Low Cost, Erosion Resistant Coatings for High Temperature Divert and Attitude Control System (DACS) Structural Insulators

The overall objective of this proposed program extends and increases the performance of MATECHs light-weight, low cost, breakthrough Carbon Fiber reinforced Zirconium Oxy-Carbide ceramic matrix (Cf/ZrOCm) structural insulator with refractory seal coatings for current and future generation threat-interceptor Solid/Throttleable Divert and Attitude Control Systems (SDACS/ TDACS) in Kill Vehicles (KVs). MATECHs ultra-high-temperature, dimensionally stable Cf/ZrOCm structural insulator material, has demonstrated breakthrough performance in missile aero-thermal and propulsion applications according to subject matter experts (SMEs). After performing well in hot fire motor test bed activities, MATECHs silica carbide and Rhenium coated components show promise as a drop in replacement for existing DACS nozzle assemblies. This effort seeks to increase TRL/MRL of coating-substrate pairings and understand margins associated with the successfully hot fire motor tested DACS components with respect to erosion resistance and ultimate survivability. Should this Phase II program be selected for award, MATECH will address all areas appropriate to improving SDACS performance over existing technology including greater temperature capabilities, increased operating durations, material mass reduction, and material stability of coated C/ZrOC by optimizing methods for applying refractory seal coatings on DACS components. Approved for Public Release 15-MDA-8169 (20 March 15)