SBIR-STTR Award

Future aluminized propellant boost missile systems for DoD and MDA applications will create extremely severe conditions (temperature, pressure and particle impingement) in the nozzle region that will prevent conventional nozzle materials and designs to achieve the performance levels and costs that are being targeted for next-generation solid rocket motor (SRM) boost systems. The demonstration of zero or near-zero erosion in the throat area is a much sought after goal for SRM propulsion systems, since it offers direct payoff potential in the way of increased motor performance, reduced nozzle weight and lowered cost relative to current-generation of high performance rocket motors. For this Phase 1 SBIR effort, the materials system we propose for examination are based on high strength, net-formed, tantalum carbide (TaxC1-x) compositions and variants thereof; these ultrahigh temperature compounds will be fabricated by novel isostatic densification methods we have developed over the past few years. Due its extremely high melting point and predicted stability against aluminized propellant exposure, we anticipate that such TaC-based compositions will be able to withstand 3000 - 3500°C propellant flame temperatures. The principal markets that would benefit from the availability of such ultrahigh temperature materials are in the MDA and DoD boost nozzle realm.

Keywords:
Net-Forming, Hot Isostatic Pressing, Tantalum Carbide, Ultrahigh Temperature, Boost Motor

This Phase 2 SBIR proposal addresses the technical and manufacturing challenges associated with development of cost-effective materials solutions for ultrahigh temperature solid rocket motor throat components ¡V particularly those associated with boost nozzle solid rocket motor (SRM) or solid divert/attitude control SDACS components for vehicles such as KEI and SM-3. Exothermics and their Phase 2 partners ATK Launch Systems Division, MR&D and the Southern Research Insitute will seek to increase the reliability, producibility and performance of aluminized and nonaluminized propellant throat and nozzle hardware by systematically optimizing, testing and then deploying a new family of net-formed ultrahigh temperature (>3000„aC) tantalum carbide- and hafnium nitride-based refractory compounds and cermets. These UHT materials will be manufactured in net or near-net shape fashion using novel hot isostatic pressing (HIP) densification methods we developed in our Phase 1 SBIR program. Based upon the highly successful outcome of our Phase 1 efforts pertaining to forming of TaC-based compounds and our partnership with ATK Launch Systems Division, we believe that this Phase 2 program represents an excellent opportunity for fielding a new generation of UHT solid propulsion components with performance and cost attributes that are superior to legacy materials such as thoriated tungsten.

Keywords:
ULTRAHIGH TEMPERATURE MATERIALS, TANTALUM CARBIDE, HAFNIUM NITRIDE, BOOST NOZZLE, KEI