Materials Development for High Performance Solid Rocket Motor Cases

Achieving increase performance with current rocket motor technology (i.e., graphite reinforced epoxy case materials) will rely on reducing the inert mass of the rocket motor case assembly. Higher temperature rocket motor case resins have been identified as a technology that is capable of delivering the improved performance that next generation boosters demand. Optimizing the thermal performance of the case using resins with higher temperature capability than epoxy materials affords the designer the ability to reduce the external and internal insulation mass and volume. The mass saved by the higher operating temperature case will provide increased propellant mass fraction. Additionally, replacing the inert volume with propellant will achieve even higher performance. The objectives of this Phase II SBIR include demonstrating the mass fraction improvement of the rocket motor subsystem using advanced materials, including domestic graphite fibers, higher temperature resins and innovative internal insulation. Performance will be measured with subscale rocket motor case testing through live firings. BENEFIT: A high temperature rocket motor case technology offers the following benefits and capabilities to the Air Force: 1. Increases the mass fraction performance by reducing inert weight of the external and internal insulation 2. Leverages the extensive work in high temperature resin development in the aerospace industry 3. Provides the propulsion contractor a parallel effort for risk mitigation associated with weight budgets 4. Provides the propulsion contractor with a rocket motor case solution at technology readiness level (TRL) 5 by 2012.