Additive Ceramic Tubular Structure for Propulsion
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Solution Overview
Problem
Current methods for fabricating silicon carbide (SiC)-based ceramic composite components for propulsion devices, such as rocket engines, are limited by the need for hand lay-up and tooling, which restricts complexity, accuracy, and assembly efficiency, and do not effectively utilize additive manufacturing techniques for creating intricate shapes and optimized performance parameters.
Innovation Solution
The development of a ceramic composite tubular structure formed through additive manufacturing, where a monolithic ceramic preform with integrated cooling passages is created using 3D printing, and then wrapped with ceramic matrix composite (CMC) plies, followed by melt-infiltration to produce a unitary thrust chamber assembly with optimized geometry and performance characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If hand lay-up and tooling methods are used for fabricating ceramic composite components, then manufacturing process simplicity is maintained, but manufacturing precision and ability to create intricate shapes are limited
Solution Approach 1:
The patent changes the fundamental manufacturing approach from traditional hand lay-up to additive manufacturing, enabling precise control of geometric parameters and material distribution. This allows creation of complex internal structures and optimized geometry that were previously unattainable with manual fabrication methods.
Solution Approach 2:
The patent replaces the mechanical hand lay-up process with an additive manufacturing system that uses digital models and automated deposition. This substitution enables higher precision and complexity in the fabricated components while reducing manual intervention and associated variability.
2Productivity
If traditional fabrication methods with hand lay-up are used, then process simplicity is maintained, but assembly time and costs increase
Solution Approach 1:
The patent merges multiple fabrication steps into a single additive manufacturing process, creating near-net-shape components that require minimal post-processing and assembly. This integration of operations reduces both assembly time and associated costs while maintaining process simplicity through automation.
3Adaptability or versatility
If additive manufacturing is used to create complex geometries, then manufacturing precision and functionality are improved, but device complexity increases
Solution Approach 1:
The patent employs additive manufacturing as a universal fabrication method that can create a wide variety of complex geometries and internal structures within a single process. This multi-functionality allows the same system to produce different component designs without requiring separate tooling or processes for each geometry type.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the production of complex, high-performance ceramic composite tubular structures with reduced assembly time and costs, improved reliability, and enhanced functionality by leveraging additive manufacturing for precise geometry and material distribution, addressing the limitations of traditional fabrication methods.
Implementation Method 1
The monolithic ceramic preform is burned out and melt-infiltrated, and an inner wrap and outer wrap of ceramic matrix composite plies are disposed on respective inner and outer surfaces of the monolithic ceramic precursor or preform, and the monolithic ceramic precursor or preform with the inner and outer wraps is then burned out and melt-infiltrated
Data Source
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AI summary
A ceramic composite tubular structure (10, 100, 200) includes a monolithic ceramic preform (40, 140, 240) being tubular-shaped created using an additive manufacturing process. The monolithic ceramic preform (40, 140, 240) includes a first end (24, 124, 224), a second end (26, 126, 226), an inner surface (42, 142, 242), and an outer surface (44, 144, 244). The monolithic ceramic preform (40, 140, 240) includes one or more apertures (50, 150, 250) formed between the inner surface (42, 142, 242) and the outer surface (44, 144, 244) where at least one of the one or more apertures (50, 150, 250) is open to at least one of the first end (24, 124, 224) or the second end (26, 126, 226). An inner face sheet (60, 160, 260) is formed on the inner surface of the monolithic ceramic preform (40, 140, 240) by a first quantity of ceramic matrix composite plies (64, 164, 264). An outer face sheet (62, 170, 262) is formed on the outer surface of the monolithic ceramic preform (40, 140, 240) by a second quantity of ceramic matrix composite plies (66, 182, 266).