THE HIGH MELT COATING SYSTEM IS APPLIED TO A CARBON-CARBON STRUCTURE AND EMBEDS HFC, ZRB2 IN THE OUTER LAYERS. ACC HIGH MELT BUILDS ON THE TIME TESTED BASE MATERIAL SYSTEM OF T-300 FIBERS, IMPREGNATED WITH PHENOLIC RESIN, PYROLYZED, DENSIFIED, AND SIC CONVERSION COATED FOR PHASE 2, C-CAT PROPOSES TO TEAM WITH PRATT AND WHITNEY ROCKETDYNE TO FULLY DEVELOP HIGH MELT INTO A MATERIAL SYSTEM THAT WHEN COMBINED WITH THE APPROPRIATE DESIGN WILL PRODUCE NOZZLE EXTENSIONS FOR FUTURE NASA SPACECRAFT. PWR WILL SUPPLY THE DESIGNS FOR A NOTIONAL NOZZLE EXTENSION FOR A 2000 LBF LOX/LCH4 LUNAR DESCENT ENGINE AND A NOZZLE EXTENSION FOR A NOTIONAL LUNAR ASCENT ENGINE SIZED AT 5500 LBF LOX/LCH4. OBJECTIVES: C-CAT ENGINEERING WILL WORK WITH PWR DESIGNERS TO INSURE THAT THE NOZZLE EXTENSION DESIGN FOR EACH PROTOTYPE IS BOTH MANUFACTURABLE AND WILL MEET THE TECHNICAL REQUIREMENTS. C-CAT ENGINEERING WILL DESIGN AND C-CAT WILL FABRICATE LAY-UP TOOLS THAT WILL TAKE INTO ACCOUNT PLY SHRINKAGE DISTORTION AND STILL MAINTAIN DIMENSIONAL TOLERANCES DURING PROCESSING. LAY-UP THE NOZZLE EXTENSIONS WITHOUT DEFECTS PROCESS EACH NOZZLE EXTENSION THROUGH PYROLYSIS, HEAT TREATMENT AND COATING WITHOUT DEFECTS. APPLY SIC CONVERSION COATING TO THE ACC HIGH MELT MATERIAL WITHOUT SPALLING.