High Temperature Dynamic Seals for Solid Propulsion

RT&L FOCUS AREA(S): Hypersonics TECHNOLOGY AREA(S): Materials; Weapons The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), 22 CFR Parts 120-130, which controls the export and import of defense-related material and services, including export of sensitive technical data, or the Export Administration Regulation (EAR), 15 CFR Parts 730-774, which controls dual use items. Offerors must disclose any proposed use of foreign nationals (FNs), their country(ies) of origin, the type of visa or work permit possessed, and the statement of work (SOW) tasks intended for accomplishment by the FN(s) in accordance with section 3.5 of the Announcement. Offerors are advised foreign nationals proposed to perform on this topic may be restricted due to the technical data under US Export Control Laws. OBJECTIVE: Develop dynamic seals capable of withstanding temperatures over 800 degrees F and pressures over 3,000 lbf/in^2 (psi) in a solid rocket motor environment. DESCRIPTION: The government desires solid propulsion systems with greater impulse and thrust for future systems. Increasing solid propellant burn temperatures may help achieve this goal but also creates thermal challenges for materials. This topic seeks to improve thermal capability of dynamic seal materials for use in solid propulsion systems. Materials should be capable of operating at temperatures over 800 degrees F and pressures over 3,000 lbf/in^2 (psi). Additionally, low friction, long shelf life, and chemical compatibility in a solid rocket motor environment is desired. One application of dynamic seals is in pintle valves for controllable solid propulsion systems. Traditional elastomeric materials used in these dynamic seals include Polytetrafluoroethylene (PTFE) and other fluorocarbons. Proposed solutions could be elastomeric materials with higher temperature capabilities or other innovative concepts for dynamic seals. PHASE I: Evaluate feasibility of proposed material concept by modeling and simulation and/or proof of concept testing. Material formulation and/or coupon fabrication is recommended to provide evaluation of critical properties. Work with solid propulsion system developers to understand environments. PHASE II: Continue material and process development through design, analysis, and experimentation. Optimize processing parameters for yield and quality. Material testing should be conducted to validate material models and generate property databases. Demonstration in a representative environment is desired. Phase II should identify an insertion opportunity and conclude with a mature manufacturing process. PHASE III DUAL USE APPLICATIONS: Work with a solid propulsion system manufacturer to iteratively design and fabricate prototype components for high-fidelity testing in a relevant solid rocket motor environment for current or future missile defense applications. A successful Phase III would provide the necessary technical data to transition the technology into a missile defense application. REFERENCES: 1. National Aeronautics and Space Administration. October 1973. Space Shuttle Seal Material and Design Development for Earth Storable Propellant Systems. ; 2. U.S. Missile Defense Agency. March 3, 2016. Ballistic Missile Defense System. Retrieved from http://www.mda.mil/index.html ; 3. George P. Sutton. 2010. "Rocket Propulsion Elements." 8th edition, John Wiley & Sons Inc. ; 4. William E. Hansen. 2009. United States Patent #7,509,796, Pintle Controlled Propulsion System with External Dynamic Seal