A Reliable Manufacturing Technology for Solid Rocket Nozzles to Reduce Cost and Environmental Impact

Foster-Miller proposes to demonstrate cost, reliability, and environmental advantages of an advanced solid rocket motor (SRM) nozzle manufacturing technology. Technology developed in Phase II could be readily incorporated into the Integrated High Pay-off Rocket Propulsion Technology (IHPRT) program. Currently, SRM nozzles are fabricated by tape wrapping compliant bias (+-45 deg) carbon/phenolic prepreg tape produced from bias slid and sewn strips of 0/90 fabric tape. This tape is formed onto a nozzle mandrel, cured, and machines to final configuration. Over 50% of the material used is scrapped or machined away during nozzle manufacture. In Phase I, Foster-Miller will demonstrate that advanced braiding technology can be adapted to produce nozzles with increased reliability, 50 % overall cost savings, and reduced environmental impact. A flat braided tape will be formed and wound in-situ onto a nozzle mandrel. The finished part will be near net shape significantly reducing machining and its waste environmental impact. The preform will be densified and sectioned for property measurements. Our partner Thiokol will ensure a commercialization pathway, relevancy to the IHPRPT program, and provide a detailed cost analysis model to demonstrate advantages over current methods.