Development of a High Strength Low Thermal Diffusivity Insulator Material

C9 propses to develop a high strength, low thermal conductivity insulator material for use in Divert and Attitude Control Systems. The goal is to develop a 15ksi tensile strength material with thermal conductivity of 1 Watt/Meter-oK. Probable success is based on the starting material using a low cost, net shape, chopped fiber reinforced ceramic matrix composite material that has an amorphous matrix even after firing to 1100oC and already has 3W/MK thermal conductivity and 8-12ksi tensile strength. The work will proceed by substituting hollow and low thermal conductivity fillers into the composite, use a modified ceramic matrix forming polymer that is even more likely to remain less crystalline, reduce the fiber thermal conductivity and further improvements in strength by better molding and densification. Thermal Mechanical Testing will include outside test labs. The initial target application is a pintle guide for a DACS propellent control valve. We are supported in this application by Aerojet General Corporation that is currently using either Noveltex reinforced C/Sic that has too high thermal conductivity at 15-20W/MK and is very expensive, ablative phenolic that is not shape stable, or Sodium-Phosphor-Zirconate(NPZ) that is low strength , brittle and subject to thermal shock. Although the target application is the pintle guide this material is applicable to the pintle, and other DACS and rocket motor applications such as valve blocks, nozzle flange insulator rings, thrust chamber internals, and wherever ablative phenolic, NPZ and noveltex reinforced C/SiC is currently used.