LIGHTWEIGHT, COMPOSITE PROPULSION MANIFOLD SYSTEM WITH INTEGRAL PROPELLANT LINES

The objective of this program is to develop and demonstrate the feasibility of a lightweight, producible Integral Composite Manifold-Attitude Control System (ICM-ACS) for the THAAD interceptor KV Divert Attitude and Control Subsystem (DACS) missile defense interceptor system liquid propulsion application. The ICM-ACS component is intended to serve as a structural bulkhead that incorporates propellant lines into the composite as part of the manufacturing process as an alternative to complex, costly and heavier machined aluminum parts. The ICM-ACS design concept incorporates propellant lines during the infusion of the manifold component using the precision resin transfer molding (PrecisionRTMT) process. Structural, thermal, shock and other design requirements for the THAAD DACS ACS application were assembled. An ICM-ACS conceptual design was developed using a composite design utilizing carbon fibers, resin, and foam core sandwich along with integral aluminum propellant/ pressurization lines. Tooling was designed and fabricated, and three full-size but subscale test articles were fabricated to demonstrate the key design features of the composite and integral lines interfaces after fabrication. NDE and destructive evaluation tests were completed to verify the quality of the manufacturing process. The proposed Phase II program will develop and demonstrate a full-scale prototype of the ICM-ACS design concept for the THAAD DACS ACS application, and evaluate other hypersonic interceptor applications. The long-term objective is to insert the ICM-ACS design concept and technology into the Missile Defense Agency (MDA) and U. S. Army Space and Missile Defense Command (SMDC) THAAD Program in a future hardware upgrade program and to commercialize the concept for other hypersonic missile applications.