Development of Integrated Composite Structures

Fiber Materials, Inc. teamed with Lockheed Martin Space Systems Company proposes to demonstrate a composite material system, fabricated utilizing co-processing technology for an integrated structure that can serve as a kill vehicle airframe.Current composite airframe technology uses a three-part structure comprised of separately processed substrate and heatshield components with different matrix materials. The heatshield is attached to the substrate using adhesive. The adhesive is chosen toaccommodate the stress due to thermal mismatch between the heatshield and substrate.A co-processed airframe combines the substrate with the heatshield in a single molding step through utilizing one matrix material with suitable structural, thermal, and ablative characteristics. FMI has identified several high temperature resin systemssuitable for both the heatshield and substrate applications, and investigated the feasibility of potential manufacturing approaches for co-processed heatshields and composite substrates using machine woven preforms that result in lightweight and low-costinterceptor airframes.The proposed airframe materials system will utilize a current structural fiber as the substrate reinforcement, with braided or 2D fabric and unidirectional tape as the preform architecture. A suitable high temperature resin will be the co-processablematrix. The current system of materials to provide EMI/lightning protection will also be included in the system.