Study on CerAMfacturing of Novel Alumina Aerospike Nozzles by Lithography-Based Ceramic Vat Photopolymerization (CerAM VPP)

Research output: Contribution to journalResearch articleContributedpeer-review

Contributors

Abstract

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.

Details

Original languageEnglish
Number of pages1
JournalMaterials
Volume15
Issue number9
Publication statusPublished - 3 May 2022
Peer-reviewedYes

External IDs

Scopus 85129966842
PubMed 35591613
WOS 000794737100001
Mendeley 4edd5b1e-9094-3446-a5a9-4de4270c128e

Keywords

Keywords

  • Additive Manufacturing (AM), Aerospike nozzle, Alumina, CerAMfacturing, Cold-gas nozzle, Digital Light Processing (DLP), Lithography-based Ceramic Manufacturing (LCM), Vat Photopolymerization (VPP)