Fiber Reinforced Soluble Matrix Composites (FRSMC) for Rocket Motor Cases

Why:            Imagine the most technically advanced aerospace platforms (F22, Rocket motors, satellites…) being produced using the tooling techniques that were perfected almost a century ago. These age-old techniques have limits. These limits have led to serious technical tradeoffs and costs in all industries. Specific to Composite Rocket Motor Cases (CRMC) the nozzle size, length, composite properties, fabrication lead time and cost have all been limited by the internal shape (Mandrel) that defines the CRMC. With similar restrictions felt across many aerospace applications, it is time to move to the next level. What:The proposed work will validate in-situ polymerization of water-soluble polymers with fiber reinforcement using common industrial composite manufacturing techniques. The ultimate goal is to produce lightweight water removable interior shapes for extreme technical composites applications i.e. (CRMCs, Rotor Blades, Aerostructures, etc.). Current composite plastic processing techniques will be leveraged with the new soluble plastic chemistries to allow direct utilization into existing manufacturing lines. Specific fabrication techniques will be analyzed with the new material (VARTM, RTM, Fiber Winding and Wet Layup). Solariz has already produced the first soluble composite shapes with this new concept that are able to perform within the final operating conditions greatly lowering the risk barrier.       How:The program seeks to continue on current development with an existing Prime. Phase 1 will kick off with a technical review of current water-soluble polymerization chemistry developed by Solariz for optimization of mechanical and thermal properties. These values will be supplied to the prime to define a specific DOD related CRMC that can be evaluated using FRSMC. Phase 2 will seek to produce a fully functional OEM defined soluble shape for direct introduction into current test beds. The team will test and compare the newly developed shape as a direct replacement for current RMC production and evaluate the resultant case fabricated from the interior shape for performance, and savings allowing for a real time comparison to the current available technology. Successful validation of the process will lower the risk to the OEM of integrating a new technology into existing manufacturing processes and encourage continued manufacturing investment. A successful CRMS demonstrator will spur huge interest from the remaining primes as they are all also struggling with these exact same issues.