SiC Matrix Composite Rocket Thrust Chamber with Integrated SiC Foam Propellant Diffuser/Injector

The feasibility of open-cell reticulated silicon carbide foam as a potential replacement for traditional metallic rocket combustion chamber injectors had been demonstrated in Phase I. Reticulated foams promise to: (1) increase injector performance by improving mixing efficiencies and combustion stability; (2) increase injector reliability by reducing vulnerability to particulate fouling of orifices; (3) decrease manufacturing cost by eliminating the need for precision machining numerous small diameter orifices, thus greatly simplifying fabrication; and (4) significantly decrease weight. The objective of this Phase II program is to demonstrate producing and testing a fully functional reticulated SiC foam injector/thruster assembly which meets the performance requirements for MDA divert propulsion applications. This proposed effort will address detailed propellant injector design and optimization with continued evaluation of the reticulated ceramic foam injector/diffuser concept. Additional foam samples of various porosities and densities will be produced and evaluated to determine their respective liquid and gaseous hydraulic characteristics, specific surface area, and compressive strength properties to access their potential for use in advanced propellant injector designs. Efforts will focus on developing foam diffuser/injector concepts for both bipropellants (including hypergolic) and advanced monopropellants (catalytic). Consistent with MDA's divert propulsion needs, prototype composite DAC thrusters with integrated diffuser/injectors will be produced and hot-fire tested by Aerojet General Corporation.