Carbon-Carbon/Carbon Foam/Aerogel Process for Integrated Aerostructure TPS

Award Information
Agency: Department of Defense
Branch: Missile Defense Agency
Contract: HQ0006-09-C-7127
Agency Tracking Number: B083-020-0586
Amount: $99,995.00
Phase: Phase I
Program: SBIR
Awards Year: 2009
Solitcitation Year: 2008
Solitcitation Topic Code: MDA08-020
Solitcitation Number: 2008.3
Small Business Information
Touchstone Research Laboratory, Ltd.
The Millennium Centre, R.R. 1, Box 100B, Triadelphia, WV, 26059
Duns: 101582922
Hubzone Owned: N
Woman Owned: Y
Socially and Economically Disadvantaged: N
Principal Investigator
 Drew Spradling
 Senior Product Development Engineer
 (304) 547-5800
 dms@trl.com
Business Contact
 Brian Joseph
Title: President, COO
Phone: (304) 547-5800
Email: bej@trl.com
Research Institution
N/A
Abstract
Extreme heating conditions of future MDA missions are too severe for existing low-density systems (i.e., PICA – Phenolic Impregnated Carbon Ablator); and existing high-density systems (i.e., carbon-carbon, carbon-phenolic) are too heavy and thermally inefficient. The proposed effort seeks to demonstrate the feasibility of wrapping a lightweight, rigid carbon foam with a carbon-carbon outerlayer that serves as an integrated aerostructural TPS. To enhance the thermal performance of the carbon foam without dramatically increasing its weight, a carbon aerogel is infiltrated into the open pore structure, providing decreased radiant heat transfer. An innovative manufacturing process that involves the wrapping of a carbon fiber phenolic prepreg over a carbon foam/aerogel cylindrical mandrel will be demonstrated under the Phase I effort. Co-carbonization issues such as differential shrinkage between the carbon-carbon and carbon foam will be investigated. Also, characterization of the boundary layers will be performed along with a preliminary economic assessment for scale up.

* information listed above is at the time of submission.

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