If you have suddenly got a work outside US, you need to get passport as soon as possible, so at that hurry moment you cannot go for normal apply of the passport, so look for the hurry options in the passport companies

If you are in a condition to get passport very soon, you can apply for the passports, but the cost increases than the normal application, check the following link to view the complete details:

http://travel.state.gov/passport/get/first/first_831.html

If you are applying through private agencies, but the cost is much higher than the government office, take a look on the costs of the various processing times offered by a private passport agency:

http://www.passportvisasexpress.com/passports/first-time-passport.xml

No matter which Airlines you choose to travel from Australia to Chicago but dealing with airports can be ordeal.

You cannot afford to go to Airport without alternate plan to reach Chicago in case of flight delay or cancellations.In case, your aircraft gets cancelled due to technical snag.

You should always plan for a substitute arrangement which can be a sea route, land route or a charter flight.

If struck due to some unknown reasons you have to sleep, eat and devote your entire time on the same airport.

http://www.smartraveller.gov.au