Domestic Production of Plant-based Carbon Fiber Precursors in Support of Hypersonic Applications

Objective: Develop an environmentally friendly processing method to produce a plant-based carbon fiber precursor for high-temperature applications. Description: Rayon-based carbon fibers remain the choice of material as reinforcement in carbon phenolic composites used as thermal protection systems for hypersonics. Currently, rayon fiber precursors used to make rayon-based carbon fibers are not produced in the United States and are subject to the volatile global market for rayon fibers. Moreover, rayon fibers are vital to other Department of Defense programs, NASA, and commercial space companies due to their proven superior thermal performance over polyacrylonitrile (PAN) and pitch-based carbon fibers [Ref 1]. The production of rayon fibers ceased in the United States in 1997 due to the increased cost associated with environmental concerns from the traditional viscose process to produce rayon fibers. Since then, rayon fiber precursors have been sourced from European textile companies that primarily produce rayon for applications other than as a precursor for carbon fiber. Among the 6.5 million metric tons of rayon fibers produced per year, approximately 1.6-3.2 metric kilotons are rayon fiber precursors used to make carbon fiber [Ref 2]. The global market for rayon is shifting toward a non-toxic process to produce rayon fibers; however, new rayon fibers and other plant-based (cellulose or lignin) fibers have yet to be proven as adequate precursors to produce carbon fibers for thermal protection systems. Therefore, research on environmentally friendly processes to produce a rayon fiber precursor or another plant-based fiber is needed to establish a domestic source of carbon fiber precursor suitable for thermal protection systems. The fiber precursor must be able to be carbonized into a carbon fiber and characterized for structure and properties. Work produced in Phase II may become classified. Note: The prospective contractor(s) must be U.S. owned and operated with no foreign influence as defined by 32 U.S.C. § 2004.20 et seq., National Industrial Security Program Executive Agent and Operating Manual, unless acceptable mitigating procedures can and have been implemented and approved by the Defense Counterintelligence and Security Agency (DCSA) formerly Defense Security Service (DSS). The selected contractor must be able to acquire and maintain a secret level facility and Personnel Security Clearances. This will allow contractor personnel to perform on advanced phases of this project as set forth by DCSA and NAVSEA in order to gain access to classified information pertaining to the national defense of the United States and its allies; this will be an inherent requirement. The selected company will be required to safeguard classified material during the advanced phases of this contract IAW the National Industrial Security Program Operating Manual (NISPOM), which can be found at Title 32, Part 2004.20 of the Code of Federal Regulations. Keywords: Carbon fiber; rayon; carbonization; cellulose; lignin; thermal protection system; hypersonics; ultra high temperature material CMMC Level: Level 2 (Self)