Low-Cost In-Situ Rapidly Carbonized Carbon-Carbon Composite Material

Estes Energetics and Battelle Memorial Institute will apply a fast, affordable manufacturing technology—proven to Technology Readiness Level (TRL) 4 and Manufacturing Readiness Level (MRL) 4—that manufactures a layer of carbon-carbon directly on composite structures without requiring use of an autoclave or densification process holds, resulting in reduced manufacturing time while improving component quality and allowing additional design options. This technology will drastically reduce the cost and lead times associated with carbon-carbon insulation material, thereby allowing broader use of the material across industry and supplanting less effective insulation materials in hypersonic environments. Our team’s concept and technical solution combines mature materials and processes with a novel yet proven patented manufacturing technique, selective laser heating (SLH), to manufacture insulation in-situ. A combination of laboratory testing and integrated testing using solid rocket motors provide the greatest TRL advancements. Approved for Public Release | 22-MDA-11339 (13 Dec 22)