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MAY 15th, 2024~Advancing Scandium Use in Metal Alloys for U.S. Weapon System Production and Sustainment

OUSD (R&E) CRITICAL TECHNOLOGY AREA(S): Advanced Materials

In the United States mining operations for Sc ore are being planned and developed to feed a domestic supply chain and, recently, new sources of Sc now exist in Canada (an important member country of DoD’s National Technology Industrial Base). There are also established defense industrial base companies and other businesses in both countries that can significantly contribute to development and commercialization of Al-Sc supply chains for both military and commercial applications.

Specific materials, processing and manufacturing areas of interest include:

• Raw material refining
• High purity Sc metals, compounds, and alloys
• Additive manufacturing feedstock
• Additively manufactured DoD systems prototype parts

DESCRIPTION: DLA seeks SBIR project opportunities in new and innovative materials, processing, and manufacturing of Sc compounds, Sc metal, Al-Sc alloy and master alloys, and related areas of additive manufacturing. While Al and Sc are the primary metals of interest for this solicitation, it is anticipated that additional alloying elements may be included to tailor the final alloy properties. Specific areas of interest include:

• Processing mining ores (and/or scrap waste streams) into high purity Sc compounds (ex., Sc-oxide) feedstock for production of pure Sc metal, Al-Sc alloy, master alloys, etc.
• Commercial production of high purity Sc metal (domestic feedstock preferred)
• Commercial production of Al-Sc alloy powder and wire for additive manufacturing
• Demonstrating additively manufactured Al-Sc alloy parts for DoD weapon systems.

Strong industry supply chain collaboration with established materials companies relevant to the above areas of interest in scandium materials and processing, along with involvement from traditional and/or non-traditional DoD weapon systems suppliers, is required, along with strong support from interested DoD weapon system program offices and/or relevant DoD RDT&E organizations.

1. Period of Performance: TBD
2. Budget: $ TBD

1. Delivery of a production level product to J68 ready for integration into the overall DLA Enterprise system.
   
2. Develop a sustainment plan to support the delivered system for the lifetime of the program.
   

1. Mineral Commodity Summaries 2024, U.S. Department of the Interior, U.S. Geological Survey

Jones, R.; Peng, D.; Ang, A.; Aston, R.W.; Schoenborn, N.D.; Phan, N.D. A Comparison of the Damage Tolerance of AA7075-T6, AA2024-T3, and Boeing Space, Intelligence, and Weapons Systems AM-Built LPBF Scalmalloy. Aerospace 2023, 10, 733.

https://doi.org/10.3390/aerospace10080733

1. Conclusions Noting that AA7075-T6 is widely used by both fixed- and rotary-wing military aircraft, as well as in space structures, the initial objective of this study was to directly compare crack growth in identical AA7075-T6 and Scalmalloy specimens tested in the same servohydraulic facility under the same stresses and by the same operators. The experimental data reveal that Boeing Space, Intelligence, and Weapons Systems AM-built Scalmalloy appears to be more damage tolerant than the conventionally built aluminium alloy AA7075-T6. As a result, Boeing Space, Intelligence, and Weapons Systems printed Scalmalloy would appear to be particularly attractive for use on a range of military aircraft, as well as for space applications. It also highlights the potential for Boeing Space, Intelligence, and Weapons Systems Scalmalloy to be used to extend the operational lives of military aircraft through the on-demand printing of limited life Scalmalloy replacement parts. The results of this initial test program have led to the hypothesis that the da/dN versus ∆K curves associated with Scalmalloy and conventionally built AA2024-T3 should be similar. This hypothesis was, subsequently, validated by comparison to AA2024-T3 da/dN versus ∆K curves taken from the Nasgro database. This observation subsequently led to the conjecture that the small crack da/dN versus ∆K curves associated with Scalmalloy and AA2024-T3, which are needed for a durability analysis, should be similar. If this hypothesis can be confirmed, then given that: (i) Scalmalloy has a yield stress significantly greater than that of AA2024-T3; (ii) AA2024-T3 is widely used in both fixed- and rotary-wing aircraft; (iii) MIL-STD-1530D mandates that there must be no yield at 100% DLL and the US Joint Services Structural Guidelines JSSG2006 states that there should be no yield at 115% DLL, the use of Scalmalloy for both fixed- and rotary-wing aircraft, and drones would appear to be very attractive. As such, the next stage in the study will involve the determination of valid upper bound da/dN versus ∆K curves for the growth of short cracks in AA2024-T3.

