Fiber-Reinforced Propellant Bond

This project investigates a novel fiber reinforcement concept for propellant bonding that replaced most or all of the adhesive liner with a high surface area carbon fiber substrate. The fiber diameter, length, packing fraction and surface treatment are adjusted for maximum bond effectiveness corresponding to a given grain distribution and binder composition. Proposed electrostatic fiber placement and resertion methods are suited for large scale use. The proposed bondline reinforcement concept potentially results in a simpler motor assembly process, as well as lighter and more reliable propellant castings. Phase I effort involves initial coupon peel testing from which promising configurations will be selected for evaluation using the blister test method with 12" specimens. Candidate fiber attachment and insertion methods will be evaluated. ESLI carbon fiber electroflocking and fiber implantation will be tailored for use with rocket insulation materials. Test results will be interpreted in terms of a preliminary model that accounts for fiber type. Fiber distribution and interfacial adhesion properties. Phase 2 would further develop processes conducive to cost-effective assembly of high-reliability solid rocket motors.