Additive Manufacturing of Silicon Carbide (SiC) Ceramic Rocket Nozzles

Rocket motor nozzles are typically made of materials such as graphite and fiber-reinforced phenolics or epoxies with low erosion rates, relatively low manufacturing costs, andor reduced weight. Additive manufacturing AM methods enable unique control of geometry and composition and can improve the weight and thermal performance of rocket nozzles. A newly developed AM process called vibration assisted printing VAP can process a unique combination of ceramic-forming polymer binders with a large amount of solid particles at very high solid loadings and viscosities. This research investigated the formulation, pre-processing and post-processing of these materials, determined their final microstructure and phase composition, and compared them to some of the materials utilized in rockets today. Some of the parameters investigated included mixture ratio, curing temperature, and sintering temperature of silicon carbide SiC-ceramic forming polymer particles. These mixtures were used for 3D printing of SiC-ceramic matrixSiC composite parts. The results of the study will help improve the performance of modern-day rockets and other applications within the aerospace industry.