High Strength Nanomaterials Fiber for Lightweight Composite Missile Cases (MSC P5019)

In order to meet more challenging performance goals for next-generation tactical missile systems, significant improvements in material and structural performance are needed. While recent developments in carbon nanotube (CNT) reinforced composite material technology offer the promise for substantial improvements in material/structural performance, material and process development and characterization is needed to translate the extraordinary nano-scale properties of CNTs to macroscale structural performance. Under the Phase I SBIR program, Materials Sciences Corporation and Drexel University have demonstrated the capability for producing meter lengths of fibers/yarns reinforced with single wall nanotubes (SWNTs) and multiwall nanotubes (MWNTs) using a modified drum electrospinning process. The proposed Phase II research will build on the Phase I process trials and results to develop and demonstrate a prototype Continuous Drum Electrospinning and Yarn Twisting System for automated production of significant lengths of CNT-reinforced carbon fibers/yarns that can be incorporated into a composite motor case filament winding manufacturing process. Phase II material/process development will include microstructure characterization and evaluation of macroscale properties to demonstrate the translation of nano-scale CNT properties to macro-scale CNT/carbon fiber reinforced composite performance for a representative filament wound composite motor case structure. An important goal of the Phase II research will be to work closely with a major carbon fiber manufacturer to ensure technology transition for future commercial production of the CNT/carbon fibers for sustainability.