R2R Fabrication of Millimeter Wave Dipole Chaff with High Radar Cross Section

Physical Sciences, Inc. (PSI) has developed a continuous process to manufacture RF chaff by copper coating commercial carbon fiber during a recently completed Phase I program. The continuous copper coated carbon fiber (Cu/CF) can then be cut to a resonant length, correlating to high RCS from 2 to 90 GHz. We were able to cut and pack these chaff fibers into RR-129 cartridges for test firing at Esterline Defense Technologies. Simulations and single fiber lab measurements indicate that these Cu/CF provide an order of magnitude increase in extinction at 35 GHz compared to the current aluminum on glass (Al/SiO2) chaff. During the Phase II base program several kilograms of Cu/CF will be produced, the tows will be cut, treated with a dissemination aid and packaged into RR129 and M-1 cartridges. We will deliver chaff cartridges to our partners, Esterline and Capco, Inc., for dissemination testing. Prof. Charles Bruce at NMSU will provide RF chaff fiber and cloud characterization during the development effort.During the proposed Phase II Option program, PSI will continue scale-up this roll to roll (R2R) process. We will continue to optimize the cutting, treatment, packaging, dissemination and characterization of the Cu/CF chaff.