An innovative concept for regeneratively cooled ceramic matrix composite propulsion components has been developed. ESLI’s flocking technology for attaching fibers to

substrates has been used to demonstrate the feasibility of fabricating 3D cooled composite structures consisting of carbon and silicon carbide.

INNOVATION

Energy Science Laboratories, Inc.San Diego, CA

SmallBusinessInnovation Research

GOVERNMENT/SCIENCE APPLICATIONS Numerous potential NASA launch vehicle applications exist for the

use of actively cooled fintube ceramic matrix composites. Rocket propulsion component applications include: cooled panels for rocket-based combined cycle systems, cooled nozzles and ramps, and cooled thrust cells. The technology could also be applied to actively cooled thermal protection systems for high-heat flux regions such as leading edges.

This actively cooled composite technology could also be used in Department of Defense launch and in-space vehicles, and in Department of Energy power generation fusion tokamaks.

Marshall Space Flight CenterFY99 Subtopic: 3.04, Light-Weight Engine ComponentsDate: April 2001

Regeneratively Cooled Composite Structure for Lightweight Engines

ACCOMPLISHMENTS Assessment of fintube composite structures indicated that X-33 aerospike nozzle

ramp design requirements could be met.

Thermostructural analyses showed aerospike ramp thermal stresses could be feasibly managed with all silicon carbide composite structures or silicon carbide structures with glassy carbon tubing.

Cooled panel structures were fabricated to demonstrate the ceramic matrix composite materials concept.

Through mechanical and heat transfer testing, the low-density fintube concept was shown to meet the thermal conductivity requirements necessary for an actively cooled composite structure such as the X-33 nozzle ramp.

While further development is necessary, the SBIR program has enabled the feasibility of the innovative composite fintube concept to be demonstrated in a cost-effective manner.

COMMERCIALIZATION While the technology needs to be further developed, many applications of this

technology should be possible. Fintube ceramic matrix composites of the type examined in this SBIR are being considered for possible inclusion in high-temperature propulsion systems currently being developed by several major aerospace companies.

Where heat removal is important and the use temperature is not as severe as in rocket propulsion applications, high-conductivity polymer or metal matrix composites should be feasible. MSFC Contact: Tom Knight, 256-544-5353

MSFC Technical POC: Peter G. Valentine, 256-544-2837ESLI Contact: Dr. Timothy R. Knowles, 858-552-2034

1999 Phase I, NAS8-00080

Left: Composite structures, each containing 23 cooling tubes.

Right: 3-tube composite fintube structure.