MDA27BZ02-DV007 — Low Cost / Rapidly Producible Booster Insulation Methods

This topic will develop affordable, scalable, high production rate insulation technologies for solid rocket motors.

Solid propellant rockets use insulation to protect motor cases from the high temperature combustion gases and, in the case of composite cases, prevent egress of gases. Heritage methods for insulating motor cases utilize filled polymers with low thermal conductivities which absorb heat as they decompose. The insulation layer is typically applied through time consuming processes on custom mandrels which require significant manual labor. The Government seeks novel insulation material/processing technologies which reduce insulation processing time and/or cost compared to legacy processes for a variety of motor case geometries and sizes. The primary motor case materials of interest for this solicitation are polymer matrix composites, though applicability to metallic cases is also desirable. Proposals developing reusable or low-cost consumable mandrels which can be easily and quickly removed after insulation lay-up and winding are also of interest. The proposed insulation solution must consider stress limitations in the propellant with variations in temperature during storage and operation. The proposed insulation technology should also meet or exceed the insulating ability of the current state of the art with equal or lower inert mass with an increased production rate and/or lower per unit price.

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 Technology Readiness Level (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: 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).

Produce subscale insulated cases with novel, scalable insulation technology, and characterize the erosion rate compared to the current state of the art in sub-scale motor tests with relevant motor propellants. Show that the proposed insulation should meet a 20-year storage life as well as storage conditions as low as -40 °C. The proposed insulation technology must demonstrate adequate adhesion to the propellant to survive storage and operating conditions. The proposal for novel insulation technology must include thermal conductivity and other relevant material characterization. Proposals incorporating novel mandrel technologies must show that motors incorporating the technology can achieve thrust misalignment of less than 1°.

Partner with a propulsion manufacturer to insulate and static test full size motors with a variety of propellants.