Low Cost THAAD Interceptor Kill Vehicle Integrated Airframe Manufacturing Process

The objective of this program is to develop and demonstrate the feasibility of manufacturing a low cost composite Integrated Heatshield and Structure (IH&S) aeroshell design concept for hypersonic interceptor structures, including the primary application to the THAAD interceptor KV midbody airframe. The IH&S design concept is based on simultaneous manufacturing of the missile composite heatshield layer (S2 glass fiber knitted cloth) and substructure layer (M40J carbon fiber knitted cloth) using the high performance vacuum assisted assisted resin transfer molding (HyPerVARTMT) process to infuse a single high temperature resin (YLA RS-9e cyanate novolac). The IH&S design concept feasibility was demonstrated for the THAAD KV application in Phase I by successful manufacturing of flat panel and conical section subscale test articles with high quality and performance in ground tests; ablation tests of the heatshield; mechanical properties and structural design analyses predicting high strength and stiffness structure performance for THAAD KV applications; and analytical predictions of a lightweight and low cost aeroshell. The proposed Phase II program will develop and demonstrate a full-scale prototype of the IH&S aeroshell for the THAAD KV midbody airframe, and demonstrate other hypersonic interceptor applications such as boost phase interceptor shrouds. The long-term objective is to insert the IH&S aeroshell design concept and technology into the Missile Defense Agency (MDA) and U. S. Army Space and Missile Defense Command (SMDC) system programs, including the THAAD Program, in future hardware upgrade programs and to commercialize the concept for other hypersonic missile applications.