DON26BZ04-NV067 TITLE: High Precision Specialized Waveguides for Extreme Temperatures

OUSW (R&E) CRITICAL TECHNOLOGY AREA(S): Scaled Hypersonics (SHY)

COMPONENT TECHNOLOGY PRIORITY AREA(S): Advanced Materials;Hypersonics;Sustainment

PROJECTED CMMC LEVEL REQUIREMENT: Level 2 (Self)

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: Provide specialized waveguides capable of high temperature, high power, low loss, robust, and agile transmission of radio frequency (RF) signals within a hypersonic vehicle.

DESCRIPTION: The use of RF cables has difficulty meeting environmental conditions while maintaining signal integrity and power requirements. Hypersonic surface temperatures can exceed over 1,000-degree C. Waveguides provide high power transmission and might be easier to manage under extreme hypersonic conditions.

The Navy seeks RF transmission that focuses on high frequency, is consistent performance across a vast range of extreme thermal temperatures, and provides long durations of high thermal loads. The ability to produce complex and unique shapes while maintaining signal performance is required. The development of these waveguides should address extreme hypersonic conditions. The RF frequencies are across a large spectrum for different antennas/capabilities, but waveguides become too large at lower frequencies. To be successful, the waveguides should target frequency bands of X, Ku, K, and Ka. Any dielectric medium may be used within the waveguide. A successful dielectric material would have a permittivity near that of a vacuum, such as air, to ensure low-loss transmission, specifically at extreme temperatures.

Work produced in Phase II may become classified. Note: The prospective contractor(s) must be U.S. owned and operated with no foreign influence as defined by 32 U.S.C. § 2004.20 et seq., National Industrial Security Program Executive Agent and Operating Manual, unless acceptable mitigating procedures can and have been implemented and approved by the Defense Counterintelligence and Security Agency (DCSA) formerly Defense Security Service (DSS). The selected contractor must be able to acquire and maintain at least a secret-level facility and Personnel Security Clearances. This will allow contractor personnel to perform on advanced phases of this project as set forth by DCSA and SSP in order to gain access to classified information pertaining to the national defense of the United States and its allies; this will be an inherent requirement. The selected company will be required to safeguard classified material during the advanced phases of this contract IAW the National Industrial Security Program Operating Manual (NISPOM), which can be found at Title 32, Part 2004.20 of the Code of Federal Regulations.

PHASE I: Provide feasibility of producing X through Ka band waveguides out of a material robust enough to withstand the extreme environmental conditions of a hypersonic vehicle. During this stage of the development, a prototype of any band is desired to demonstrate operation, but not required to transition to Phase II. Tolerances, bends, and refined connections/adapters will be implemented in the Phase II. Describe how this manufacturing capability can make custom waveguides that will meet all hypersonic conditions. Define the limitations, improvements over other materials, improvements over other manufacturing methods, and description on high volume production (including any limitations or areas of future investment opportunities).

The Phase I Option, if exercised, will include the initial design specifications and capabilities description to build a prototype solution in Phase II.

PHASE II: Develop a custom part that meets extreme environmental condition tests that must assess the transmission of X, Ku, K, or Ka band RF signals. Do extensive machining and testing to provide tolerances, bending limits, and custom connections/adapters concepts that could be adopted and implemented quickly. (Note: The design may be an iterative process to improve performance of the waveguide and to specific requirements.) Demonstrate the prototype’s ability to meet the requirements presented at the beginning of Phase II.

It is probable that the work under this effort will be classified under Phase II (see Description for details).

PHASE III DUAL USE APPLICATIONS: Support the Government in transitioning the technology for Government use. The transitioned product is expected to support current and future hypersonic and space systems, as well as a wide range of other air, land, and sea-based systems.

REFERENCES:

1. Ponchak, G. E.; Jordan, J. L. and Scardelletti, M. C. "High Temperature Characteristics of Coplanar Waveguide on R-Plane Sapphire and Alumina." IEEE Transactions on Advanced Packaging, vol. 32, no. 1, pp. 146-151, Feb. 2009. doi: 10.1109/TADVP.2008.2009123 https://ieeexplore.ieee.org/document/4785306
2. Shen, J. et al. "Rapid prototyping of low loss 3D printed waveguides for millimeter-wave applications." 2017 IEEE MTT-S International Microwave Symposium (IMS), Honololu, HI, USA, 2017, pp. 41-44. doi: 10.1109/MWSYM.2017.8058593 https://ieeexplore.ieee.org/abstract/document/8058593
3. National Industrial Security Program Executive Agent and Operating Manual (NISP), 32 U.S.C. § 2004.20 et seq. (1993). https://www.ecfr.gov/current/title-32/subtitle-B/chapter-XX/part-2004

KEYWORDS: waveguides; advance manufacturing; RF transmission; high power; extreme temperatures; hypersonics; RF cables; ceramics; metals; conductors; advanced materials; ruggedized; specialized; custom; radio frequencies; additive manufacturing

TPOC: SSP SBIR POC
ssp.sbir@ssp.navy.mil