Low-Cost, Net-Shaped, Non-Eroding Composites for Rocket Motor Components

Foster-Miller, working with Phillips Laboratory and rocket manufacturers, will demonstrate a rapid, low-cost manufacturing process for high-quality non-eroding rocket motor components. The process employs RTM processable ceramic precursors that convert motor components. The process employs RTM processable ceramic precursorss that convert to tantalum carbide (TaC) and fiber preforms to fabricate fiber reinforced, non-eroding C/TaC rocket motor components. The process will circumvent the current limitations of chemical infiltration and depositions (CVI and CVD) techniques for TaC matrix composites of high cost, long lead times, and part geometry constraints.Amongst others, TaC is a candidate high-temperature, non-eroding material for rocket motor components. A non-eroding material, that does not require cooling, would increase the performance of the rocket motor manufacturer, estimates that a non-eroding rocket nozzle would increase the payload capacity of the motor over 7 percent.The proposed technology would be applicable to a variety of other potential non-eroding high-temperature matrices currently made with CVI/CVD techniiques including HfC and ZrC. The technology proposed addresses technical and cost challenges necessary to achieve goals of the IHRPT initiative and its ultimate goal of doubling rocket propulsion capability by the year 2010.