Metallized Ceramic-Based Structural Insulators

This proposal will specifically seek to demonstrate metallized ceramic-based structural insulators for solid rocket motor applications.Metallized ceramic-based structural insulators, fabricated by the Vacuum Plasma Spray (VPS) process, are anticipated to offer improved performance compared to rayon-based fiber Carbon Cloth Phenolic (CCP) composites and many other fiber composite materials.Ceramic materials, such as Yttria-stabilized zirconia (YSZ) and zirconium carbide (ZrC), will theoretically perform better compared to many fiber composite materials based on comparative performance related to outgassing, insulating, charring, shape stability, stiffness, elevated temperature performance, and domestic availability.Furthermore, metallized ceramic-based structural insulators can be made non-permeable, making the technology applicable to other applications such as high temperature valves whereas most fiber composite materials, including ceramic matrix composites (CMCs), are permeable.The performance enhancements will allow for higher maximum temperature use, improved insulating capabilities, enhancements for dual-pulse motor applications, and significant cost savings by avoiding the long and costly processing/machining times for many fiber composite materials.The Phase I work plan includes: nozzle component selection and identification of associated details; candidate metallized ceramic-based structural insulator materials selection; preliminary design and analysis trade studies; simple component and test specimen fabrication, optimization design and analysis trade studies; and advanced component fabrication.Approved for Public Release | 17-MDA-9219 (31 May 17)