DEVELOPMENT OF MANUFACTURING PROCESSES FOR REINFORCED PLASTIC SOLID PROPELLANT ROCKET NOZZLES.

A large nozzle fabrication process was developed. The process uses a high tension, precisely controlled overwrap to provide the curing pressure ordinarily furnished by means of a hydroclave, autoclave or matched die. The system chosen for development was selected with a major emphasis on maximum mobility. The process requires only the conventional turn table with controlled feed, a simple tensioning device and a heat source for curing. Secondary program events include studies of the effects of density on material performance, tape wrapping experiments, tooling evaluations and the design, fabrication and post-firing evaluation of four subscale nozzles that were produced with the developed technique. During the program, an exit cone for a 120-inch motor nozzle, a complete nozzle for a 156-inch motor and an exit cone for a 260-inch motor nozzle were fabricated by means of the developed process. All were produced at lower total costs than associated with conventional methods, with no sacrifice of reliability, weight or performance. Author