Novel Production Processes for High Strength Ablative Insulators

OUSD (R&E) CRITICAL TECHNOLOGY AREA(S): Hypersonics; Advanced Materials 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 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 new processes for producing high strength, ablative insulators rapidly with low scrap rates. This effort focuses specifically on high temperature, fiber reinforced matrix composites. DESCRIPTION: High temperature, fiber reinforced composites are frequently used as ablative insulators for various aerospace applications. Ablative insulators, like carbon-phenolic and silica-phenolic, are traditionally produced by involute lay-up with manually intensive processes with low reproducibility. Conventional methods of production require highly skilled labor with weak control of production parameters. Recent advances in automation for various additive manufacturing processes provide new opportunities to eliminate production variability for ablative insulators while increasing production rates. The primary application of this technology is propulsion, but a secondary application is for thermal protection systems for aeroshells. PHASE I: Phase I-like proposals will not be evaluated and will be rejected as nonresponsive. For this topic, the Government expects the small business would have accomplished the following in a Phase I-like effort via some other means, e.g., independent research and development (IRAD) or other source, a concept for a workable prototype or design to address, at a minimum, the basic capabilities of the stated objective above. Proposal must show, as appropriate, a demonstrated technical feasibility or nascent capability. The documentation provided must substantiate the proposer's development of a preliminary understanding of the technology to be applied in their Phase II proposal in meeting topic objectives. Documentation should comprise all relevant information including but not limited to, technical reports, test data, prototype designs/models, and performance goals/results. Feasibility = maturity and what have you already done/validated. Proposers interested in participating in Direct to Phase II must include in their responses to this topic Phase I feasibility documentation that substantiates the scientific and technical merit and Phase I feasibility described in Phase I above has been met. (i.e., the small business must have performed a proof of concept like Phase I component and/or other validation in a relevant environment, and/or at a much higher TRL level (5 or higher) and describe the potential commercialization applications. The documentation provided must validate that the proposer has completed development of technology in previous work or research completed.) IRAD work, previous Phase I/Phase II work: Documentation should include the most relevant information including, but not limited to: technical reports, test data, prototype designs/models, and/or performance goals/results. Work submitted within the feasibility documentation must have been substantially performed by the proposer and/or the principal investigator (PI). PHASE II: Develop scalable, automated processes to produce high strength, ablative insulators with scrap rates lower than 5%. Minimization of custom production equipment is also desired. The proposed process must be capable of producing fiber reinforced composites with fiber ply angles from 0 to 90 . The mechanical and thermal properties of the ablative insulators produced by the proposed process must meet or exceed those of conventional production processes. Proposers must have demonstrated experience producing fiber reinforced polymer matrix composites and must specify any size limitations, such as length, width, or thickness, to the proposed production process. PHASE III DUAL USE APPLICATIONS: Partner with a system manufacturer to produce fiber reinforced ablative insulators. REFERENCES: Automated fiber placement: A review of history, current technologies, and future paths forward. https://www.sciencedirect.com/science/article/pii/S2666682021000773?via%3Dihub Chemical Erosion of Carbon-Phenolic Rocket Nozzles with Finite-Rate Surface Chemistry. https://arc.aiaa.org/doi/abs/10.2514/1.B34791 Experimental Studies on the Effect of Ply Orientation on the Thermal Performance of Silica Phenolic Ablative Material. https://arc.aiaa.org/doi/abs/10.2514/6.2007-418 KEYWORDS: Propulsion