SBIR-STTR Award

C-C material systems have high strength:weight ratios at high temperatures, making them well suited for future hot structure designs. However legacy C-C solutions are subject to poor through thickness properties (for 2D laminates), or manufacturing speed and capacity issues (for Cartesian billets.) These issues are often compounded for tubular or conical geometries. With this SBIR Phase I submission TEAM, Inc. proposes to advance the state art for tubular and conical preforming methods for use in C-C hot structure applications. A parallel process development and testing program is proposed: Process Development: We will use “off the shelf” and versatile braiding technology to demonstrate fabrication of conical, carbon fiber preform(s) with up to 1” wall thickness and conical geometry. We will modify TEAM's custom designed, automated z-stitching line to insert stitches into a conical geometry preform at controlled and repeatable spacing(s). Testing Program: In parallel with the process development, we will quickly fabricate flat panel test coupons of stitched and un-stitched braided laminates. (A phenolic-resin system will be used to meet cost and schedule constraints in Phase I.) ~Half the panels will be tested by partner Southern Research Institute to characterize in-plane and inter-laminar tensile properties of stitched vs. un-stitched variants. The other ~half of panels will be delivered as-is for potential C-C densification and testing by NASA or by TEAM at beginning of Phase II. The advantage of the proposed approach is that both the braiding process and the stitching work cell are easily scaled in terms of part size and geometry. Through thickness property issues with traditional C-C tape-lay are addressed by the proposed stitching process. Cost / capacity / geometric constraint issues associated with Cartesian / Polar billets are addressed by versatility and relative speed of the braiding and z-stitching processes. Potential NASA Applications (Limit 1500 characters, approximately 150 words) Potential NASA users of this technology exist for a variety of propulsion systems, including upper stage engine systems, in-space propulsion systems, Lunar/Mars lander descent/ascent, solid motor systems, including those for primary propulsion, hot gas valve applications, and small separation and/or attitude control systems. Potential programs of interest include Commercial Orbiter Transportation Services (COTS), Commercial Lunar Payload Services (CLPS) and NASA HEOMD programs including Space Launch System (SLS) and Human Landing System (HLS). Potential Non-NASA Applications (Limit 1500 characters, approximately 150 words) The proposed C-C preforming & material system proposed here-in is of great interest to various DoD stakeholders currently developing hypersonic missile and vehicle systems. (Army, Navy, Air Force, DARPA and their prime contractors). The technology would likely be applied as TPS or hot structure for aeroshell bodies, frustras, nose-tip adaptors, leading edges and other control surfaces.

TEAM, Inc. proposes to advance the state of the art of C-C material systems and preforming methods for use in hot structure applications. A program with parallel Testing and Process Development tracks is planned: Testing Program: The carbon-phenolic material system from Phase I will be replaced with C-C and C-C/SiC matrix in Phase II. (densification sub-contractor Exothermics.) The flat panel testing from Phase I will be repeated to understand in-plane and through thickness property trade-offs between stitched and un-stitched variants, as well as between C-C and C-C/SiC variants. Qty 2 net shape converging / diverging nozzle components (stitched vs. un-stitched) will be provided for hot fire testing by Aerojet Rocketdyne. Process Development: We will use “off-the-shelf” braiding technology, coupled with our custom z-stitching line, to produce net shape converging-diverging nozzle preforms with through thickness reinforcement. The semi-automated z-fiber stitching line from Phase I will be re-designed to introduce full automation, resulting in a repeatable and robust process. The Phase II converging / diverging nozzle will be designed to fit the sub-scale test rig at Aerojet Rocketdyne’s Orange, VA facility. It will also serve to demonstrate versatility of the proposed braiding / stitching processes to handle geometric complexity. The advantage of the proposed approach is that both the braiding process and the stitching work cell are easily scalable in terms of part size and geometry. Z-axis issues with legacy tape-lay approaches are addressed by the stitching process. Cost / capacity / geometric constraint issues with legacy Cartesian / Polar billet approaches are addressed by versatility of the braiding and z-stitching processes. Potential NASA Applications (Limit 1500 characters, approximately 150 words): Potential NASA applications for the proposed technology include upper stage and in-space propulsion and lunar/Mars lander and ascent. The Advanced Exploration Systems (AES) and Commercial Lunar Payload Services (CLPS) initiatives are both particularly notable NASA programs well suited to fund a hot structure technology demonstration effort. Blue Origin, Dynetics and SpaceX are the current prime contractors working on lunar lander solutions for the NASA Artemis program. Potential Non-NASA Applications (Limit 1500 characters, approximately 150 words): The proposed C-C material system and preforming technology are of interest to various DoD stakeholders currently developing hypersonic missile and vehicle systems. (Army, NAVY, Air Force and their prime contractors.) The technology has use as TPS or hot structure for aeroshells, glide bodies, frustras, nose-tip adaptors, leading edges and other control surfaces. Duration: 24