Lightweight Nozzle Extension for Liquid Rocket Engines

The ARES J-2X requires a large nozzle extension. Currently, a metallic nozzle extension is being considered with carbon-carbon composite as a backup. In Phase 1, Plasma Processes Inc. (PPI), with the support from subcontractor ATK Launch Systems, fabricated, coated and test fired Haynes 230 and domestically produced 2-D carbon-carbon nozzle extensions. The test results show coated carbon-carbon intact and Haynes 230 in need of film cooling and emissivity and, or thermal barrier coatings. Oxide emissivity coating reduced the Haynes 230 wall temperature by 500F. In Phase 2, the primary goal will be to develop the optimum thermal solution for a metallic J2X nozzle extension. Working with Pratt & Whitney Rocketdyne, high emissivity and thermal barrier solutions will be demonstrated on successively larger components until full size capability is demonstrated. A secondary goal is to continue the demonstration of domestically produced 2-D C/C composite nozzle extension materials and oxygen protective liners for use on liquid rocket engines. The team of Plasma Processes, Inc., Pratt & Whitney Rocketdyne and ATK Launch Systems offers the state of the art skill set that is uniquely suited to the Phase 2 program.