Development of Hydrazine-Compatible Elastomeric Materials for Long-Duration Spaceflight

Subtopic Problem Statement/Description: Heritage AF-E-411 rubber was originally developed in the 1970s to provide extended-duration hydrazine compatibility for propulsion systems. However, the original formulation is no longer viable because several key precursors are no longer commercially available, leading to increased variability and reduced chemical compatibility. This creates a critical gap for NASA missions that require long-duration exposure to hydrazine in space environments. A replacement elastomer, formulated from currently available precursors and capable of meeting or exceeding the performance of AF-E-411, is urgently needed to ensure reliable propulsion system operation for ongoing and future missions. Scope and Objectives: The objective of this subtopic is to develop and validate a new elastomeric material that: Maintains chemical compatibility with hydrazine for extended durations (multi-year exposure). Exhibits mechanical properties comparable to or better than AF-E-411 (e.g., tensile strength, elongation, compression set). Is manufacturable using commercially available precursors and scalable processes. Performs reliably under spaceflight conditions, including vacuum, thermal cycling, and radiation exposure. The effort should include: Identification and screening of candidate formulations. Compatibility testing with hydrazine under relevant environmental conditions per NASA-6001 Test 15. Evaluation of aging and degradation mechanisms over extended durations.