Northrop Grumman Systems Corporation

Northrop Grumman Innovation Systems, Inc.

Alliant Techsystems Inc.

Thiokol Corporation

David R Nelson

Benjamin W C Garcia

Brian Russell Christensen

Marcus A Darais

Elizabeth K Bonderson

Darrel G Turner

Braden Day

Roger D Wright

James A Yorgason

Alan J Loveless

Dean C Youngkeit

Thomas Loveless

A multi-component structure includes a first hybrid metal composite structure, a second hybrid metal composite structure, and a joint structure. The first and second hybrid metal composite structures include layers, each layer comprising a fiber composite material structure including a fiber material dispersed within a matrix material and at least one metal ply located between layers of the layers. The joint structure extends between and connects the first hybrid metal composite structure and the second hybrid metal composite structure. Additionally, the joint structure exerts a clamping force on the first and second hybrid metal composite structures and to reduce gaps between the layers, between the layers and the at least one metal ply, and between the joint structure and the first and second hybrid metal composite structures to less than half a thickness of the at least one metal ply.

Hybrid metal composite structures, joint structures, and related methods

A preceramic resin formulation comprising a polycarbosilane preceramic polymer, an organically modified silicon dioxide preceramic polymer, and, optionally, at least one filler. The preceramic resin formulation is formulated to exhibit a viscosity of from about 1,000 cP at about 25&#xb0; C. to about 5,000 cP at a temperature of about 25&#xb0; C. The at least one filler comprises first particles having an average mean diameter of less than about 1.0 &#x3bc;m and second particles having an average mean diameter of from about 1.5 &#x3bc;m to about 5 &#x3bc;m. Impregnated fibers comprising the preceramic resin formulation are also disclosed, as is a composite material comprising a reaction product of the polycarbosilane preceramic polymer, organically modified silicon dioxide preceramic polymer, and the at least one filler. Methods of forming a ceramic matrix composite are also disclosed.

Impregnated fibers comprising preceramic resin formulations, and related composite materials and methods

A hybrid metal composite (HMC) structure comprises a first tier comprising a first fiber composite material structure, a second tier longitudinally adjacent the first tier and comprising a first metallic structure and a second fiber composite material structure laterally adjacent the first metallic structure, a third tier longitudinally adjacent the second tier and comprising a third fiber composite material structure, and a fourth tier longitudinally adjacent the third tier and comprising a second metallic structure and a fourth fiber composite material structure laterally adjacent the second metallic structure. At least one lateral end of the second metallic structure is laterally offset from at least one lateral end of the first metallic structure most proximate thereto. Methods of forming an HMC structure, and related rocket motors and multi-stage rocket motor assemblies are also disclosed.

Hybrid metal composite structures, rocket motors including hybrid metal composite structures, and related methods

A hybrid metal composite (HMC) structure comprises tiers comprising fiber composite material structures, and additional tiers longitudinally adjacent one or more of the tiers and comprising perforated metallic structures and additional fiber composite material structures laterally adjacent the perforated metallic structures. Methods of forming an HMC structure, and related rocket motors and multi-stage rocket motor assemblies are also disclosed.

Hybrid metal composite structures, rocket motors and multi stage rocket motor assemblies including hybrid metal composite structures, and related methods

Preceramic resin formulations, impregnated fibers comprising the preceramic resin formulations, and related methods

A method of forming a hybrid metal composite structure including at least one metal ply. The method includes forming at least one metal ply, forming the at least one metal ply comprising forming at least one perforation in the at least one metal ply, abrasively blasting at least one surface of the at least one metal ply to coarsen the at least one surface of the metal ply, and exposing the at least one metal ply to at least one of an acid or a base. The method further includes disposing at least one fiber composite material structure adjacent the at least one metal ply. Related methods of forming a portion of a rocket case and related hybrid metal composite structures are also disclosed.

Hybrid metal composite structures, rocket cases, and related methods

Pressure vessel end dome reinforcements are placed upon resin-impregnated fiber-wound pressure vessels to improve the strength-to-weight ratio of high performance pressure vessels, such as those that are used as rocket motors, gas generators, and the like. The reinforcement structures are assembled from gore pieces to form gore bodies over dome regions of the pressure vessels.

Apparatus and method for reinforcing a pressure vessel

A process and equipment for making seamless composite tubes. Composite material is applied on a mandrel which includes an inflatable bladder and inserted in a single piece mold. The bladder is pressurized for pressing the composite material against the mold wall for molding and curing thereof. In order to prevent seizing of the tube by the mold and thus allow easy removal of the cured tube, the mold is composed of a composite of resin impregnated carbon fiber material wherein the carbon fiber material has a negative coefficient of thermal expansion along the length thereof and is oriented at an angle of between about 15 and 40 degrees relative to a radial plane of the mold. In order to eliminate the use of inefficient and inconvenient cure ovens, a heat generating element is disposed internally of the mandrel for curing of the composite material.

Growing community of inventors

Logan, UT, United States of America

David R Nelson