Fabrication and erosion studies of C–SiC composite Jet Vanes in solid rocket motor exhaust

doi:10.1016/j.jeurceramsoc.2011.06.007

Journal of the European Ceramic Society

Volume 31, Issue 13, November 2011, Pages 2425-2431

https://doi.org/10.1016/j.jeurceramsoc.2011.06.007 Get rights and content

Abstract

C–SiC composite Jet-Vanes were fabricated using liquid silicon infiltration and tested in a plume of aluminum based solid propellant to study erosion resistance. The Jet-Vanes showed excellent resistance to thermo-oxidative erosion; average linear and mass erosion rates were 1 mm/s and 5 g/s, respectively. Morphology of the eroded surfaces suggests that alumina particles in the plume hit the leading edge of the Jet-Vane, damage it and some material is eroded away. Residual silicon melts and reacts with oxygen to form silica which in turn reacts with SiC matrix. The matrix of SiC, silicon and un-reacted carbon is loosened and erode by high shear forces. Once carbon fibers get exposed directly to the plume, these may be both eroded and oxidized.

Introduction

C–SiC composites are considered as potential materials for advanced aero-engines, Jet-Vanes, leading edges and nose-tips of re-usable space vehicles.¹ These composites are lighter than the refractory metals like tungsten and hence provide higher payload capacity of the aerospace vehicles. The Jet-Vane material must have good erosion resistance to the particulate flow in addition to high thermal shock resistance i.e. high thermal conductivity, low CTE and good strength. Erosion of Jet-Vanes depends on the fiber architecture, fiber to matrix ratio and testing conditions. Though numerical simulation studies have been reported to assess thermal response,² there is no mathematical model to predict erosion for a given composite, experimental method is the only way to study the erosion rate and its mechanism.

Liquid silicon infiltration based 3D stitched C–SiC composites have excellent thermal and mechanical properties3, 4, 5 and thus would have good erosion resistance to solid rocket motor (SRM) plume due to oxidation resistant hard SiC matrix and third direction stitching.

Aim and scope: In this study, typical sized C–SiC composite Jet-Vanes were fabricated and exposed to SRM plume to investigate erosion resistance. The erosion morphology and mechanisms are discussed.

Section snippets

Fabrication of Jet-Vanes

Fibrous preforms of near net shape Jet-Vanes were prepared by stitching several carbon-fabric layers of the 3k 8H-satin with 6k carbon fiber tows. Number of stitches was maintained in the range 350–400 per 100 cm². The preforms were rigidized by vacuum infiltration of coal–tar pitch at 200–300 °C followed by carbonization at 900–1000 °C, and graphitization at 2400–2600 °C in the nitrogen atmosphere. The rigidized preforms were further densified by a hot-isostatic-pressure-impregnation-carbonization

Properties of Jet-Vanes

It was found that the Jet-Vanes have un-reacted carbon (12–15%), residual silicon (8–12%) and SiC matrix (28–30%) by weight. Physical, mechanical and thermal properties of the 3D stitched C–SiC composites were also determined and have been reported already3, 4, 5; these are also summarized here: fiber content = 40–42% (v/v); flexural strength = 160–240 MPa; tensile strength = 70–100 MPa; Young's modulus = 40–45 GPa; strain at failure = 0.15–2.0%; Vickers hardness = 2800 g/mm²; fracture toughness = 5–6 MPa/m^1/2;

Conclusions

•
3D stitched C–SiC composite Jet-Vane shows excellent thermal shock and erosion resistance under SRM.
•
Stitching prevents fabric layers to get separated even under large shear force and very high CTE in the through thickness of the composite.
•
Erosion pattern is similar in all the Jet-Vanes; however it varies from 1 to 2 mm/s depending upon the location.
•
Morphology of the eroded surfaces suggests that alumina particles in the plume hit the leading edge of the Jet-Vane, damage it and some material is

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Fabrication and erosion studies of C–SiC composite Jet Vanes in solid rocket motor exhaust

Abstract

Introduction

Section snippets

Fabrication of Jet-Vanes

Properties of Jet-Vanes

Conclusions

Scripta Mater

Compos Part A

Ceram Int

Carbon

Aerosp Sci Technol

Carbon

Ceram Int

Compos Part A: Appl

Carbon fiber reinforced CMC for high performance structures

Int J Appl Ceram Technol

Numerical study on a thermal response of the Jet Vane System in a Rocket Nozzle