High Temperature Composite Rocket Motor Cases for Missile Defense

Next generation missile defense interceptors will achieve hypersonic velocities during flight to provide the capability of reaching offensive missile targets sufficiently early to minimize threat capability. Achieving the peak velocity with current rocket motor technology (i.e., graphite reinforced epoxy case materials) is proving a challenge for the system level contractors. Meeting the booster performance goals with innovative materials technologies is a much lower system level cost approach than by increasing the booster diameter or length. In Phase I, higher temperature rocket motor cases resins were shown to be a technology that is capable of delivering the improved burn out velocity by reducing the propulsion inert weight of the thermal protection system. The volume and mass saved by the higher operating temperature case can be filled with propellant to achieve increased burn-out velocities or quicker time to target. In the Phase II program, the manufacturing of a rocket motor case using a wet wind system will be demonstrated. Validation of the reproducibility of the resin system will be shown through coupon level and bottle burst testing. The objective of the Phase II program is to take the resin to TRL 5 to facilitate technology insertion to the prime contractor.