Lightweight C/SiC Lined Carbon Foam Kick Motor Nozzle for Kill Vehicle Application

"FMI proposes to examine the potential of a C/SiC composite low erosion throat/exit cone that makes use of carbon foam as a support and insulation structure. This basic concept has been forwarded by Opeka and by Buesking et al., where a strong, lowconductivity carbon foam insulator supports a high temperature thin ceramic liner. FMI has recently demonstrated that light weight, potentially low cost carbon fiber reinforced silicon carbide ceramic matrix composites can survive simulated DACSenvironments under 3700F propellant testing. Bulk C/SiC test materials were shown to survive 4000F propellant conditions. As a class of materials, only fiber reinforced ceramic matrix composites are likely to withstand the thermal shock and operationalvibration loading present in DACS and axial boost applications in advanced kill vehicles. Densified and coated liners will be surrounded by a foamed-in-place carbon foam substructure to provide mechanical support and attachment, and a means to controlthermal environment of the liner. A Phase I optimized integral liner/support structure nozzle test article will be made available for testing as a C/SiC CMC lined Carbon Foam backed kick motor throat/nozzle for enhanced kill vehicle application. Currenthigh performance rocket throat/nozzles can be costly and/or fabricated with high density refractory metals or massive carbon/graphite components. A weight reduction through the use of ceramic composites and