Optimized Matrices for Low-Cost Composites with Tailored Interphases

Through this SBIR program, Tetramer will demonstrate carbon fiber composite rocket motor cases with at least 25% reduced processing cost and enhanced mechanical strength compared to current processes and materials. This will be accomplished by developing an in-depth understanding of the influence of processing time, temperature, and chemistry on the resin-sizing-fiber interphase. Utilizing that knowledge Tetramer will optimize matrix materials to reduce processing cost and improve mechanical performance. The interphase region of composite materials is not a discrete layer of the material but rather an area around the fiber where the attributes of the fiber reinforcement, sizing, and the matrix resin coalesce. Since the interphase transfers stress between the matrix resin and the fiber reinforcement, small changes in the interphase can greatly impact the bulk properties of the composite. In the Phase I period, Tetramer will develop an epoxy resin system with optimized interphase behavior tailored for excellent mechanical performance when used in low-cost composite manufacturing. The epoxy material will be designed to possess a glass transition temperature greater than 400 °F and cure temperature less than 370 °F, providing attractive performance in a range of high temperature composite applications.