Low-Cost Refractory Metal-Lined Graphite Components for Advanced SDACS

Rhenium hot gas path components are used extensively in the solid divert and attitude control system (SDACS) of the MDA/Navy Standard Missile-3 Aegis LEAP Interceptor missile defense program, on which Ultramet is a key subcontractor. The mechanical, thermal, and chemical performance of rhenium is unmatched. However, a need clearly exists to reduce the cost and weight of rhenium-based structures for advanced SDACS such as that being developed for MDA by Valley Tech Systems. In previous and current work, Ultramet has demonstrated the potential for fabrication of refractory metal-lined low-density graphite components, sometimes in combination with a carbon diffusion barrier interlayer. The potential exists to apply this same technology for the fabrication of hot gas valve and thruster components for use in advanced SDACS systems. The combination of materials will potentially allow the benefits of flight-qualified rhenium to be retained while offering substantially reduced weight and cost. In this project, Ultramet will team with Valley Tech Systems to demonstrate the feasibility of rhenium-lined graphite as an alternative to monolithic rhenium structures for SDACS. Ultramet’s current manufacturing contract for SM-3 components, as well as flight-qualified thrust chambers used in commercial satellite propulsion systems, makes it well-suited for the proposed development and demonstration of lower cost and lighter weight rhenium-based components.