scope:

Practice:

Fabrication of ablative composite materials for solid rocket motor nozzles requires a precision, integrated, multi-disciplinary, multivendor approach to design and manufacture. Creation of the material requires stringent process controls during manufacture of the rayon fiber, weaving the rayon fiber into cloth, carbonizing the rayon cloth, impregnation of carbon cloth with resin and filler, wrapping the carbon-phenolic onto a mandrel to the proper thickness, curing, nondestructive inspection and final machining to the designed configuration. Environmental conditions and cleanliness levels must be closely monitored when bonding the ablative material to the metal housing. The critical material properties for acceptance of carbon cloth-phenolic prepreg material are cloth content, dry resin solids content, volatile content, carbon filler content, and resin flow. Use of certified and highly skilled tape wrapping operators, bonding technicians, machinists, and destructive and nondestructive testing personnel, is a must.