New Method for Producing Ultra-Strong Rocket Composites: Reducing Time from Months to Days

Rocket Nozzles and Hypersonics: A Revolutionary Way to Create Ultra-Strong Composites Developed

According to НВ — Техно: On September 7, 12:12. Engineers from the Applied Physics Laboratory at Johns Hopkins University have developed the FAST CAR2 technology, which allows for the production of ultra-strong and heat-resistant carbon-carbon composites in just days. Previously, this process took months. The carbon material is embedded directly into the fiber preform, after which the preform is sintered with electrical current under high pressure. The densification itself takes several minutes, significantly reducing the cost of producing components for the aerospace and defense industries.

Carbon-carbon composites consist of carbon fibers embedded in a solid carbon matrix. They are lightweight, strong, and can withstand very high temperatures, making them essential for:

• rocket nozzles,
• hypersonic vehicles,
• aviation brakes,
• thermal shields for space probes.

This type of protection is used, for instance, on NASA's Parker Solar Probe.

The traditional method required a long process of filling microscopic voids with gas or multiple resin impregnations followed by burning out. In contrast, the new process significantly speeds up the production of the material.

“Speed is what makes this approach attractive: it opens the way to efficient manufacturing of modern materials for high-load systems,” explains program director Sal Nimer.

Engineer William Fahey adds: “Without carbon-carbon composites, it is impossible to protect devices from extreme heating during hypersonic flight. The most challenging stage is scaling up, but the results achieved give grounds for optimism.”

Currently, developers, along with external partners, are working on using larger presses to manufacture larger parts with complex profiles. The FAST CAR2 technology has the potential to significantly impact the aerospace and defense industries, providing both speed and economic efficiency. Accelerating such production is critically important for projects where long material creation cycles hinder the development of new rockets and advanced aircraft.

As the aerospace industry continues to innovate, advancements in material production are crucial. In a related development, researchers are exploring how more affordable 3D printing methods for rocket alloys could complement these new composite technologies. This synergy could lead to even greater efficiencies and cost savings in the manufacturing of aerospace components.