Method of constructing insulated metal dome structure for a rocket motor

A method of constructing an internally insulated metal dome structure of an open-ended rocket motor, comprising:

• disposing a shear-ply layer formed of a preselected elastomeric material onto at least a selected portion of an inner surface of a longitudinally extending dome structure;
• curing and bonding the shear-ply layer to the at least a selected portion of the inner surface of the dome structure;
• preforming a first dome insulator of a phenolic composite material comprising fibers impregnated with a preselected curable resin and generally having an outer surface and an inner surface;
• precuring the first dome insulator;
• machining at least a portion of the first dome insulator;
• positioning and bonding the machined at least a portion of the first dome insulator onto a selected portion of an inner surface of the shear-ply layer, the first dome insulator positioned and bonded onto the inner surface of the shear-ply layer such that the shear-ply layer extends slightly forward of the first dome insulator;
• forming in situ a second dome insulator onto at least a portion of the inner surface of the dome structure and onto at least a portion of the inner surface of the shear-ply layer longitudinally proximate to the first dome insulator by laying up a sheet material comprising a curable rubber, a flame retardant, a phenolic resin, and at least one curing system constituent;
• and
• bonding the second dome insulator onto at least a portion of the inner surface of the dome structure and onto at least a portion of the inner surface of the shear-ply layer.