INNOVATION

1. Regeneratively Cooled Composite Structure for Lightweight Engines Small Business Innovation Research Energy Science Laboratories, Inc. San Diego, CA An innovative concept for regeneratively cooled ceramic matrix composite propulsion components has been developed. ESLI’s flocking technology for attaching fibers to substrates has been used to demonstrate the feasibility of fabricating 3D cooled composite structures consisting of carbon and silicon carbide. INNOVATION Left: Composite structures, each containing 23 cooling tubes. • ACCOMPLISHMENTS • Assessment of fintube composite structures indicated that X-33 aerospike nozzle ramp design requirements could be met. • Thermostructural analyses showed aerospike ramp thermal stresses could be feasibly managed with all silicon carbide composite structures or silicon carbide structures with glassy carbon tubing. • Cooled panel structures were fabricated to demonstrate the ceramic matrix composite materials concept. • Through mechanical and heat transfer testing, the low-density fintube concept was shown to meet the thermal conductivity requirements necessary for an actively cooled composite structure such as the X-33 nozzle ramp. • While further development is necessary, the SBIR program has enabled the feasibility of the innovative composite fintube concept to be demonstrated in a cost-effective manner. • COMMERCIALIZATION • While the technology needs to be further developed, many applications of this technology should be possible. Fintube ceramic matrix composites of the type examined in this SBIR are being considered for possible inclusion in high-temperature propulsion systems currently being developed by several major aerospace companies. • Where heat removal is important and the use temperature is not as severe as in rocket propulsion applications, high-conductivity polymer or metal matrix composites should be feasible. Right: 3-tube composite fintube structure. • GOVERNMENT/SCIENCE APPLICATIONS • Numerous potential NASA launch vehicle applications exist for the use of actively cooled fintube ceramic matrix composites. Rocket propulsion component applications include: cooled panels for rocket-based combined cycle systems, cooled nozzles and ramps, and cooled thrust cells. The technology could also be applied to actively cooled thermal protection systems for high-heat flux regions such as leading edges. • This actively cooled composite technology could also be used in Department of Defense launch and in-space vehicles, and in Department of Energy power generation fusion tokamaks. MSFC Contact: Tom Knight, 256-544-5353 MSFC Technical POC: Peter G. Valentine, 256-544-2837 ESLI Contact: Dr. Timothy R. Knowles, 858-552-2034 1999 Phase I, NAS8-00080 Marshall Space Flight Center FY99 Subtopic: 3.04, Light- Weight Engine Components Date: April 2001