Introduction

The patented technology allows to realize a new class of ceramic matrix composites for ultra-high temperatures with near-zero erosion to equip the next generation of hypersonic spacecrafts with reusable heat shields and rocket motors with the ability to deal with sudden temperature changes even above 1800 °C, in particularly aggressive environments from a chemical and mechanical point of view.

Technical features

Italy has a long tradition in space activities, currently AVIO uses materials manufactered in Germany to realize components of satellite launchers. Those materials are so called CMCs or CAMCs and they are characterized by an extremely expensive production processes which are far from the future industrial scenarios of the “green deal”.

The patent protects a new class of materials for applications in severe environments (aerospace, high speed transport, nuclear fusion power plants, etc.) and an innovative process to make them. The special formulation of ultra-high temperature ceramic phases gives the materials greater resistance to wear using a fast process and replacing toxic organic solvents with water.
From a technical point of view, the process is mainly based on 1) impregnation of carbon fiber fabrics with a suspension in water of a mixture of ceramic powders and 2) consolidation by sintering in graphite ovens in a few hours.

Related Patent: Near-zero erosion ultra-high temperature ceramic composite 

Possible Applications

• Aerospace: thermal protection system tiles, atellite launcher solid propellant rocket nozzles;
• Energy: anti-plasma wall into ITER;
• Transportation: brake systems of Formula 1 and heavy means of transport;
• Any application in which is required low deformability under an extreme hot environment.

Advantages

• Green and time saving process;
• Near-zero ablation above 2000°C;
• Coatings not necessary;
• Improvement of mechanical properties with increasing temperature;
• Machinable via EDM (electrical discharge machining).