Castable Structural Polyurethane Sensor Outer Heads/Housings

The photonics mast (PM) and integrated ESM mast outer sensor heads/housings planned for advanced submarine (NSSN) system applications will be exposed to demanding structural loads and severe environmental exposures. The PM housings must be able to withstand hydrostatic loads, hydrodynamic loads, underwater explosive shock, mechanical wave slap shock, wind loads, thermal shock, and exposure to high heat, extreme cold, UV radiation, rain, snow and icing. The housings must be durable, inexpensive to manufacture, corrosion resistant, resistant to fungal growth, and have superior radar absorbing capability and have a 15 year service life. PM head/housing designs, materials and manufacturing methods are needed to meet these design requirements. This research project will develop low cost, high performance PM housing designs using innovative castable structural polyurethane (CSP) materials and manufacturing processes. The Phase I development effort will include determining the housing design requirements, performing a CSP materials survey and evaluation, performing CSP material testing, designing CSP outer sensor housings, performing a structural analysis, and defining low cost CSP manufacturing methods.