Hybrid metal composite structures, rocket motors including hybrid metal composite structures, and related methods

A method of forming an HMC structure, comprising:

• forming an uncured fiber composite material comprising a single tow of fibers substantially aligned with one another in a single direction by infiltrating the single tow of the fibers with an uncured matrix material during at least one filament winding process;
• forming first tiers using the at least one filament winding process, the first tiers comprising portions of the uncured fiber composite material;
• forming second tiers using the at least one filament winding process, the second tiers longitudinally alternating with the first tiers and comprising metallic structures and additional portions of the uncured fiber composite material directly adjacent opposing lateral sides of the metallic structures, each of the metallic structures exhibiting ends laterally offset from corresponding ends of a longitudinally neighboring one of the metallic structures;
• and
• subjecting the first tiers and the second tiers to at least one curing process.

A rocket motor, comprising:

• a casing comprising:
• a first hybrid metal composite (HMC) structure;
• a second HMC structure laterally adjacent to the first HMC structure, each of the first HMC structure and the second HMC structure comprising alternating tiers of metallic structures and fiber composite material structures, each of the metallic structures exhibiting lateral surfaces laterally offset from corresponding lateral surfaces of the metallic structures most longitudinally proximate thereto;
• and
• at least one fastener assembly connecting the first HMC structure to the second HMC structure, the at least one fastener assembly comprising elongate structures individually extending through one of the first HMC structure and the second HMC structure as well as joining structures overlying and underlying the first HMC structure and the second HMC structure;
• a propellant structure within the casing;
• and
• a nozzle assembly connected to an aft end of the casing.