Innovative Methods of Integrating Fibrous Monoliths into SDACS Applications

In this phase I program, Advanced Ceramics Manufacturing (ACM) proposes to develop a processing technique that will integrate Fibrous Monolith (FM) composite materials into propulsion systems. Specifically, ACM will develop an innovative joining process toattach carbide FM throat liners to support structures. FM liners offer high temperature stability in non- and aluminized propellants. This process will utilize gel-casting to infiltrate a porous graphite body and provide a strong interface layer betweenthe FM composite and support structure.This joining technique, although developed for integration of FM high temperature composites, could easily be used to integrate other ceramic materials into carbon based structures. Thus, providing the thermal and chemical stability sought in nextgeneration propulsion parts, at a reduced cost, minimized weight, with improved toughness. The process will be developed for manufacturing scale-up and quality including reliable and reproducible performance in operational environments.The fabrication of a ZrC throat liner can be applied to the integration of other high temperature carbides and diborides. These material systems can be utilized within Sold Rocket Motor applications such as Space/Tactical Boosters, SDACS and gasgenerators. This research is directly applicable to ballistic missile defense systems like the Sea-based Midcourse Defense kinetic energy weapon. The development effort in this Phase I program could lead to a new advanced material technology that givesMDA expanded propulsion capability to propel, divert and control missile interceptors such as the Navy Sea-based Midcourse Defense kinetic energy weapon. In addition to aerospace applications, the manufacturing processes developed under this program areapplicable to the integration of FM ceramics in industrial applications for the manufacturing of durable load-bearing high temperature insulating materials.