N102-164 TITLE: Large-Area, Monolithic Reconnaissance Window

TECHNOLOGY AREAS: Air Platform, Materials/Processes, Sensors

ACQUISITION PROGRAM: Naval Unmanned Combat Air System (NUCAS) PMA-268

RESTRICTION ON PERFORMANCE BY FOREIGN CITIZENS (i.e., those holding non-U.S. Passports): This topic is "ITAR Restricted." The information and materials provided pursuant to or resulting from this topic are restricted under the International Traffic in Arms Regulations (ITAR), 22 CFR Parts 120 - 130, which control the export of defense-related material and services, including the export of sensitive technical data. Foreign Citizens may perform work under an award resulting from this topic only if they hold the "Permanent Resident Card", or are designated as "Protected Individuals" as defined by 8 U.S.C. 1324b(a)(3). If a proposal for this topic contains participation by a foreign citizen who is not in one of the above two categories, the proposal will be rejected.

OBJECTIVE: Scale up window technology to make large, strong, monolithic windows from sapphire, spinel, or aluminum oxynitride (ALON).

DESCRIPTION: There is a continuing need for durable, infrared-transmitting sensor windows with areas up to 0.8 x 0.8 meter for reconnaissance purposes. The size of monolithic windows is presently limited by crystal growing equipment used to make sapphire, and by the availability of hot pressing and hot isostatic pressing equipment for spinel and ALON. One approach to make large windows is by edge-bonding of small windows. The mechanical strength of the bond and the ability to image through the bond are potential limitations of this approach. An alternative approach is to scale up processes to make large, strong, monolithic windows. Excellent optical and mechanical properties of small windows must be preserved in the large windows.

PHASE I: Identify and demonstrate key steps of a scaleable method to make optical quality, mechanically strong, monolithic sapphire, spinel, or ALON blank plates. The method must have clear potential to be scaled up to at least 0.40 x 0.80 x 0.013 m and, preferably, 0.80 x 0.80 x 0.013 m panels. Identify the major cost drivers for scaleup. Devise a Phase II plan to make the maximum area window consistent with a Phase II budget.

PHASE II: Produce the maximum area window consistent with a Phase II budget. Apply an "inspection polish" to the faces to demonstrate the absence of voids, bubbles, or inclusions and to demonstrate refractive index homogeneity and the absence of stress birefringence. Use coupons cut from a large blank to measure transmittance and optical scatter and mechanical strength in biaxial flexure. Identify a path to scale up to 0.80 x 0.80 x 0.013 m blanks.

PHASE III: Scale up for commercial production of 0.8 x 0.8 m finished windows.

PRIVATE SECTOR COMMERCIAL POTENTIAL/DUAL-USE APPLICATIONS: There is a large market for bulletproof windows for armored vehicles if cost per unit area can be decreased.

REFERENCES:
1. J. Locher, C. Jones, H. Bates, and J. Rioux, "Characteristics of Thick (>12 mm) Class 225 EFG Sapphire Sheet for IR Window Applications," Proc. SPIE 2009, 7302, 730202.

2. L. M. Goldman, R. Twedt, R. Forti, M. Smith, and S. A. Sastri, "Large-Area ALON Windows for Reconnaissance and Armor Applications," Proc. SPIE 2009, 7302, 730205.

3. J. Sepulveda, R. O. Loutfy, S. Chang, and S. Ibrahim, "Advances in Spinel Ceramic Technology for large Windows and Domes," Proc. SPIE 2009, 7302, 73020E.

KEYWORDS: Sapphire; Spinel; Aluminum Oxynitride (ALON); Reconnaissance window; Infrared Window; Transparent Ceramic

** TOPIC AUTHOR (TPOC) **

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