Fabrication of TBC-armored rocket combustion chambers by EB-PVD methods and TLP assembling |
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Authors: | Uwe Schulz Klaus Fritscher Manfred Peters Dirk Greuel Oskar Haidn |
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Affiliation: | 1. Deutsches Zentrum für Luft-und Raumfahrt (DLR), Institute of Materials Research, Koln, 51170, Germanyuwe.schulz@dlr.de;3. Deutsches Zentrum für Luft-und Raumfahrt (DLR), Institute of Materials Research, Koln, 51170, Germany;4. Deutsches Zentrum für Luft-und Raumfahrt (DLR), Institute of Space Propulsion, 74239, Lampoldshausern, Germany |
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Abstract: | A thermal barrier coating (TBC) system for rocket chambers made of Cu-based high strength alloys has been developed in a pilot project in line with EB-PVD (electron-beam physical vapor deposition) technology aiming at TBC application on Cu-based walls of real rocket combustion chambers. The TBC system consists of a metallic bond coating compatible with Cu-based material and an yttria partially stabilized zirconia TBC. The TBC overlayer is a distinctive ceramic structure designed for an exceptionally low Young’s modulus to withstand the extreme mismatch stresses between the internally LN-cooled high thermal expansion Cu metal base and the low thermal expansion hot ceramic shell. The TBC system has been qualified under close-to-service conditions on cylindrical LH2-cooled combustion chamber segments, where they have performed superior.As EB-PVD technology is a line-of-sight process that is rather able to coat internal cavities, a transient liquid phase (TLP) joining technique for fully coated parts has been developed, that allows to assemble complete components out of vapor-accessible fully coated parts. It is capable, e.g. to incorporate sinuous cooling passages in the throat areas of combustion chambers, and/or to assemble oversized parts out of smaller components by maintaining parent metal properties. A manufacturing process is outlined for making internal TBC armored combustion chambers. |
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Keywords: | Thermal barrier coating Transient liquid phase joining |
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