Innovative Polymeric Materials and Processes for Reducing Missile Component Costs

Composites have traditionally been considered high cost compared to metallic materials. The primary motivation to replace a metallic material in a weapon system has been lower weight. There is no DoD application where this pathos has been more evident than in tactical missile airframes. However, as metal prices increase, particularly for titanium and superalloys, it is becoming increasingly evident that some airframe structures not only benefit from the lower density of composites, but also from lower cost. Many emerging tactical missiles operate at high Mach numbers resulting in high aerothermal heat loads and temperatures in control surfaces and fins, where superalloys are currently used. This program has selected a missile component for demonstration of a high temperature polymer composite, which provides the added benefit of reducing the areal weight of the parasitic thermal protection layer. This program will take the high temperature polymer composite through the entire development process, starting with requirements, concept development, preliminary and detailed design, and coupon and subcomponent testing, with the program culminating with the delivery of detailed engineering drawings for production of units for qualification tests. Once qualified, there will be excellent potential for proliferation of this technology across many DoD missile applications.