APD proposes to investigate the feasibility of introducing its textile preforming processes for advanced composite materials manufacturing into the processing cycle for carbon phenolic heatshields, to address the need identified by the Navy Strategic Systems Program Office to identify and quantify payoff of processing variations which reduce cost of carbon phenolic reentry body heatshields. Both braiding (2-Dimensional or 3-Dimensional) or net-shape knitting may provide solutions for a more cost effective production. In general textile preforming operations allow for a much more cost effective production of advanced composite structures. APD will use its integrated design for manufacturing approach to assess which textile preforming operation is most suitable. With textile preforming technologies it is also possible to create structures with a high toughness, by introducing through the thickness reinforcements. This may introduce means of controlling the ablative behaviour of the heatshield during reentry and provide for improved impact resistance. It is proposed to do a thorough review of the current material configuration and processing cycle and to start from there the creative process of finding alternative processing methods, including the composite impregnation and consolidation phases. APD will work with Thiokol Corporation, a.o. to assess the suitability of the RTM process. Cost estimations will be made for various alternative processing cycles, to assess which processing variations or alternatives should be further developed in phase II.
