Lightweight Structures for Future Interceptors

Touchstone Research Laboratory proposes to develop fiber reinforced aluminum (FRA) metal matrix composite components to replace those that were originally made from Ti-6-4. It was proven that the FRA is able to outperform titanium at temperatures up to 1000°F. Given the increase in elevated temperature strength, the components may be made with reduced material usage, leading to weight savings. Phase II work will consist of increasing FRA manufacturing capabilities to prepare for large diameter missile cases, further characterizing the FRA material, and produce a sub-scale rocket motor case made out of FRA that can be used for static firing proof-of-concept testing. The sub-scale rocket motor case will be produced as a result of design and analysis work with the goal to fully utilize the capabilities of the FRA material. Touchstone will also aim to integrate its CFOAM (carbon foam) lightning strike and thermal protection system into the FRA motor case technology. Phase III work will consist of scaling up the production capabilities of the FRA motor cases to fit the geometry of ground-based interceptors along with static firing tests on the produced rocket motor case from the Phase II effort and further capability testing of the combined FRA motor case with the integrated lightning strike and thermal protection system. Approved for Public Release | 21-MDA-11013 (19 Nov 21)