Innovative Manufacturing of Hafnium Carbide Insulation Materials

In Phase I, Cornerstone Research Group, Inc. (CRG), proposed to fabricate solid rocket motors with increased erosion performance and improved manufacturability by integrating MATECH’s zero-erosion Hafnium Carbide (HfC) insulation system into CRG’s innovative rotomolding manufacturing process. These integrated technologies are primary focused on axial propulsion systems, as rotomolding is best suited for symmetrical components such as the internal insulation on an axial motor. Due to its zero-erosion characteristics, the HfC exhibits less particulate and better mission assurance as compared to Kevlar-filled EPDM, and therefore would benefit multiple munitions systems. Additionally, CRG developed a cyanate ester elastomer, which has generated interest within the missile community for its high temperature and elastomeric properties. CRG and MATECH propose to continue the HfC insulation system effort in Phase II, as a means to further investigate the cyanate ester-HfC system compared to the state-of-the art (SOTA) Kevlar-filled EPDM, and to develop a scale-up manufacturing plan and production costs of the HfC material. CRG and MATECH also propose to integrate the optimum material system into a Phase II prototype via an appropriate manufacturing method.