Low-Cost Hybrid Rocket Nozzle Fabrication Methods

Rayon based materials have shown excellent performance for rocket nozzle applications. In addition, conventional tape wrap methods for fabrication have been successful to obtain the required component strengths. However, with the current lack of a domestic rayon supply, a low-cost replacement is desperately needed. Foster-Miller has previously demonstrated a low-cost fabrication technique for tape-wrapped rocket nozzle components. This method of in-situ braiding and nozzle wrapping has successfully achieved the high performance and low-cost requirements for such applications. As an adjunct to this technology, Foster-Miller proposes expand the braiding process to include the capability to create hybrid flat tape. This triaxial braid will have carbon bias fibers on one side of the braid, and glass bias on the other, with the two fibers interlocked at the interface. The system will tailor the thermal conductivity so that the material system has the carbon's ablation resistance with the glass insulation capabilities, while maintaining the structural performance requirements. Foster-Miller's Phase I teaming partner, Thiokol Corporation, is eager for the development of such a low-cost process for current rocket nozzle exit cone applications. The successful development of this novel technology will provide a robust, low-cost alternative to rayon which can be easily implemented into existing rocket motor technology.