High Strength, High Modulus Nano-Composite Missile Structures (MSC P8024)

The use of lightweight, high strength carbon fiber reinforced composites in rocket motor cases has provided the ability to increase the propellant mass fraction, extend range and/or increase velocity for advanced tactical missile systems. While continuous fiber reinforced composites are being used for the motor case, relatively heavy metallic components are still employed for the case end closures and pole piece, for example. The objective of the Phase II SBIR program is to design and fabricate a prototype compression molded composite component(s) to achieve a low cost, reduced weight structure with mechanical properties that are equal to or greater than (currently used) Aluminum 7075. The project will build upon the Phase I molding compound formulation, characterization, and testing results for feasibility demonstration, and focus on scaling up processing methods from lab-scale produced parts to representative-size components. The program will explore the utilization of higher strength fibers, such as IM9 and T1000 and carbon nanotube reinforced resin systems to achieve target multifunctional performance goals. In addition, a major thrust in the composite end closure design will be utilizing and incorporating customized oriented molding compounds to achieve tailored properties over more conventional compression molding processing approaches.