Improve Stability within EKV Seeker Assembly by Utilizing Ceramic-Nanotube Composites

Raytheon Missile Systems (Tucson, AZ) has presented Advanced Ceramics Manufacturing, LLC (ACM) with a materials challenge; replace a current isolator material with a more creep resistant, thermally isolating and stiff material for use within the EKV seeker assembly. ULTEM currently being used to fabricate the component is not dimensionally stable and creeps even at room temperature. This program proposes a new design that meets material and manufacturing requirements such that when proven viable, it can be immediately implemented into the EKV seeker. The material and process must transition to scale-up production environment including post machining, finishing and assembly. ACM proposes to address this problem by fabricating the isolator component from a ceramic-nanotube composite. Nanotubes have been added to partially stabilized zirconia where thermal conductivities less than 0.1 W/m-K could be achieved with <1 wt% addition. The non-aqueous gel-casting method will be used to fabricate a near net shape prototype for Raytheon to evaluate from this composite material. Preliminary studies characterizing the thermal and mechanical properties of the material will be conducted. A first generation isolator prototype will be fabricated for Raytheon's evaluation.