Advanced Rail Materials for Electromagnetic Launchers Navy SBIR FY2010.1 Sol No.: Navy SBIR FY2010.1 Topic No.: N101-086 Topic Title: Advanced Rail Materials for Electromagnetic Launchers Proposal No.: N101-086-0357 Firm: Schultz-Creehan, LLC 2200 Kraft Drive Suite 1475 Blacksburg, Virginia 24060-6704 Contact: Jeff Schultz Phone: (540) 443-9215 Web Site: www.schultz-creehan.com Abstract: Improving the useful rail life is major technical barrier to developing a fleet-deployable electromagnetic (EM) launcher. Current copper alloy rails, while having excellent electrical conductivity, are highly susceptible to hypervelocity gouging, galling, and attack by liquid aluminum transferred from the armature. Without a solution for these rail wear problems, the utility of EM launchers may be greatly limited due to high costs (resulting from a limited number of firings between scheduled rail replacements). Metal matrix composite coatings with refractory metal reinforcement, such as tungsten, molybdenum or tantalum, have been identified by NSWCDD as candidate coating materials for improving rail life. A revolutionary wrought metal deposition method, based on friction stir technology, is being developed through ONR funding by Schultz-Creehan to deposit coatings, including MMC coatings, that are metallurgically bonded with the substrate. This wrought metal deposition technology is referred to as friction stir fabrication (FSF). The application of this technology to the EM rail problem would be a straightforward extrapolation of current research and development efforts. As such, herein, Schultz-Creehan presents a novel but realistic approach to improve EM rail life through the application of MMC coatings using FSF. Benefits: The friction stir fabrication technology is currently being developed to meet future naval needs for welding, coating, and repair of aluminum vessels. Extrapolating this technology to copper-based materials will enable extend the operable life of the EM rails between replacement or refurbishment. The process could then be applied to any electro-mechanical application under conditions of high heat, stress, and/or current, requiring both the beneficial thermal and high current aspects of conducting metals combined with the need for higher toughness and hardness with traceability to relatively long sections. Example applications could be high-speed mag-lev contacts, electrical generation facilities, high current switches and sections for re-entry protection of space-craft. Return