Abstract: A process for manufacturing metal and ceramic matrix composite materials. The invention also encompasses various composite products made by the disclosed method. The resulting composite material comprises a reinforcement material in either continuous or discrete form embedded in a matrix material which is either a pure metal, a metal alloy, or a ceramic. The reinforcing material is optionally coated with a barrier coating material. An electric arc or plasma arc is used to spray a thin layer of matrix material over a preplaced layer of reinforcement material. Successive layers are built up until a desired object shape and thickness are achieved. There is an optional final step of high-temperature diffusion annealing or hot isostatic pressing.

Abstract: An exhaust gas management system for missile launch arrangements which incorporates multiple launch cells exhausting into a common plenum. The system provides a flow passage configuration with a transition section that permits rocket exhaust flow gas to expand to fill the channel area downstream of the nozzle exit. Automatic aft closure members are included which serve to close off the flow passages to inactive cells while providing an open passage for exhaust gases from an active cell undergoing a missile firing. This arrangement prevents back flow or recirculation of exhaust gases into the volume in the cell which is upstream of the rocket nozzle exit.

Abstract: A method is presented for the accurate quantitative determination of amounts of reactive (water and ethanol) and non-reactive N-methyl-2-pyrrolidone (NMP) volatiles in graphite-polyimide prepreg samples. The method is also applicable to other condensation-curing and/or solvent-impregnated prepreg systems, regardless of the type of reinforcement. Prepreg samples are heated in a containment chamber and the volatiles are subsequently flushed from the chamber with dry nitrogen gas. The volatiles are condensed, weighed, and analyzed via gas chromatography to determine the volatile composition. The method offers a means of purging the extremely tightly held, relatively non-volatile NMP solvent from the resin matrix by means of high temperatures applied to the sample chamber. The higher volatility reaction products are also captured by means of the specially designed very low temperature condenser. An internal check (collection efficiency) on the accuracy of the results is included in the test method.

Abstract: A pre-stressed cartridge of the invention generally comprises a cylindrical liner wrapped with a plurality of layers of wound fibers or high tensile wires. These high tension wrapped windings put the walls of the cartridge liner into compression, thus pre-stressing the cylindrical liner. A cartridge constructed in this fashion may develop an ultimate strength in the circumferential direction which approaches ten times the ultimate strength of a typical solid metal cylinder alone. Special reinforcing elements may also be provided, located at the points where the maximum stress is developed upon detonation. Various modifications of this structure include fabricating the liner out of ceramic instead of aluminum, incorporating a steel cup containing the explosive at the base of the internal space of the cartridge, and combining the composite windings with the steel cup to provide a cartridge consisting of a steel cup with the rest of the cartridge being composite fiber windings.

Abstract: A structural arrangement is provided in conjunction with the upper closure of a missile cell which, upon launch of the missile, generates a rarefaction wave which assists in closing the bottom closure of the missile cell. As a result, reverse flow of exhaust gases back up into the missile chamber from an associated plenum chamber is prevented or minimized.

Abstract: An exhaust gas management system for missile launch arrangements having multiple launch cells exhausting into a common plenum includes automatic aft closure members which serve to close off the flow passages to inactive cells while providing an open passage for exhaust gases from an active cell undergoing a missile firing. This arrangement prevents back flow or recirculation of exhaust gases into the volume in the cell which is upstream of the rocket nozzle exit.

Abstract: A carbon composite tensile test specimen for high temperature testing and a method of fabricating the same are disclosed. A plurality of holes are drilled in first and second end sections of the specimen and then the end sections are electroplated with nickel. The nickel plating of the end sections prevents breakage of the ends in the jaws of a tensile testing apparatus. For high-temperature testing, a standard-sized specimen may be used with the jaws in the hot zone.

Abstract: A method for manufacturing a probe test structure for microcircuits utilizes a multiple coating method in conjunction with a novel double-cell electroplating apparatus having a relatively high-resistance ion path between the cells. Photoresist is applied to both sides of a copper foil, copper posts are electroformed onto selected areas of one side of the foil through image hole patterns, the remaining photoresist is stripped away, polyimide prepreg is laminated to the post side of the foil, the copper posts are exposed by sanding, photoresist is reapplied to both sides of the sanded remainder, additional copper is electroformed on each post through image hole patterns in the post side of the photoresist, the foil on the side opposite the posts is chemically milled to provide leads integral with each post using appropriate masking techniques and, finally, all of the remaining photoresist is removed to leave the desired test probe set.

