Ultrahigh Temperature Oxidation-Resistant Ceramic Matrix Composites for Rocket Propulsion Components, Phase II

Future Air Force space, missile, and aircraft systems require advanced high temperature materials to meet projected performance requirements. Rocket engine and turbine engine programs such as the IHPRPT and IHPTET initiatives, respectively, are intended to double next-generation propulsion capabilities. Reaching this aggressive goal demands the implementation of high temperature capability, environmentally resistant, lightweight material systems. Prominent among the alternative materials under consideration for such applications are ceramic matrix composites (CMCs). Recent Air Force and NASA programs have considerably progressed the development of CMCs for ~2500 F combustion environments, but additional work is required to extend current CMC capabilities to temperatures >=3500 F. In this project, Ultramet will scale up processes for and fabricate components from an ultrahigh temperature capable CMC using a matrix such as zirconium carbide/silicon carbide or hafnium carbide/ silicon carbide (ZrC/SiC or HfC/SiC) or other composition analogous to Ultramet's Ultra2000TM microlayered HfC/SiC coating system that has previously been shown to be effective for ultrahigh temperature applications. Specifically, an innovative approach to melt infiltration processing, as demonstrated in Phase I, will be used to fabricate test articles and demonstrator components that will be evaluated in representative test environments. The baseline application initially identified for technology demonstration purposes is a monopropellant thrust chamber.