Integration of Plasma Electrolytic Oxidation (PEO) for the Creation of Functional Ceramic-Metal Composite Surfaces in Monolithic Spacecraft Structures

Abstract

The invention relates to a functional ceramic-metal composite surface technology applied to a monolithic hexagonal spacecraft architecture to enhance structural integrity and reusability. Within the scope of the invention, the outer surface of the monolithic Al-Sc alloy fuselage, the central aerodynamic channel (200), the Tesla valve manifolds (400), and the inner fuel tank walls are coated with an integrated ceramic layer converted in situ by Plasma Electrolytic Oxidation (PEO). This integration prevents fuel heating by providing thermal insulation in the central channel, eliminates geometric wear within the manifold, maintains pogo-damping stability, and achieves high-temperature and corrosion resistance on the outer shell. The invention enables the sustainability of a solid-state rocket structure that does not require mechanical valves or heavy turbopump systems, while maintaining the ductility of the base metal and providing diamond-hard surface protection.

Description

1 TARIFF FUNCTIONAL CERAMICS IN MONOLITHIC SPACECRAFT STRUCTURES. PLASMA FOR CREATING METAL COMPOSITE SURFACES ELECTROLYTIC OXIDATION (PEO) INTEGRATION 5 TECHNICAL FIELD This invention is a monolithic rocket made of Al-Sc (Aluminum-Scandium) alloy produced by additive manufacturing. To increase the thermal resistance, corrosion resistance and geometric stability of their bodies, 10 Ceramic-metal composite surfaces by Plasma Electrolytic Oxidation (PEO) method. It is related to its creation. STATE OF THE ART In traditional spacecraft, thermal protection is achieved through ceramic tiles glued to the fuselage or This is achieved with heavy ablative layers. These systems introduce additional weight and adapt to structural flexibility. It is unable to provide this. Furthermore, it occurs in high-pressure (600 psi) fluid channels. Erosion impairs the precision of the propulsion system. Current techniques allow for the erosion of a rocket body. 20 that both maintains structural flexibility and offers diamond-hard protection on the surface. It fails to provide an integrated solution. TECHNICAL PROBLEMS SOLVED BY THE INVENTION Thermal Insulation: High 25 formed during air-assisted thrust inside the central channel (200). To prevent heat from transferring to the fuel tanks. Geometric Accuracy: Prevents wear in the internal channels of solid-state manifolds. By stopping, the pogo-damping effect is stabilized. Structural Ductility: The ceramic coating allows the rocket's main body (lattice) to remain fragile without becoming brittle. It only provides high strength on the surface. 30 2 Corrosion and Erosion: The outer wall is exposed to atmospheric effects, while the inner walls are under high-pressure supercritical conditions. To protect against fuels. Figures to Help Understand the Invention 5 Figure 1: Cross-sectional view showing the layer structure of the PEO coating on the metal core. Figure 2: Cross-sectional view of a Tesla valve manifold with its inner surface coated with PEO. Figure 3: Showing the zonal (gradual) distribution of the PEO coating on the rocket body. Schematic view. 10 Part Reference Description 101: Thin PEO Coating for the Outer Wall 201: Central Channel Thick PEO Coating (Thermal Barrier) 15 301: Al-Sc Metal Core 302: Transition / Diffusion Zone 303: PEO Ceramic Exterior Surface 401: Manifold Inlet 402: Fixed Geometry Tesla Valve Cycle 20 403: Interior Ceramic Coating DETAILED DESCRIPTION OF THE INVENTION The system described in the invention represents a monolithic hexagonal architecture (patent no. tr2026-001188) in a ceramic-25 It transforms the metal into a composite structure. The PEO process transforms the aluminum alloy surface in situ (in-situ). It transforms into an alumina and spinel-based ceramic layer. This transformation is a molecular-level change between the metal core (301) and the ceramic surface (303). It forms a diffusion zone (302). This structure provides hardness to the ceramic while absorbing impact of the metal. and retains its flexibility properties. 3 The inner surface of the central aerodynamic channel (200) is coated with high-thickness PEO (201). This The layer isolates the tanks from the high temperatures generated during "air-augmentation". (400) Tesla valves (402) inside are also coated with PEO (403), supercritical fuel It prevents the erosion it might cause and ensures thrust stability. The PEO layer (101) on the outer surface of the rocket protects the faceted edges, thereby improving aerodynamic efficiency. The coating thickness is fixed by gradually adjusting it according to the intensity of the thermal load. Unnecessary weight increase is avoided and the rocket's "solid-state" (without moving parts) structure is maintained. It is optimized.

Claims

4 REQUESTS 1. The invention is a monolithic spacecraft body characterized by being made of Al-Sc (Aluminum-Scandium) alloy. the outer surface of a main carrier structure, the inner surface of the central aerodynamic channel (200) and the fuel at least a portion of the inner walls in contact with each other, Plasma Electrolytic Oxidation (PEO) 5 It is coated with an integrated ceramic layer that has been transformed in situ using this method.

2. A spacecraft body conforming to Claim 1, characterized by the fact that the PEO coating in question adheres to the base metal. By creating a molecular diffusion region (302) between the body and the ductility of the metal It contains a composite phase that combines the hardness of the ceramic. 10 3. A spacecraft body conforming to Claim 1, characterized by its Tesla-like supercritical fuel pathways. By coating the inner surfaces of monolithic manifolds in the form of valves (400) with PEO (403), preserving geometric stability against high-pressure fluid erosion and pogo- It is the stabilization of the damping frequency. 15 4. A spacecraft body conforming to Claim 1, characterized by having a central aerodynamic channel (200) inside. The PEO coating on its surface absorbs the thermal load generated during air-assisted thrust, acting as a common carrier. acting as a thermal barrier isolating the fuel cells (110) from the walls (120). It is seeing. 20 5. A spacecraft body conforming to Claim 1, characterized by the fact that the PEO coating on the outer wall, In addition to providing protection against atmospheric friction heat, it also creates micro-vortices on the surface. It has a faceted texture that delays boundary layer separation by forming a surface.

6. A spacecraft body that complies with Claim 1, characterized by its PEO coating thickness and thermal load. The maximum is in the aerospike nozzle and central channel regions, where it is highest, and structurally. The gradual reduction in flexibility will be minimal in the middle sections of the fuselage where flexibility is paramount. It is implemented as follows.

7. A spacecraft body conforming to Claim 1, characterized by having internal wetness of the fuel cells (110). The PEO coating on their surfaces creates a chemical barrier between supercritical fuels and the metal surface. It forms an inert barrier that prevents interaction and increases corrosion resistance.

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