Low Cost HfC(f)/HfC(m) CMC DACS Thrusters for THAAD

In this MDA Phase I proposal, MATECH/GSM proposes to demonstrate fabrication of low cost HfC(f)/HfC(m) CMC's suitable for insertion into DACS Thrusters for THAAD. MATECH has brought in key propulsion contractors, Lockheed Martin and Boeing Rocketdyne and have enlisted the support of an established high temperature composite manufacturer, Fibers Materials, Inc. In two on-going Phase II MDA SBIR programs, MATECH developed different methods of producing HfC ceramic fibers and woven cloth. One method involves conversion of a rayon fiber or fabric into HfC through the infusion of a proprietary polymer followed by carbothermal reduction in inert atmosphere resulting in the formation of a stoichiometric HfC fiber or fabric. MATECH has also developed pre-ceramic polymers that can be melt spun into HfC fibers. Scale up technology to fabricate panels and sub-element components has been demonstrated. Several of the pre-ceramic polymers have shown suitability in molding components and PIP densification processing. Using demonstrated technology, material fabrication and densification, lowers the risks and enhances the likelihood of a successful program effort by MATECH/GSM. If successful in Phase I, the Phase II program would entail the design, fabrication, and delivery of THAAD DACS thrusters to Boeing Rocketdyne for "hot fire" testing.