Additive Manufacturing of Ceramic Composites For Thermal Protection Systems
Abstract
The study and use of the space domain, including the recent reinvigoration of manned space exploration to the moon and beyond, drives the search for higher-performance materials for spacecraft thermal protection systems (TPSs). Ceramics and high-performance carbon both exhibit material properties that are suitable for TPS applications, but their performance can be maximized using additive manufacturing (AM) methods. Vibration-assisted printing (VAP) is a newly developed AM process that can fabricate parts using highly viscous mixtures of ceramic-forming polymers with solid ceramic particles. This work explores the AM of a ceramic sandwich TPS utilizing VAP. The TPS outer layers consist of silicon carbide (SiC) for high oxidation resistance, high melting point, and low thermal conductivity. A thin middle layer consists of a carbon-based material that provides high in-plane thermal conductivity to redistribute heat. Numerical simulations showed that this configuration was effective at reducing maximum temperatures under simulated re-entry conditions. A highly viscous mixture was prepared from a polycarbosilane polymer and pure SiC powder, which could be 3D-printed using VAP, and the middle layers for assembly were printed via standard thermoplastic extrusion using carbon-loaded or carbon-fiber-loaded filaments. SiC components were cured up to 248.8C and pyrolyzed at up to 1,600C, and were characterized via SEM, EDS, and XRD and tested for compressive strength.
Document Details
- Document Type
- Technical Report
- Publication Date
- Jun 01, 2020
- Accession Number
- AD1114702
Entities
People
- Kelly M. Raisch
Organizations
- Naval Postgraduate School