Toronto-based Integran Technologies Inc. (Integran) today announced that it has received the 2013 SERDP (Strategic Environmental Research and Defense Program) Project-of-the-Year Award for Weapons Systems and Platforms for the development of a nanostructured alloy for copper-beryllium replacement.
For decades, essential parts in fixed and rotary wing military platforms have been made with copper-beryllium alloys. Beryllium is particularly useful for this purpose because it is both lightweight and strong, a rare combination not found in most other metals. The problem is beryllium is a toxic material that can be harmful to workers who handle it during assembly and repair. Working with beryllium, which requires donning protective gear and taking extensive precautions, is costly and time-consuming.
With support from US DoD's SERDP program and Industry Canada's Strategic Aerospace and Defense Initiative (SADI) program, Integran developed and validated an electroforming process that produces a nanostructured alloy that matches the desirable properties of copper-beryllium, particularly for use as high load bushings. This pulsed electroplating process goes beyond merely coating a metal object. Rather, near-net-shape components are created that require little to no machining to achieve final dimensions, resulting in very little material waste. The work also showed this innovative process can be used successfully for large metal sheets and high conductivity wires, both of which are used in multiple military applications.
Integran's Aerospace and Defense R&D Unit Manager Brandon Bouwhuis states, "The validation testing performed in this project demonstrates that these nanostructured alloys can meet or exceed the performance of copper beryllium in many applications, and could result in substantial cost savings for the US DoD and Canadian Military through the decreased use of toxic substances."