Novel Thermal Barrier Coating for Nozzle Exit Cone Insulators

High performance solid and liquid propulsion systems are subject to severe operating conditions and are required to perform at appreciably higher use-temperatures. Rocket nozzles must withstand an extremely rapid temperature increase in a highly corrosive atmosphere while maintaining a high degree of integrity. Current nozzles are often made from a variety of metal alloys, carbon-carbon or carbon phenolic composites, which are able to withstand high temperature and pressure environments. However, the phenolic nozzle exit cones typically experience extreme heat during operation and lead to premature failure of the bond line joints and housing components during firing and heat soak. This effect is more pronounced in the dual pulse rocket motors where additional heat soak is experienced due to presence of Inter Pulse Delay (IPD). The additional delay results into extra heat soak there by possible damaging the housing components such as flex bearing. In order to address these aspects, in this phase I proposal we intend to develop novel high temperature thermal barrier coatings using integrated metal bond layer and thermal barrier ceramic top layer technology on Carbon Cloth Phenolic base material.