Lightweight Multi-Functional Nano-Composite Structures for MKV Interceptor Structures (PVG07-062)

Lightweight and high performance miniature kill vehicle interceptors are required for interceptor systems, such as the Multiple Kill Vehicle (MKV), being developed by MDA. A lightweight interceptor structure is a critical component required to integrate component and subsystems and provide the structural strength and stiffness to meet the overall interceptor performance requirements. Conventional light-weighting approaches use graphite fiber-reinforced polymer matrix composite materials to provide structural performance. Typically, parasitic weight is then added to the structure to provide additional subsystem functionalities, such as EMI shielding and thermal management for electronic housings. Lighter weight and lower cost miniature interceptors can be provided by incorporating structural, thermal, electrical, and radiation shielding functionality in multi-functional composite structures. Vector has demonstrated the use of Resin Transfer Molding (RTM) composite structures manufacturing technology for the fabrication of lower cost and higher performance precision, complex interceptor structures using hybrid designs of graphite composites and metallic materials to incorporate these multi-functional properties. The next generation of multi-functional composite structures will use nano-materials technology instead of hybrid design approaches. The Vector team includes Applied Science Inc. (ASI), a world leader in carbon nano-fiber (CNF) materials technology development and production, and Nanosperse, Inc. (NSI), a world leader in nano-composite resin technology development. ASI’s milled CNF and NSI’s nano-resin technologies have been shown to significantly improve mechanical, thermal, electrical, and radiation hardness properties of polymer composite structures. The proposed program will combine these nano-materials technologies with Vector’s RTM manufacturing process to demonstrate nano-composite manufacturing technology for multi-functional lightweight composite structures for miniature kill vehicle interceptor structures