AFRL Develops Carbon-Carbon Rapid Densification Process for Rocket Exit Cone Published May 6, 2008 By Thomas Brown, AFRL/RZOP Propulsion DIrectorate WRIGHT-PATTERON AIR FORCE BASE, Ohio -- AFRL engineers developed an in situ carbon-carbon rapid densification method that has since been applied for the first time to an EM-76 solid rocket exit cone. ATK Launch Systems initially rigidized the exit cone with phenolic. Allcomp, Inc, was then able to use the AFRL-developed process to further densify the cone to aerospace quality in just 5 days. AFRL's in situ process not only takes just 20% of the time that current state-of-the-art methods require, it also saves costs throughout the manufacturing cycle. As a result of this breakthrough, engineers now have an improved materials capability available to consider for applications presently reliant on traditional materials. Due to concerns involving cost, schedule, and manufacturability, the aerospace industry has employed carbon-carbon technology sparingly for many years. AFRL's new in situ rapid densification process increases the viability of using carbon-carbon composites for propulsion systems and other potential applications. Future plans include a test-fire demonstration for evaluating the process-enhanced exit cone's performance.