Advanced ceramics are recognized as key enabling materials possessing combinations of properties not achievable in other material classes. They provide very high thermal, chemical and mechanical resistance and typically exhibit lower densities than metals. These properties predestine ceramics for many different applications, especially those in space. Aerospike nozzles promise an increased performance compared to classic bell nozzles but are also inherently more complex to manufacture due to their shape. Additive manufacturing (AM) drastically simplifies or even enables the fabrication of very complex structures while minimizing the number of individual parts. The applicability of ceramic AM (“CerAMfacturing”) on rocket engines and especially nozzles is consequently investigated in the frame of the “MACARONIS” project, a cooperation of the Institute of Aerospace Engineering at Technische Universität Dresden and the Fraunhofer Institute for Ceramic Technologies and Systems (IKTS) in Dresden. The goal is to develop novel filigree aerospike nozzles with 2.5 N and 10 N thrust. For this purpose, CerAM VPP (ceramic AM via Vat Photopolymerization) using photoreactive and highly particle-filled suspensions was utilized. This contribution gives an overview of the component development starting from CAD modeling, suspension development based on alumina AES-11C, heat treatment and investigation of the microstructure of the sintered components. It could be shown that modifying the suspension composition significantly reduced the formation of cracks during processing, resulting in defect-free filigree aerospike nozzles for application in space.

No abstract

Advanced ceramics are recognized as key enabling materials possessing combinations of properties not achievable in other material classes. They are characterized by very high thermal, chemical and mechanical resistance and also usually have a lower density than metals. These properties predestine ceramics for many different applications, especially space applications.In the aerospace sector aerospike nozzles promise performance and application advantages compared to classic bell nozzles but are also inherently more complex to manufacture due to their shape. AM methods drastically simplify or even enable the fabrication of those complex structures while minimising the number of individual parts. The applicability of ceramic AM (“CerAMfacturing”) on rocket engines and especially nozzles is consequently investigated in the frame of the “MACARONIS” project, a cooperation of the Institute of Aerospace Engineering at Technische Universität Dresden and the Fraunhofer Institute for Ceramic Technologies and Systems (IKTS) in Dresden. The goal is to develop novel large size aerospike thrust nozzles including areas of highest resolution and fineness. Finding a suitable AM process that enables the realisation of both aspects is extremely challenging. One possibility could be the hybridization of shaping methods, in that case CerAM VPP (ceramic additive manufacturing via vat photopolymerization) and CerAM FFF (ceramic additive manufacturing via fused filament fabrication) in combination with sinter joining. This contribution focuses on the high resolution CerAM VPP process, in particular the development, characterization and testing of a new photoreactive Al2O3 suspension validated by AM of novel aerospike nozzles.

High performance ceramics, particularly Ceramic Matrix Composite (CMC) materials found their way into liquid rocket engines. Yet, so far, mainly carbide or nonoxide CMCs have been of interest. This paper explores the potential and challenges of oxide–oxide ceramic matrix composites (OCMCs) for application in rocket thrust chambers. Therefore, strength, leakage and hot gas tests are conducted with material samples. A particular focus lies on the application of coatings to seal the permeability inherent to the material. Furthermore, prototypes in the form of flame tubes, ceramic chambers with nozzles and ceramic chambers with graphite inlays are developed and investigated experimentally in test firings. The results show that a recrystallised glass of a Y-Al-Si-O compound can successfully create an impermeable coating of the OCMC without affecting its damag-tolerant behaviour. However, the prototype developments show that it is still very challenging to manufacture even slightly complex structures without critical failures. Nevertheless, OCMC structures of relatively simple geometries showed promising results in hot firings and could be used as a lightweight housing, while the inner contour of the chamber and nozzle are realised, e.g., by a graphite inlay of appropriate quality.

As advanced nozzles may offer alternative solutions to conventional nozzles for the future class of reusable launch vehicles, a critical aspect is to tailor these novel technologies to current recovery strategies, more specifically to vertical landing sustained by retro-propulsion. Researchers at Technische Universität Dresden have developed a dedicated test-bench for the vacuum wind tunnel facility, where Advanced Nozzle Concepts (ANCs), such as aerospike and dual-bell nozzles, are tested in cold-gas configuration while invested by subsonic counter-flows. The main objective of the test campaign is to evaluate the performance and altitude–compensation characteristics of such ANCs by simulating a vertical landing manoeuvre through the variation of ambient pressure experienced during the landing burn. A detailed description of design and development of the test-bench, together with preliminary results from the commissioning activities, are here offered to the reader. The force measurements, together with pressure and temperature data, contribute to evaluate thrust levels and coefficients, as well as the monitoring of the interaction between the nozzle cold-flow and the opposing free-stream. A background-oriented schlieren system allows to visualise the external flow-field. In conclusion, an outline of the upcoming test campaign and a description of the expected results is offered.