Abstract: A safety harness for use with an electrostatic spray paint gun is disclosed which fits over the feed tube and the barrel of a standard electrostatic spray gun and acts both to protect the hand of the spray gun operator from an electrostatic discharge and to provide an indication of the electrostatic operation of the spray gun. A T-shaped safety shield made of non-conductive material is placed over the portions of the spray gun which may develop an electrostatic charge thereon, and is held onto the spray gun by mating strips of material. Located on the inner surface of the safety shield is a thin sheet of conductive foil which acts to channel the discharge through a wire to illuminate an indicator light located remote from the spray gun in a highly visible position.

Abstract: A notched cartridge or casing is provided to mitigate the shock damage to a gun barrel or firing chamber when a cartridge with large amounts of explosive or propellant is fired. The cartridge or casing comprising a generally cylindrical shell with an open top end and a closed base is provided with an annular area near the base and a circular area on the base which have reduced wall thicknesses compared to the rest of the cartridge. The annular and circular areas have external surfaces which are inwardly displaced with respect to the outer surface of the remainder of the cartridge. Upon firing of the cartridge, the areas of reduced wall thickness expand outwardly and are plastically deformed without touching the barrel or firing chamber. Damage to the barrel and/or breech is prevented and the cartridge is easily removed for reloading of the gun system.

Abstract: A lateral thruster for missiles is provided which comprises two or more individually rotatable thruster motors with integral nozzles. If the thrusters are located at or near the center of gravity of the missile, the missile can be maneuvered while it remains pointed at the target. Locating the thrusters forward or aft of the missile center of gravity enables steering forces as well as lateral translational and roll forces to be provided. The thruster motors need not be disposed in pairs. The use of integral nozzles obviates sealing problems and allows mountings that permit rapid rotation of the thruster motors to improve missile response time. The lateral thruster disclosed is effective at nearly all aerodynamic angles of attack, missile velocities, and altitudes. The thruster as a unit is enclosed by a shroud that blends into the missile body contour. Possible propellants for the thruster motors include solid propellants and compressed gases.

Abstract: An electronic digital system for performing discrete Fourier transforms in real time. Read only memory (ROM) modules are used as look-up tables for providing inputs for multiplier stages corresponding to sequences of sample signals as well as for logic and other input converting elements of the system. Two such systems are coupled together so that their real and imaginary output signal components may be additively and subtractively combined. The entire transform output is available one cycle period after the last sample input.

Abstract: An expandable telescoped airframe for a missile provides a shorter configuration for convenience in handling and a longer configuration to provide added predetermined clearance in front of a shaped charge warhead after launch. The airframe is mechanically locked into its extended configuration upon deployment of its expansion feature by means of a wedge brake collar. Possible deployment means include gas pressure, one or more springs, and a drogue parachute. Tail and other control surfaces spring open after clearing the airframe tube to provide aerodynamic stability.

Abstract: An apparatus and method are described for electroplating surfaces. The apparatus reduces the anode effect on current density, and is therefore particularly suitable for copper or nickel plating of fine-line metal circuitry. Current density regulation is achieved by separating the anode and cathode into separate cells and achieving electrolyte communication between the cells by providing a relatively high-impedance ion path. The preferred embodiment includes a siphon tube as an ion path and a pump and filter in a separate path to maintain electrolyte circulation between the cells.

Abstract: A condensing apparatus is provided which can be used in gas chromatography measurements to determine N-methyl-2-pyrrolidone (NMP) content in polyimide prepreg. The condenser comprises a straight vertical section of thin-walled copper tubing followed by an ascending helical coil surrounding the straight section. The condenser is equipped with valves at the inlet and outlet which are capable of withstanding the combination of high and low temperatures as well as being resistant to damage by aggressive solvents. Liquid condensate accumulates at the bottom of the coil, making decanting easy. The condenser apparatus of the present invention yields very high collection efficiencies for volatile mixtures with a very wide range of boiling points. The condenser is very compact and lightweight and does not require any packing insulation to achieve the high collection efficiencies. Maintenance and cleaning are greatly simplified by the absence of packing.

Abstract: A method is disclosed for creating a strong point for the attachment of carbon composites to metallic bodies that is suitable at high temperatures (1600.degree. F.) as well as ambient temperatures. A pocket of suitable dimensions and depth is molded into the carbon composite structure on both sides at an edge, with the edge relieved and rounded. A hole for a fastening member is molded or drilled in the approximate center of the pocket. After preparation of the surface the pocket, through hole, and relieved edge are nickel-plated to produce a rigid strong point. A doubler can be brazed to the nickel plate to strengthen the bond. The disclosed method can be used for attaching any type of electrically conductive composite material to a metallic structure.