Non-Eroding Hot Gas Components for Strategic Propulsion Systems Produced by Reduced Cost, Rapid Manufacturing Techniques

Innovative solutions are sought to reduce cost and lead-time of hot gas valve components located in the post boost control system (PBCS) of the U.S. Navys Trident II D-5 Fleet Ballistic Missile. Current PBCS components are based on Nb, Ta10W and TZM, with protective coatings. Although structurally sufficient and compatible with the oxidizing propellant, disadvantages include density, cost and lead-time. A concept promising to reduce weight, cost and lead-time is comprised of a carbon-based core and thin (i.e. <0.075) protective coating. Plasma Processes has successfully demonstrated a variety of components (e.g. nozzle liners, pintles, valves and jet vanes) based on this concept in aluminized and non aluminized hot fire tests. During the Phase I investigation, the team of Plasma Processes, MR&D and ATK will build on past experience to identify economical and robust solutions for PBCS hot gas valve components. Thermal-structural analyses will be employed to model architectures that maintain performance, while minimizing cost and weight. Non-eroding materials (e.g. metals, borides, carbides, nitrides) will focus on those that are compatible with PBCSs oxidative propellant. High strength graphite, C/C, and CMCs will be evaluated for structural support. Promising concepts will be fabricated and tested.