Low Cost Carbon-Carbon Development for Hypersonic Flight Systems

OUSD (R&E) MODERNIZATION PRIORITY: Hypersonics TECHNOLOGY AREA(S): Materials OBJECTIVE: Develop automated low cost Carbon-Carbon material production methods to provide consistent and quality components that can survive in extreme hypersonic thermal and structural environments. DESCRIPTION: This topic seeks mature manufacturing processes of low-cost Carbon-Carbon materials for use in government hypersonic flight systems. The Government is looking for material solutions for Carbon-Carbon that can reduce manufacturing time while maintaining component quality. Government hypersonic applications desire Carbon-Carbon solutions that can obtain a density that is consistent and reliable throughout the material component. Emphasis is placed on innovative rapid densification methods, automated weaving techniques, and/or additive manufacturing processes that can enable the significant reduction in manufacturing time. Additional structural requirements will be communicated upon award. PHASE I: Demonstrate the technical feasibility of the proposed materials approach. Provide technical demonstration that scaled material solutions are viable in hypersonic environments. Develop test plans to demonstrate automated manufacturing parameters and thermo-structural ground testing of subscale components. Develop manufacturing and quality approach for full-scale components. Subscale Carbon-Carbon technology development for Phase I expands to prove manufacturing at a full-scale during the Phase II effort, with sizing requirements provided upon Phase II award. PHASE II: Actively demonstrate material approach by manufacturing subscale coupons of innovative material(s) for laboratory and ground testing. Evaluate material performance in hypersonic relevant environments via analysis and testing. Conduct manufacturing assessments to determine statistical parameters of quality and repeatability. Provide the Government with preliminary cost and schedule projections of material components compared to the current state-of-the-art. Evaluate material performance in hypersonic relevant environments via analysis and testing. Conduct manufacturing assessments to determine statistical parameters of quality and repeatability. PHASE III DUAL USE APPLICATIONS: Demonstrate use of full-scale components in hypersonic environments. Develop full-scale manufacturing capabilities providing data on quality and reliability of components. Provide full-scale cost assessments for production. REFERENCES: Muhammed, F., Lavaggi, T., Advani, S. et al. Influence of material and process parameters on microstructure evolution during the fabrication of carbon carbon composites: a review. J Mater Sci 56, 17877 17914 (2021). https://doi.org/10.1007/s10853-021-06401-3 Reveles, N.D., R.S. Miskovish, and E.L. Blades. A Closely Integrated Fluid/Solid Framework with Chemistry for Hypersonic Ablating Vehicles. National Space and Missile Symposium, Chantilly, VA. Jun 2015. KEYWORDS: Hypersonics; Advanced Manufacturing; Advanced Materials; Carbon-Carbon