Localized 3-D Fiber Reinforcement in Carbon and Ceramic Composites

This proposal addresses technology for reusable propulsion and vehicle hot structures specified in topic H5.02:Propulsion systems for Commercial Space industry supporting NASA efforts.Upper stage engine systems, such as those for Space Launch System.Lunar/Mars lander descent/ascent propulsion systems.Aerodynamic structures for aeroshells, control surfaces, and leading edges for hypersonic flight vehicles.North Country Composites (NCC) worked with Lancer Systems to adapt their commercial ceramic matrix composite (CMC) manufacturing methods to produce affordable, high performance rocket engine components. The components are showing the ability to operate in highly oxidative and corrosive environments to temperatures above 4000oF for significant periods of time. This is occurring without the use of expensive coatings. Through the utilization of low cost ISO 9001 controlled manufacturing methods, affordable, high performance components can rapidly be transitioned for commercial use. In addition, NCC successfully utilized 3D reinforcements of the fiber preforms to significantly increase (3X) interlaminar strength properties with only a mild decrease in in- plane properties.The high strength, light weight and high temperature capabilities of these structures will significantly increase the performance of space vehicles by increasing the thrust to weight, operational temperatures, and pay-load capabilities.In parallel to the Phase II program, our industrial partner will be performing significant rocket exhaust testing of UHT-CMC components. They, however, will not be generating thermal-mechanical material properties. As a result, NCCrsquo;s overall Phase II objective is generate material properties over the temperature range from room temperature to at least 4200oF. These properties can then be used in finite element models to optimize the design of CMC component designs. Because this work is completed as an SBIR, the properties will be available to the community at large.