Development of short fiber C/C-SiC material for rocket nozzle applications
Manufacturing analysis and material characterisation for a CMC nozzle prototype
Y.J. van Haaren (TU Delft - Aerospace Engineering)
O.K. Bergsma – Mentor (TU Delft - Structural Integrity & Composites)
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Abstract
C/C-SiC is a type of ceramic matrix composite, which consists of a silicon carbide matrix phase, combined with reinforcing carbon fibres. This material has high specific strength and stiffness, good damage tolerance, as well as excellent thermal properties. It is commonly applied in environments where these properties are utilized, such as thermal protection systems, engine components and refractory industry parts. Thus, also rocket nozzles, which contain a highly mechanically and thermally stressed environment. This thesis aims to add to the research on C/C-SiC for rocket nozzle applications. Specifically, using pitch-based short fibers as a reinforcing stage. This has the potential to have manufacturing, cost and performance benefits over other materials, however, this has never before been developed. The influence of manufacturing parameters was quantified, where it was found that temperature cycle, pressure application and resin application have a significant influence on part properties. Also, the effect of the composition parameters of fibre length, fibre type, volume fraction and resin type was investigated on microstructural, mechanical and thermal properties. Based on this, extrapolation could be done, and an optimal material defined. This knowledge was combined in the design and planning of a proof-of-concept rocket nozzle from short fiber C/C-SiC material.