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Near net-shape, ultra-high melting, recession-resistant ZrC/W-based rocket nozzle liners via the displacive compensation of porosity (DCP) method

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Abstract

Dense, near net-shaped ZrC/W-based composites have been fabricated at modest temperatures and at ambient pressure by a reactive infiltration process known as the Displacive Compensation of Porosity (DCP) method. Porous WC preforms with hourglass shapes (for rocket nozzle liners) were produced by gel casting, whereas simple bar-shaped preforms were produced by uniaxial pressing. The porous preforms were exposed to molten Zr2Cu at 1200–1300°C and ambient pressure. The Zr2Cu liquid rapidly infiltrated into the preforms and underwent a displacement reaction with the WC to yield a more voluminous mixture of solid products, ZrC and W. This displacement reaction-induced increase in internal solid volume filled the prior pore spaces of the preforms (“displacive compensation of porosity”) to yield dense, ZrC/W-based composites. Because the preforms remained rigid during reactive infiltration, the final composites retained the external shapes and dimensions of the starting preforms. A DCP-derived, ZrC/W-based nozzle insert was found to be resistant to the severe thermal shock and erosive conditions of a Pi-K rocket motor test. The DCP process enables dense, ceramic/refractory metal composites to be fabricated in complex and near net shapes without the need for high-temperature or high-pressure densification or for extensive machining (i.e., relatively expensive processing steps are avoided).

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Authors and Affiliations

  1. School of Materials Science & Engineering, Georgia Institute of Technology, 771 Ferst Drive, Atlanta, GA, 30332, USA

    M. B. Dickerson & K. H. Sandhage

  2. MetaMateria Partners, LLC, 1275 Kinnear Road, Columbus, OH, 43212, USA

    P. J. Wurm & J. R. