Composite Preburner & Turbopump Housing Materials and Process

Composite technology exists for application to cryogenic fluid storage without an interface liner. This technology is being applied to an LH2 storage pressure vessel under Air Force Contract F29601-C-0217. This proposal outlines a program to transfer the LH2 composite technology to liquid rocket engine components. This proposal will address requirements for feed system assemblies, such as preburners, gas generators and turbopumps. Segments of housings of these components will be selected for review, analysis and design. A material system review is described together with an investigation of manufacturing processes to integrate with the housing design and materials selection. The basic material system to support the program will be the Fiberite IM7/977-2 prepreg. Alternatives will be considered, including their interface with proposed manufacturing processes. Manufacturing processes reviewed for these complex structures will be lay-up, filament winding and molding. Non-crimped fabric, unidirectional tape and chopped fiber reinforcement forms will be used. Hybrid methods will also be considered. Fabrication of prototype demonstration boss component will be performed for evaluation purposes. A selected material system and manufacturing method will be used. A Phase II program is planned to demonstrate the selected material and process with prototype hardware.