GIVEN ONCE FINANCED:

ON Sept. 28, 2023~ NioCorp ANNOUNCES Plans to Produce Made-in-USA Scandium Master Alloy to Supply Lightweight Parts to Vehicles

Three-Phase Commercialization Program

1. Pilot scale batch production of 10 kilogram master alloy ingots**. Master alloy produced will be fully analyzed (metals and gases) at independent test facilities. Ingot samples will be available for third-party examination and prospective customer testing / sampling.**
2. Commercial demonstration production of 100 kg ingots**. NioCorp expects to perform this work at a third-party ingot casting facility, which is expected to significantly reduce development timelines and cost as well as leverage existing facility permits and operator experience. The objective of this stage will be to optimize the production process and operating conditions.**
3. Full scale commercial production of master alloy**. Assuming successful results at the pilot scale and commercial demonstration stages, and once project financing is obtained, NioCorp intends to secure an Engineering, Procurement, and Construction contractor to construct, start up, and commission a full-scale production facility with the capacity to consume up to the Elk Creek Project’s projected scandium production of approximately 100 tonnes (Sc metal contained in master alloy) per year. NioCorp intends to co-locate the full-scale production facility with the Elk Creek Project in Nebraska in order to take advantage of the infrastructure (i.e., low-cost power, water, and natural gas) that will be in place for mining operations.**

***SEE RESPONSES FROM NIOCORP/JIM SIMS FROM AUGUST 14, 2023 ~Good morning - Jim!

While waiting for Niocorp’s 2023 F.S. Release… The announcement for Scandium Alloy Production & Scandium alloy funding are most welcome!

Leading me to add to my line of questions regarding Scandium & (Niocorp).

"This funding was placed in the FY24 DoD Appropriations bill at the request of Nebraska Senator Deb Fischer, a member of the Senate Appropriations Committee, for the purpose of helping to fund NioCorp's effort to establish domestic commercial production of AlSc master alloy. There is always a process within the DoD to select appropriate projects with funding provided to it by Congress. In this case, however, the House and Senate Armed Services Committees provided additional guidance to DoD on this topic in their respective National Defense Authorization bills, including prioritizing domestic production of such materials. "

Next Question ~ For context:

"Latent markets for scandium oxide and aluminum-scandium master alloy – both commercial and military -- are quite large, and we are working with a number of potential scandium consumers and related technology companies interested in scandium. We will make announcements in this area as developments require. In general, we don’t comment on detailed commercial business strategies except in the course of necessary announcements and/or public filings. "

"There are multiple such engagements ongoing now for each product in our planned product offering. In general, we don’t comment on commercial business strategies except in the course of necessary announcements and/or public filings. "

"YES!"

FOLLOWING THE TRAIL....

NIOBIUM, TITANIUM, SCANDIUM & RARE EARTH MINERALS: ~H.R. 2670 - NATIONAL DEFENSE AUTHORIZATION ACT FOR FISCAL YEAR 2024~ The urgent need to diversify the United States Defense Industrial base to advance domestic capability, production, modernization, and resilience!

CRPT-118hrpt125.pdf (govinfo.gov)

Page #251~Secure Supply of Niobium Oxide

Page # 232 & 233 ~Extraction and Processing Methods of Rare Earth Elements and Critical Minerals

Page # 223 -224 Aquisition of Titanium

Page # 225-26 ~Aluminum-Scandium Master Alloy Production

AUGUST 9, 2023 ~Nebraska’s U.S. Senator Deb Fischer and Congressman Don Bacon Secure $10 Million in Federal Funding for U.S. Aluminum-Scandium Master Alloy Production~

FORM YOUR OWN OPINIONS & CONCLUSIONS ABOVE:

IMHO- "I think the DoD is still interested! plus...."

All the above BODES WELL FOR NIOCORP & for all the Goodies they will produce -(The Critical Minerals Niobium, Scandium, Titanium, Terbium, Dysprosium, Praseodymium, Neodymium, {lus BYPRODUCTS ~CaCO3, MgCO3 & some IRON STUFF~) should Financing be achieved.... !

FULL STEAM AHEAD NIOCORP! Waiting with many....

Chico