Low-Cost Polymer-Derived Zirconium-Silicate CMC for Rocket Nozzle Applications

NASA has identified a need to reduce weight and cost of cooled composite nozzle ramps. A lightweight actively cooled ceramic matrix composite (CMC) system would be lighter than metallic designs and would require significantly less cooling during re-entry. Composite Factory proposes a zirconium-silicate or Zr-Si-O glass CMC with integral ceramic tubes reinforced with a low cost discontinuous ceramic fiber preform. Integral ceramic composite mounting structure offers potential for a 2.0 lb/ft2 structurally integrated exhaust ramp.The Phase-I project proposes to demonstrate the feasibility of producing an ultra high temperature CMC based on the zirconium-silicate materials currently used in EBC coatings for SiC-SiC CMC¿s. Low cost pre-ceramic polymer CMC manufacturing methods combined with automated low-cost fiber preforming methods will be applied in order to keep both material and processing costs at a minimum. Mechanical test coupons will be fabricated and tested. Phase-II objectives would include design and fabrication of a sub-scale test component to verify durability of the composite structure along with manifolding and hermeticity of coolant channels. The development of a low cost zirconium-silicate matrix would be applicable to turbine engine combustor liners and other commercial engine exhaust components used to mix exhaust gas and reduce noise emissions.