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Air Force Research Lab Munitions Directorate (AFRL/RW)
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The Air Force Research Lab Munitions Directorate (AFRL/RW) has developed a Low Alloy High Performance Steel commonly referred to as “USAF-96”. This carbon steel composition does not contain Tungsten (W) or Cobalt (Co) and contains low amounts of Nickel (Ni) and can be manufactured through a variety of standard, commercial production techniques, including air-melt production.
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The Air Force Research Lab Munitions Directorate (AFRL/RW) has developed a Low Alloy High Performance Steel commonly referred to as “USAF-96”. This carbon steel composition does not contain Tungsten (W) or Cobalt (Co) and contains low amounts of Nickel (Ni) and can be manufactured through a variety of standard, commercial production techniques, including air-melt production. |
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High strength, high impact toughness steels are required in large quantities for many Air Force (AF) applications. Often crucial material properties include initial impact/shock-up survival, resistance to bending, and abrasive material losses. Many high strength alloys suffer from low toughness – particularly low temperature toughness, which leads to a reduction of initial shock/early impact survivability. Alloys containing relatively high amounts of nickel and cobalt are traditionally used in these applications as they provide an ideal balance of strength and toughness. However, these alloys are very expensive, and cost-prohibitive to make in large quantities. As an example, Eglin steel (ES-1) was developed by industry paired with the US Air Force to provide a low cost replacement for more expensive HP9-4-20, Aermet(TM), and AF-1410 alloys. USAF-96 steel development was carried out to find a lower cost alternative to ES-1 that would exhibit the same superior properties in high strength and high impact toughness even with sections up to 4” in thickness; the upper limit has not been to date. USAF-96 steel contains little in the way of expensive alloy content, and relies on special processing techniques/mechanisms to develop a high strength / toughness level even at low temperatures/conditions (-40F/-65F). USAF-96 steel is amenable to both sand/investment casting and forging processes, increasing production capability and lowering cost to the AF.
Technical specifications of USAF96, as demonstrated through laboratory testing, are as follows:
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Military Applications USAF96 was initially developed by the Air Force Research Lab for “bunker-busting” bomb applications which require a metal that is very high-strength and high-hardness but is also economical to produce. Since then, Army researchers have successfully adapted the metal to powder form and are using it in additive manufacturing to create steel components. In its powder form, USAF96 retains its toughness but is able to produce parts with a much higher dimensional accuracy than those afforded by other steel compositions. The Army has successfully printed and employed impeller fans for the M1 Abrams turbine engine. Additional military applications include projectiles, armored materials and ground engagement tools. Commercial Applications
Note: Samples of USAF96 are available to potential licensees through a Material Transfer Agreement (MTA). |
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