Embedded Chemical Sensor for Health Monitoring of Double-Base Propellants

Currently, the Military lacks the capability to monitor solid rocket motors for potentially lethal aging or handling-induced defects. The proposed research will provide the Military with embeddable chemical sensor arrays to identify defects occurring after manufacturing of the motors. Conventional high-sensitivity instruments are too heavy, costly and cumbersome to be dedicated to monitoring an individual motor used in the field. Motors must be transported to a depot to evaluate the potential for age-induce flaws in the liners, casings or propellants. We propose to develop sensitive, low-power sensors that can be embedded into the motor and can transmit electronic signals through to a conductive flex circuit to alert personnel to defective rocket motors. Seacoast manufactures chemicapacitors and chemiresistors as light-weight chemical sensors. It is envisioned that a number of chemical sensors would be embedded between the insulation and the motor casing. Electronics printed on flexible substrate would connect the sensor arrays to external displays, allowing assessment of the health of a rocket motor over its entire lifetime. The sensor arrays and support electronics would become an integral part of the motor and result in substantial reductions in cost to assess readiness of the motor.