Rapid, Affordable C-C Using MG Resin

Cornerstone Research Group Inc. (CRG) proposes to use MG resin systems to demonstrate dramatic improvements in speed of production for C-C components for DoD hypersonic vehicles.  MG resin char yield of over 70% and ease of processing promises to show 75+% reduction in labor hours and a 5x+ improvement in output from the same capital equipment compared to the benchmark ACC-6 C-C material for 1” thick medium frustrum parts.  CRG will also demonstrate the pathway to improved affordability through high volume materials production and efficient use of high cost capital equipment.  CRG has recently announced a partnership with Karman Space and Defense and their divisions Systima Technologies and AAE to scale up the production of MG resin and also insert MG resin technology into a wide variety of DoD and space-based applications.  MG resin systems provide a unique advantage to Karman-Systima and Karman-AAE to improve performance, lead times, and affordability for ablative shrouds, rocket nozzles, rocket motor cases and liners, and carbon-carbon acreage and seal structures.  Karman-Systima is currently producing hardware for multiple DoD hypersonic systems and is well positioned to insert this technology into multiple systems for the ultimate benefit of the DoD.  Karman-AAE uses over 100,000 pounds of phenolic prepreg a year in manufacturing a wide variety of ablative nozzles and other high temperature components for DoD applications.  Use of MG resin systems in place of phenolic will help improve leadtimes and reduce costs.  The CRG/Karman team will demonstrate a new, integrated supply chain option for C-C components for hypersonic vehicles based on MG resins under this SBIR program and the follow on efforts.  The current TRL and MRL of the MG resin technology for C-C is estimated to be a 3-4 with the target TRL and MRL of the technology at a 6 by the end of this multi-phase effort.