Low-Cost, High Performance Small Nozzle Carbon-Carbon Materials

The proposed program will investigate the application of advanced manufacturing processes to the development of low-cost, high performance 3D C/C for small nozzle materials. Through the use of automated weaving, pultruded rods, and accelerated processing,it is anticipated that a minimum cost reduction of 25% can be achieved for manufacturing costs. A sample 3D C/C billet will be manufactured and densified that demonstrates the advanced manufacturing techniques and the associated cost reductions. Thesample billet will produce two test articles, which ATK/Elkton will test fire to provide a data point for comparison to standard processed C/C. Finally, Phase I will produce a plan for Phase II that will look to identify further cost reductions and expandon the application and knowledge for these new materials. The direct benefit of this Phase I SBIR will be the demonstration of significant cost reduction in the manufacture of 3D C/C materials for small nozzles. The use of innovative manufacturingmethods will facilitate faster introduction of these materials into BMD systems. Commercial and DoD systems alike will benefit by being able to introduce higher performing materials in applications where cost previously prohibited the use. Furthermore,it is expected that this research will be the initial step in the development of a family of low-cost, high performance C/C nozzle materials.