An Additively Manufactured Lightweight, High Strength Motor Case Adapter for Future Interceptors

ASRC Federal Astronautics, LLC (AFA) is pleased to present this Phase II proposal, which is focused upon the continued development of a selectively laser melted (SLM) high strength, low weight kick motor case that features an integral stage adapter. Our innovation enjoys reduced costs, shorter manufacturing lead times and the potential for incorporating a topologically-optimized, lighter-weight structural design over what can be obtained with traditional manufacturing methods. In Phase II, AFA will refine our manufacturing process to meet stringent industry AM manufacturing requirements, build multiple prototype motor case adapters, with the ultimate goal of a hot fire testing the optimized Motor Case Adapter (MCA), integrated with an AFA developed Tungsten-Rhenium (W-Re) aerospike! Our refined manufacturing process will build upon the thin walled motor case and adapter concept we developed in Phase I, and will accommodate the requirements of the most rigorous standard for AM flight hardware to date, developed by Marshall Space Flight Center (MSFC). As such, our thin-walled motor case will be designed using material properties that have been generated from hundreds of SLM samples over multiple builds and a range of powder lots. Approved for Public Release 19-MDA-10203 (4 Sep 19)