Graphite Fiber Reinforced Mg EKV Sunshade for Be Replacement and Cost and Mass Reduction

In Phase I, we demonstrated that Mg-AZ31 alloy reinforced with graphite fibers has over 27% higher specific stiffness than beryllium. Since EKV sunshade is a stiffness critical application, sunshades manufactured from graphite/Mg could weigh 27% less than the current Be design. Further, testing at MMCC and preliminary results from Raytheon show the material to be gas impermeable. Using MMCC's net-shape Advanced Pressure Infiltration Casting (APICT) process, the sunshade would cost half as much, resulting in a $7- $10 million savings in procurement cost. In addition, lower mass will lead to increased performance that could result in further cost savings and increased mission capability. This project, in collaboration with the prime contractor, will demonstrate the materials and environmental performance and cost effectiveness of Gr/Mg EKV sunshades. Phase II can be considered to be a pre-production manufacturing technology readiness project and will enable direct procurement for EKV system deployment. Beyond the structural and cost enhancements, Mg/graphite is non toxic and has none of the environmental and occupational health liabilities associated with melting, machining and handling of beryllium. The establishment of this technology will enable a business line in strong, high specific stiffness structural tubing for missiles, spacecraft, satellite, airborne and sports applications.