DARPA: SBIR Opportunity: Additive Manufacturing of Rhenium for Propulsion Applications

Category	Opportunity
DoD Communities of Interest	Materials and Manufacturing Processes
Subject	SBIR Opportunity: Additive Manufacturing of Rhenium for Propulsion Applications
Due Date	29 June 2021
Government Organization	Defense Advanced Research Projects Agency (DARPA)
Description The Defense Advanced Research Projects Agency (DARPA) Small Business Programs Office (SBPO) is issuing an SBIR/STTR Opportunity (SBO) inviting submissions of innovative research concepts in the technical domain(s) of Materials/Processes. In particular, DARPA is interested in understanding the feasibility of Additive Manufacturing of Rhenium for Propulsion Applications. This SBO will open for proposals on May 27, 2021, and close at 12:00 p.m. ET on June 29, 2021. Which program will fund this topic? SBIR What type of proposals will be accepted? Direct to Phase II (DP2) Only Technology Area(s): Materials/Processes DARPA Program: Glide Breaker I. INTRODUCTION The Defense Advanced Research Projects Agency (DARPA) Small Business Programs Office (SBPO) is issuing an SBIR/STTR Opportunity (SBO) inviting submissions of innovative research concepts in the technical domain(s) of Materials/Processes. In particular, DARPA is interested in understanding the feasibility of Additive Manufacturing of Rhenium for Propulsion Applications. This SBO is issued under the Broad Agency Announcement (BAA) for SBIR/STTR, HR001121S0007. All proposals in response to the technical area(s) described herein will be submitted in accordance with the instructions provided under HR001121S0007, found here: https://beta.sam.gov/opp/d0cde4fb668d40b1982da8296d5349c0/view. II. TOPIC OVERVIEW a. Objective Develop and demonstrate the capability to additively manufacture (AM) rhenium (Re) components via powder-based methods such as selective laser sintering (SLS), selective laser melting (SLM), or powder directed energy deposition (DED) for use in applications requiring high thermal and pressure endurance. b. Description Refractory metals are a class of materials offering high melting points, wear resistance, and superior strengths, particularly at elevated temperatures. These characteristics make them suitable for numerous extreme environments, including furnaces, nuclear reactors, and propulsion systems. Manufacturing methods for refractories have largely been limited to powder metallurgy, chemical vapor deposition, electrolysis, and plasma spray methods. Progress in AM of tungsten (W), niobium (Nb), molybdenum (Mo), and their related alloys have enabled disruptive advancements in the manufacturing of complex high-temperature capable components. Pursuits to AM alternative refractory and platinum group metals have largely been hindered due to unfavorable cost and availability of appropriate feedstocks combined with relatively low demand signals. Recent advanced propulsion system trade studies have identified performance and mass benefits for novel Re component designs. However, the desired architectures cannot readily be manufactured via traditional methods. The objective of this SBIR topic is to explore AM of Re structures using powder-based methods. Key challenges include addressing viable and sustainable production of Re powder feedstock production, AM processing optimization, processing-microstructure property relationships, and fabrication of scaled components with complex geometries and high dimensional accuracy. c. Phase I This SBO is accepting Direct to Phase II proposals ONLY. Proposers must demonstrate that the following has been achieved outside of the SBIR program: · Qualified supply chain or demonstrated ability to produce AM-appropriate refractory powder feedstock with path to yield viable Re powder feedstock. · AM build volume of at least 8cm x 8cm x 8cm. · Capability to AM non-axisymmetric refractory metal (>3000℃ melt temperature) components with internal lattice structures. · Experience in AM refractory metal post-build stress relief and densification processes. · Experience in refractory metal machining, particularly with Re.
Website	https://beta.sam.gov/opp/c4fe883c5879436bad1a2096c1a10209/view