Applied Research in Advanced Thermal Spray and HEA Systems
Six government-funded research programs spanning DOE, MDA, and USAF have built a systematic body of knowledge in RHEA alloy design, thermal spray process science, and application-specific coating development.
Four Research Programs
HEA Phase Prediction
CALPHAD-based and machine-learning-assisted prediction of phase stability in multi-principal-element refractory alloy systems. Focus on BCC/HCP phase boundaries and high-temperature phase retention.
Advanced Thermal Spray Process Science
Fundamental investigation of in-flight particle dynamics, splat formation, and residual stress development in HVOF and plasma spray of refractory alloy powders. Correlating spray parameters to microstructural outcomes.
Multilayer Dielectric Systems
Development of thermally sprayed multilayer capacitor structures for high-temperature power electronics. Targeting stable dielectric constant (±5% ΔC/C) from -55°C to +350°C with breakdown strength >10 MV/m.
Thick Bimetallic Coatings
Engineering thick (>5mm) graded bimetallic coating architectures for nuclear structural components. Addressing residual stress management,porosity control, and adhesion across dissimilar material interfaces.
Three Collaboration Models
Sponsored Research
Industry-sponsored programs where DRS leads technical development with full data rights transferred to the sponsor. Suitable for proprietary application development where the customer owns the resulting IP.
- Full IP transfer to sponsor
- Milestone-based deliverables
- Joint publication rights negotiable
- NDA-protected throughout
Government & Defense Programs
SBIR and STTR programs where DRS serves as the small business prime or subcontractor. Active relationships with DOE, MDA, and USAF program offices across TRL 3–7 development stages.
- SBIR Phase I/II experience
- STTR university partnerships
- DOE / MDA / USAF agencies
- TRL 3–7 development
Academic Partnerships
Collaborative research with university materials science and mechanical engineering departments. DRS provides industrial application context and process expertise; academic partners provide characterization capabilities and graduate student effort.
- Joint publication authorship
- Graduate student projects
- Shared characterization access
- Co-PI arrangements
Six Grant Awards
Interested in a research collaboration?
We welcome discussions with program managers, principal investigators, and industry partners on new research directions.