The United States of America As Represented by the Administrator of the

Robert R Johnson

Harold G Bush

Raymond M Bluck

A process for producing seamless metal-clad composite structures includes providing a hollow, metallic inner member and an outer sleeve to surround the inner member and define an inner space therebetween. A plurality of continuous reinforcing fibers is attached to the distal end of the outside diameter of the inner member, and the inner member is then introduced, distal end first, into one end of the outer sleeve. The inner member is then moved, distal end first, into the outer sleeve until the inner member is completely enveloped by the outer sleeve. A liquid matrix material is then injected into the space containing the reinforcing fibers between the inner member and the outer sleeve. Next a pressurized heat transfer medium is passed through the inner member to cure the liquid matrix material. Finally, the wall thicknesses of both the inner member and the outer sleeve are reduced to desired dimensions by chemical etching, which adjusts the thermal expansion coefficient of the metal-clad composite structure to a desired value.

Process for the manufacture of seamless metal-clad fiber-reinforced

A metallic outer sleeve 10 is provided which is capable of enveloping a hollow metallic inner member 12 having continuous reinforcing fibers 14 attached to the distal end thereof. Inner member 12 is then introduced into outer sleeve 10 until inner member 12 is completely enveloped by outer sleeve 10. A liquid matrix member 20 is then injected into space 22 between inner member 12 and outer sleeve 10. A pressurized heat transfer medium 23 is flowed through the inside of inner member 12, thereby forming a fiber reinforced matrix composite material 26. The wall thicknesses of both inner member 12 and outer sleeve 10 are then reduced to the appropriate size by chemical etching, to adjust the thermal expansion coefficient of the metal-clad composite structure 28 to the desired value.

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Saratoga, CA, United States of America

Robert R Johnson