Localized 3-D Fiber Reinforcement in Carbon and Ceramic Composites

This proposal addresses technology for reusable propulsion and vehicle hot structures specified in topic H5.02: Propulsion systems for Commercial Space industry supporting NASA efforts. Upper stage engine systems, such as those for Space Launch System. Lunar/Mars lander descent/ascent propulsion systems. Aerodynamic structures for aeroshells, control surfaces, and leading edges for hypersonic flight vehicles. North Country Composites (NCC) worked with Lancer Systems to adapt their commercial ceramic matrix composite (CMC) manufacturing methods to produce affordable, high performance rocket engine components. The components are showing the ability to operate in highly oxidative and corrosive environments to temperatures above 4000oF for significant periods of time. This is occurring without the use of expensive coatings. Through the utilization of low cost ISO 9001 controlled manufacturing methods, affordable, high performance components can rapidly be transitioned for commercial use. In addition, NCC successfully utilized 3D reinforcements of the fiber preforms to significantly increase (3X) interlaminar strength properties with only a mild decrease in in- plane properties. The high strength, light weight and high temperature capabilities of these structures will significantly increase the performance of space vehicles by increasing the thrust to weight, operational temperatures, and pay-load capabilities. In parallel to the Phase II program, our industrial partner will be performing significant rocket exhaust testing of UHT-CMC components. They, however, will not be generating thermal-mechanical material properties. As a result, NCCs overall Phase II objective is generate material properties over the temperature range from room temperature to at least 4200oF. These properties can then be used in finite element models to optimize the design of CMC component designs. Because this work is completed as an SBIR, the properties will be available to the community at large. North Country Composites (NCC) worked with Lancer Systems to adapt their commercial ceramic matrix composite (CMC) manufacturing methods to produce affordable, high performance rocket engine components. The utra-high temperature (UHT) CMC components operate in highly oxidative and corrosive environments to temperatures above 4000oF. This occurs without the use of expensive coatings. The team successfully adapted the low cost ISO 9001 controlled manufacturing method to produce UHT CMC components. In rocket exhaust impingement testing they should little or no discernable erosion at temperatures above 3600oF during more than 30 minutes of cyclic exposure. In addition, NCC utilized 3D reinforcement of the CMCs to significantly increase (3X) interlaminar strength properties. The high strength, light weight and high temperature capabilities of these structures will significantly increase the performance of space vehicles by increasing the thrust to weight, operational temperatures, and pay-load capabilities. In parallel to the Phase II program, our industrial partner will be performing significant rocket exhaust testing of UHT-CMC components. They, however, will not be generating thermal-mechanical material properties. As a result, NCC’s overall Phase II objective is generate material properties over the temperature range from room temperature to at least 4200F. These properties can then be used in finite element models to optimize the design of UHT-CMC component designs. Because this work is completed as an SBIR, it will be available to the community at large. This will entail completing a thermal-chemical test matrix with testing of multiple samples at six key temperatures within that temperature range. Both mechanical and thermal properties will obtained. Micro-mechanical code will be used to generate the UHT-CMC properties. The NCC team will utilize the materials properties to design a nozzle extension attachment flange to a full scale regeneratively cooled metallic nozzle. NCC will produce these as process demonstrators. The NCC team will determine strength properties of the complex shape components. One will be delivered to NASA for analysis.
Benefits: Human Exploration & Operations Mission Directorate (HEOMD) would benefit by utilizing the technology in spacecraft and launch vehicles to provide improved performance and to enable advanced missions with reusability, increased damage tolerance and durability. Potential NASA users of this technology exist for a variety of propulsion systems, including: Upper stage engine systems, such as those for the Space Launch System. Lunar/Mars lander descent/ascent propulsion systems. Propulsion systems for commercial space companies supporting NASA The CMC technology would be enhancing to systems already in use or under development and enabling for missions that necessitate improved high temperature composite technology. The Air Force is interested in such technology for its Evolved Expendable Launch Vehicle, ballistic missile, and hypersonic vehicle programs. Other non-NASA users include Navy, Army, and the Missile Defense Agency.