Improved Rhenium Thrust Chambers for In-Space Propulsion

Radiation-cooled, bipropellant thrust chambers are being considered for the ascent/descent engines and reaction control systems (RCS) for future NASA missions such as Mars Sample Return. Currently, iridium-lined rhenium combustion chambers are the state-of-the-art for in-space engines. NASA's Advanced Materials Bipropellant Rocket (AMBR) engine, a 150-lbf rhenium-iridium chamber produced by Plasma Processes, Inc. (PPI) and Aerojet, recently set a hydrazine specific impulse record of 333.5 seconds. To withstand the high loads during terrestrial launch, rhenium chambers with improved mechanical properties are needed, i.e., 40ksi yield strength and 10% elongation at room temperature. Recent electrochemical forming (EL-Form) work has shown considerable promise for improving the mechanical properties of rhenium by producing a multi-layered deposit comprised of a tailored microstructure, i.e., Engineered Re. In addition, the multi-component processing ability of the EL-Form process has the potential to significantly reduce the cost of producing advanced rhenium-iridium thrust chambers. Therefore, PPI and its industry partner, Aerojet, will work together to develop rhenium based in-space engines with improved mechanical properties at a reduced cost.

Both government and commercial entities in the following sectors use advanced high-temperature materials for the following applications: coatings, defense, material R&D, nuclear power, aerospace, propulsion, automotive, electronics, crystal growth, and medical. PPI's targeted commercial applications include net-shape fabrication of refractory and platinum group metals for rocket nozzles, crucibles, heat pipes, and propulsion subcomponents; and advanced coating systems for x-ray targets, sputtering targets, turbines, rocket engines, wear and thermal/electrical insulation.

PPI's targeted NASA application is for the ascent/descent engines and reaction control systems for current and future missions such as the Mars Sample Return. Other NASA applications include in-space propulsion components for apogee insertion, attitude control, orbit maintenance, repositioning of satellites/spacecraft, reaction control systems, and descent/ascent engines, nuclear power/propulsion, microgravity containment crucibles and cartridges.

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