Advanced Nozzle Materials and Concepts for High Mass Flux Boost Motors

On this Phase I program, Advanced Ceramics Research Inc. (ACR) will develop and commercialize technology to fabricate boost motor nozzles using TaC-based Fibrous Monolith composites. These materials may also have application for other high temperaturepropulsion-related composite components such as gas divert tubes, valves, and hot gas ducts. On the commercial side, ACR is exploring and evaluating applications for the thermally insulating refractory composites. Examples of these potential applicationsinclude high temperature furnace hardware and precision insulators. ACR and the Tohono O'odham Reservation of Tucson, AZ, have teamed together to form a new $3.9 million dollar joint venture business called Advanced Ceramics Manufacturing LLC (ACM). Thepurpose of this new venture is to scale-up the high-temperature consolidation process of fibrous monolith materials to large production volumes. The venture will specifically focus on commercial production of technology developed on this and othergovernment programs. The industrial applications of the materials and components developed under this Phase II program are applicable to both the defense and commercial sectors. Our discussions with defense contractors have led to expressions of interestfrom Alliant TechSystems as well as Raytheon Missile Systems, and Aerojet. For the US government and BMDO, the potential applications are in (a) rocket nozzles (b) combustor and hot gas duct liners and (c) thruster housings. ACR has already establishedclose supplier and development relationships with a number of relevant rocket motor manufacturers.Potential commercial applications to be explored during the course of Phase II include items such as furnace supports, liners and furniture, where insulating refractory materials are desired. Based on past experience with the development of the FM coateddrill bit inserts with Smith International and the development of metal cutting tools with Kyocera Industrial Ceramics via funding from the DOE and the considerable interest has expressed in our technology for high temperature applications we expect thisprogram to move us immediately into a position of obtaining private sector support.