Carbon-Carbon (C-C) Composites for Dual-Use Aerospace and Commercial Applications

Materials and Electrochemical Research (MER) Corporation

Tucson, AZ

Carbon matrix precursors are coupled with molding operations that permit one- to two-step processing to produce high-density C-C composites. Typical state-of-the-art processing requires up to ten reimpregnation steps.

• The one- to two-step process can reduce C-C composites to well under $50/lb.compared to prices of several hundreds to thousands of dollars per pound for conventional C-C composites.

• The low cost C-C composite process has been applied to fabricating components for a variety of applications. The applications include aerospace components for reusable launch vehicles, leading edges, rocket/missile nozzles, and automotive components for engines and friction components. These include valves, blocks and pistons, brakes and clutches.
• Economical C-C composite prescursors for reinfiltration with metals are utilized for the same aerospace and automotive applications as well as thermal management materials for electronics and heat exchangers.
• MER has invested significant capital of its own in the technology. MER’s capital, plus additional private capital has lead to joint ventures and consortiums for producing C-C components in transportation.

• The low cost C-C composite technology has led to other government-sponsored R&D contracts for rocket nozzles, thermal management, controlled low-expansion materials and fusion energy applications.
• Ultra lightweight space application components for Gossamer and other programs such as solar sails.

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