferritic MA/ODS alloys at high temperatures." Intermetallics 13.3-4 (2005): 387-392. 2. Smith, Timothy M., et al. "A 3D printable alloy designed for extreme environments." Nature 617.7961 (2023): 513-518. 3. Liao, Tao, et al. "Multiscale oxide dispersion strengthened refractory high entropy alloys with superior mechanical properties." International Journal of Refractory Metals and Hard Materials 123 (2024): 106796. KEYWORDS: Next Generation Material, Refractory Alloy, Nickel-Base Superalloy, Oxide Dispersion Strenghtening (ODS), Additive Manufacturing, Elevated Temperature Performance, Manufacturing