Low Cost Carbon-Carbon Development for Hypersonic Flight Systems

The innovation proposed here is a novel carbon-carbon composite (CCC) manufacturing method based on polymer infusion and polymerization (PIP) using a novel precursor polymer with exceptionally high char yields. This results in a material that has the promise of excellent quality and mechanical properties, while offering the breakthrough advantages of (1) greatly reduced or eliminated need for backfill infusions (2) greatly reduced cycle time (3) excellent fiber wetout and microstructure after carbonization (4) ambient-pressure processing (i.e. no isostatic press needed) (5) inexpensive precursor resin. With further development, the technology proposed herein could allow rapid manufacturing of thick carbon-carbon structures. The manufacturing innovations include a precursor resin improvement with the overall goal of reducing manufacturing times of thick laminates from months to weeks. The fast-manufacturing capabilities potentially provided by this strategy must be explored as it is a feasible route to manufacturing a stockpile of TPS materials, in alignment with the DoD’s timeline. Approved for Public Release | 22-MDA-11339 (13 Dec 22)