Composite/metal hybrid rocket motor case and methods for manufacturing

A process for manufacturing a case for a rocket motor, comprising the steps of:

• obtaining a sheet of continuous, unidirectional fiber reinforcement which has been pre-impregnated with an uncured, thermoset resin;
• rolling the sheet of fiber reinforcement about a mandrel;
• repeating said obtaining and said rolling steps to form a generally cylindrically shaped liner reinforced with discontinuous fibers;
• obtaining a generally cylindrically shaped metal shell;
• forming a plurality of apertures in the metal shell;
• inserting the liner into the metal shell;
• forcing the liner against the metal shell;
• heating the liner to a predetermined temperature;
• and
• curing the liner while maintaining the liner forced against the metal shell and maintaining the liner at the predetermined temperature, thereby bonding the liner to the metal shell.