Enhanced Strength, Lightweight, High Temperature Insulating Structures

In previous work, Ultramet demonstrated the feasibility of applying extremely low-density and thermally insulating carbon aerogel-filled open-cell carbon foam insulators for interceptor components. Those insulators had lower strength than is desired for selected applications and required impermeable structural liners or jackets, which increased component weight and volume. In this project, Ultramet will build on the prior work and investigate new, innovative, higher-strength aerogel-filled foams as insulating structures for interceptor upper stage rocket motor and homing and control propulsion applications. Intrinsically lower density and lower thermal conductivity structural foam materials will be investigated. Structures combining enhanced-strength foams, impermeable surface closeouts, and necessary ancillary materials will be designed, fabricated, and tested under representative conditions to assess and demonstrate the feasibility of this innovative new concept. Approved for Public Release 14-MDA-8047 (14 Nov 14)