Design, Manufacture, and Characterization of a Carbon Fiber‐Reinforced Silicon Carbide Nozzle Extension

Abstract

Nozzle extensions made of ceramic matrix composites (CMCs) have shown the potential to replace heavy superalloy nozzles and improve the performance of future upper‐stage and orbital rocket engines. Gas permeability has been reported to be a critical issue during the manufacture for CMC nozzles. This work shows the manufacture of a dense radiation‐cooled C/C‐SiC nozzle demonstrator. A multi‐angle fiber architecture was applied using filament winding technique to reduce the incidence of delaminations during the manufacturing process under high temperatures. Additional efforts were made to improve the final gas tightness and reduce the amount of residual silicon by means of an adapted liquid silicon infiltration process. The manufacture, the material, and structural characterization as well as a finite element analysis of a performed internal pressure test are presented.

Novel ceramic matrix composites with tungsten and molybdenum fiber reinforcement

“…The application of ceramic matrix composites (CMCs) is highly dependent from the chosen fiber. Carbon fiber reinforced CMCs, such as C/SiC can be used for short time applications such as nozzles or thermal protection systems for aerospace vehicles [1][2][3]. For long time applications in high temperature environments silicon carbide fibers are utilized in SiC/SiC CMCs.…”

Characterization and application of a novel low viscosity polysilazane for the manufacture of C- and SiC-fiber reinforced SiCN ceramic matrix composites by PIP process

“…The application of such composites is highly dependent from the chosen fiber. Carbon fiber reinforced CMCs, like C/SiC usually are developed for friction applications as well as short time applications such as nozzles or thermal protection systems for aerospace vehicles [4][5][6]. Due to the oxidation sensitivity of carbon fibers, these composites are not regarded for long-time applications in high-temperature oxidative environments.…”

“…For the application in jet engines, such CMCs are equipped with additional environmental barrier coatings [7]. Since CVD-SiC coatings have proven to successfully protect in-house manufactured C/C-SiC composites under re-entry conditions, combustion chamber conditions or utilized as nozzle extension, half of the manufactured SiCN based composites were coated with CVD-SiC and compared to those without coating [4,20,21].…”

Evaluation of dynamic modulus measurement for C/C‐SiC composites at different temperatures

“…RFDA is particularly valued for very fast acquisition and processing and moreover for the accurate estimation of flexural modulus, shear modulus, and Poisson's ratio. [10][11][12][13][14][15] Conventionally the flexural modulus of the C/C-SiC materials is experimentally characterized via quasi-static bending tests. 5,6 In order to enhance numerical modeling via Finite Element Method (FEM), the consideration of the flexural modulus of the developed material sample at application temperature is even more profitable.…”

“…Since the middle 1980s, DLR has been developing a cost-efficient production route for CMC materials based on Liquid Silicon infiltration (LSI) 8,9 The resulting C/C-SiC composites allow thin-walled, complex components for example, for aerospace applications as well as thick plates for example, for brake discs. [10][11][12][13][14][15] Conventionally the flexural modulus of the C/C-SiC materials is experimentally characterized via quasi-static bending tests. At high temperatures the mechanical tests must be performed in inert atmosphere in order to prevent oxidation 16 Some typical flexural properties of C/C-SiC materials are given in.…”