Beryllium Alloy Replacement Materials for Missile Optical Structures

Foster-Miller will demonstrate an innovative, low cost and health hazard-free ceramic matrix composite (CMC) material to effectively substitute beryllium and its alloys in EKV optical structures. We previously demonstrated an affordable and scalable processing route to produce high performance and complex shaped CMC materials. During Phase I, mechanical and thermal properties of our low cost SiC materials were shown to be competitive with those of beryllium and CVD SiC. During Phase II, we will optimize these innovative materials and fabrication processes, produce an EKV optical structure element, and prove repeatability in properties/performance of Phase II specimens/components. Foster-Miller has teamed with a major military space interceptor systems integrator that will assist in producing technology that is well suited for insertion in the EKV system. We have also developed a strong Phase II plan and follow-on insertion pathway for the technology. The proposed manufacturing technology is well suited for advanced optical structures where performance, weight and cost efficiency are extremely important. One goal of DOD/MDA electro-optical systems is to increase the thermal stability of the benches while maintaining a low weight. The space environment service temperatures, high dimensional control, and service time requirements are ideal for use of SiC based materials. (P-040337)