Weaveable HfC Structural Fiber Development and Scale-Up

This MDA Phase II SBIR program seeks to further develop the first HfC structural ceramic fiber for HfC(f)/HfC(m) CMC fabrication. MATECH/GSM proposes to scale-up HfC structural ceramic fiber to a level suitable for low rate initial production (LRIP) of 500 filament HfC ceramic fiber tow during the Phase II program for ultimate structural CMC fabrication. The 500 filament HfC ceramic fiber tow will be tested per the fiber test matrix outlined in the statement of work. This HfC ceramic fiber property database will enable direct comparison with existing commercially available high temperature “state-of-the-art” ceramic fibers. In addition, HfC(f)/HfC(m) CMC “mini-composites” will be fabricated and tested for validation of CMC processing conditions. In the Phase II Option program, MATECH/GSM proposes to weave braided 2D HfC fabric and fabricate HfC(f)/HfC(m) CMC composite test panels for mechanical and thermal property measurements. Additionally, MATECH/GSM proposes to fabricate and test fire “zero erosion” HfC(f)/HfC(m) CMC thusters. Hot fire motor tests in the Phase II Option will be conducted at Aerojet’s Sacramento test facility.