Gelcasting ceramic defense parts

The goal of this work was to demonstrate an ability to gelcast and fire a particular defense-related part to net shape and to hold the required tolerances on size and shape with minimal or no post firing machining. The precision required represents a huge increase in the precision currently achievable by standard ceramic processing. The project has produced very promising results. While we did not achieve the degree of precision in as-fired parts that we had targeted ({+-}0.025%), we did improve our ability to hold tolerances to the {+-}0.25 level from our initial level of {+-}2.5 % on parts that were 5 to 10 inches in diameter. The progress to date makes us believe that the ultimate goal is achievable. We have demonstrated that gelcasting can be a viable precision forming technique for large articles. We are currently working with our industrial partner on a Statement of Work for a follow on project. This will be either a CRADA or a WFO project. The anticipated funding level is one person year in 1997 with funds coming from the industrial partner. Assuming reasonable progress is made in 1997, additional projects of similar size are expected in 1998 and out years funded either by the industrial partner or by DOD