Abstract: A valve includes a valve body and a free floating poppet. The valve body includes an inlet, an outlet, and a fluid flow passage therebetween. The free floating poppet is disposed in the valve body, and is moveable between at least a closed position, in which the free floating poppet at least substantially restricts fluid from flowing through the fluid flow passage, and an open position, in which fluid is allowed to flow through the fluid flow passage. The free floating poppet includes a base section and a cutback section. The base section has a first cross sectional area. The cutback section has a second cross sectional area that is less than the first cross sectional area.

Abstract: A cured ablative composite assembly comprises a housing enclosing a pair of ablative composite sub-assemblies joined by a film adhesive. The cured ablative composite assembly is made by surface treating both ablative composite sub-assemblies in preparation for joining; coupling one ablative composite sub-assembly to another ablative composite sub-assembly with a film adhesive and enclosing the uncured ablative composite assembly within a housing; and depositing the combination of the housing and uncured ablative composite assembly in a ventilated oven with a load applied to the combination housing and uncured ablative composite assembly. The film adhesive is cured providing a portion of a hot gas valve suitable for use in tactical missiles. The film adhesive does not erode at the high temperatures (5000° F.) encountered in hot gas rocket exhausts, thereby providing a seal that offers high strength, pressure-tight joints.

Abstract: A method is provided for manufacturing a missile component for use in a high temperature environment, where the missile component has a flow passage therethrough and the flow passage has a shape. An apparatus manufactured by the inventive method is provided as well. The method includes the steps of depositing a first metal onto a mandrel having the shape of the flow passage to create a first metal layer, applying an insulating material on to the first metal layer to create an insulating layer, machining a predetermined shape into at least a portion of the insulating layer, and applying a second metal onto the machined insulating layer to create an outer shell layer.

Abstract: A solid rocket motor including a combustion chamber, in which propellant is ignited to produce combustion gas, and a nozzle having a throat with an effective flow area, implements a system and method to inject gas into the nozzle throat to control its effective cross sectional flow area. Controlling the effective cross sectional flow area of the nozzle throat in turn controls combustion chamber pressure, thus the burn rate of the propellant in the combustion chamber, and thus the thrust generated thereby.

Abstract: A valve includes a valve body and a free floating poppet. The valve body includes an inlet, an outlet, and a fluid flow passage therebetween. The free floating poppet is disposed in the valve body, and is moveable between at least a closed position, in which the free floating poppet at least substantially restricts fluid from flowing through the fluid flow passage, and an open position, in which fluid is allowed to flow through the fluid flow passage. The free floating poppet includes a base section and a cutback section. The base section has a first cross sectional area. The cutback section has a second cross sectional area that is less than the first cross sectional area.

Abstract: A nozzle for use in a hot gas valve is provided that includes a housing, an insert, and a throat retainer. The housing is constructed of an insulating material and has a flow path formed therein. The flow path has a throat section. The insert is made of material capable of maintaining structural integrity at a temperature up to about 5000° F. and is disposed at least partially in the throat section and has a flow path extending therethrough in fluid communication with the housing flow path. The throat retainer is constructed of material having insulating and ablative properties and is coupled between the housing and the insert and configured to retain the insert within the housing throat section.

Abstract: A nozzle for use in a hot gas valve is provided that includes a housing, an insert, and a throat retainer. The housing is constructed of an insulating material and has a flow path formed therein. The flow path has a throat section. The insert is made of material capable of maintaining structural integrity at a temperature up to about 5000° F. and is disposed at least partially in the throat section and has a flow path extending therethrough in fluid communication with the housing flow path. The throat retainer is constructed of material having insulating and ablative properties and is coupled between the housing and the insert and configured to retain the insert within the housing throat section.

Abstract: A method is provided for fabricating a missile component having a flow path therein. The resulting component is a phenolic laminate constructed of layers having cavities formed therein. The method includes bonding a plurality of phenolic laminates to one another in a predetermined order and in a predetermined configuration, each phenolic laminate having a cavity formed therein, wherein the bonded phenolic laminates form the missile component and the cavities define the flow path.

Abstract: A solid rocket motor including a combustion chamber, in which propellant is ignited to produce combustion gas, and a nozzle having a throat with an effective flow area, implements a system and method to inject gas into the nozzle throat to control its effective cross sectional flow area. Controlling the effective cross sectional flow area of the nozzle throat in turn controls combustion chamber pressure, thus the burn rate of the propellant in the combustion chamber, and thus the thrust generated thereby.

Abstract: A method is provided for manufacturing a missile component for use in a high temperature environment, where the missile component has a flow passage therethrough and the flow passage has a shape. An apparatus manufactured by the inventive method is provided as well. The method includes the steps of depositing a first metal onto a mandrel having the shape of the flow passage to create a first metal layer, applying an insulating material on to the first metal layer to create an insulating layer, machining a predetermined shape into at least a portion of the insulating layer, and applying a second metal onto the machined insulating layer to create an outer shell layer.

Abstract: A cured ablative composite assembly comprises a housing enclosing a pair of ablative composite sub-assemblies joined by a film adhesive. The cured ablative composite assembly is made by surface treating both ablative composite sub-assemblies in preparation for joining; coupling one ablative composite sub-assembly to another ablative composite sub-assembly with a film adhesive and enclosing the uncured ablative composite assembly within a housing; and depositing the combination of the housing and uncured ablative composite assembly in a ventilated oven with a load applied to the combination housing and uncured ablative composite assembly. The film adhesive is cured providing a portion of a hot gas valve suitable for use in tactical missiles. The film adhesive does not erode at the high temperatures (5000° F.) encountered in hot gas rocket exhausts, thereby providing a seal that offers high strength, pressure-tight joints.

Abstract: A valve is disclosed for use in hot gas applications such as in rocket or missile engine systems or the like. The valve is designed to withstand the extreme temperatures encountered in the gas exhaust from rocket propellants. The valve seat of the valve is constructed of fibrous monolith ceramic. This material does not degrade significantly when rocket exhaust, such as resulting when ammonium perchlorate propellant is burned, is ported through the valve. The valve generally includes a valve body, a valve seat, through which gases may pass, and a poppet which opens and closes the valve by pressing against and moving away from the valve seat.