Bore Insulator Materials for a Naval Electromagnetic Launcher Navy SBIR FY2004.1 Sol No.: Navy SBIR FY2004.1 Topic No.: N04-045 Topic Title: Bore Insulator Materials for a Naval Electromagnetic Launcher Proposal No.: N041-045-0 Firm: Fiber Materials, Inc. 5 Morin Street Biddeford, Maine 04005 Contact: Stan Farrell Phone: (207) 282-5911 Web Site: www.fibermaterialsinc.com Abstract: Electromagnetic rail launchers are being designed for future long range naval surface fire support. These projectile launchers operate due to the interaction between the magnetic field and current flow between parallel conductive rails. An electric current accelerates a projectile down the barrel at hypersonic velocities. A high strength insulator is required to separate the energized launcher rails and keep them in position while being subjected to the large temperature fluctuations and mechanical forces. Current laboratory EM launcher insulator materials fail due to inadequate toughness, temperature capability, and wear resistance. Not only are materials required that demonstrate the necessary performance in this unique environment, they also must be manufactured in the necessary size for the application. FMI, with support from Lockheed Martin Missiles and Fire Control-Dallas, proposes to develop a new material capable of being produced as large composite bore insulators, with properties sufficient to withstand the electrical, thermal, and mechanical load expected during use. The composite material will utilize a silica pierced fabric preform partially densified via impregnation with colloidal silica, SiO2. After multiple impregnations with the silica, a high temperature polymer (Tg >500 C) will complete the densification and close off any remaining open porosity. Benefits: EM launchers will potentially be used by all segments of the military. Beside the U.S. Navy, the U.S Air Force, U.S. Army, and NASA are investigating electromagnetic launcher applications. Because the manufacturing approach envisioned by FMI will be versatile, different shapes and lengths can be designed and manufactured to meet individual service needs. As electromagnetic launcher systems improve allowing higher velocities and firing rates, the stresses imposed on the bore insulator will increase. This amplifies the need for a high performance bore insulator such as the one proposed by FMI. The final product will have excellent high temperature and dielectric properties that will make the material useful in many commercial activities. Marketing possibilities will include the aerospace, electrical, computer, and other composites industries. The material will be marketed as a high quality electrical insulation material because of its high resistivity, high toughness, and high temperature resistance. Specific products envisioned include high performance electrical circuit boards, electrical insulators in high speed mag-lev applications, space launch systems based upon magnetic launchers, and thermal insulators in space vehicles. Return