Amaero has been awarded a A$6.5 million contract by the United States Department of War (DoW) to develop alternative refractory alloy powders, supporting manufacturing capabilities for advanced aerospace and defence applications while aiming to reduce costs and reliance on foreign sources of critical raw materials.
According to Amaero, the 13-month contract will run through to August 2027 and includes monthly progress payments tied to project milestones.
In a news release, the company said it expects around 40 per cent of the contract revenue to be recognised during the third and fourth quarters of calendar year 2026, with a further 50 per cent expected in the first and second quarters of 2027.
Amaero said the program is intended to develop alternative high-temperature refractory alloys that can serve as substitutes for Niobium C103, a material widely used in rocket nozzles, thrusters and hypersonic components because of its high strength-to-weight ratio, ductility and ability to operate at temperatures above 2,000°C.
The company noted that while C103 has been used in aerospace systems since the Apollo lunar missions, its wider adoption has been challenged by rising and volatile costs, particularly due to significant increases in the price of hafnium, one of its key constituent materials.
Under the program, Amaero said it will work with the DoW, US national laboratories, defence and space contractors, and suppliers to identify two alternative refractory alloys for further development. The company will produce spherical alloy powders using its gas atomisation technology, manufacture test parts through its PMHIP process, and collaborate with strategic suppliers to 3D print and evaluate the new materials.
Amaero said the project further strengthens its capabilities in atomising refractory alloy powders for thermal protection and propulsion applications in hypersonic and space systems, adding that the gas atomisation technology used during the development phase is already established and scalable for commercial production.
Amaero Chairman and Chief Executive Officer Hank J. Holland said the company had worked closely with the US government and the DoW over the past two years to address supply chain challenges.
“In response to the DoW’s supply chain challenge, Amaero commissioned the only EIGA Premium in the U.S., the most advanced gas atomization technology for refractory alloy powders,” Holland said.
“As high-temperature refractory alloy powders are essential to thermal protection systems and propulsion systems in hypersonic and space platforms, it’s essential that we develop the next generation refractory alloy powders.”
He said the contract would enable the company to identify the most promising alternative refractory alloys and generate the testing data required to support future adoption.
“We appreciate being selected as a trusted and strategic partner with unique technical and production capabilities and we look forward to collaborating with DoW to advance the next generation refractory alloy powders,” Holland said.
The content of this article is based on information supplied by Amaero Ltd. For more information, please refer to the official company announcement and communications from Amaero. Please consult a licensed and/or registered professional in this area before making any decisions based on the content of this article.
