Improved manufacturing techniques for RF and laser hardening of missile domes. Phase I. Technical report

This report summarizes key results and accomplishements during the first year of a Manufacturing Methods and Technology project to adapt an existing Pacific Northwest Laboratory (PNL) optical coating capability developed for high-power fusion-laser applications to the case of rf and laser hardening of plastic missile domes used by the US Army (MICOM). The primary objective of the first year's work was to demonstrate rf hardening of Hellfire and Copperhead 1.06-micron missile domes by use of transparent conductive Indium Tin Oxide (ITO) coatings. The project thus involved adaptation of a coating material and process developed for flat glass components used in fusion lasers to the case of hemispherical or conical heat-sensitive plastic domes used on laser-guided missiles. Specific ITO coating property goals were an electrical sheet resistance of 10 Ohms/square, a coated-dome transmission of 80% or more at 1.06 micron wavelength (compared to 90% for a bare dome), and good adhesion. The sheet resistance goal of 10 Ohms/square was expected to result in an rf attenuation of 30 dB at the frequencies of importance.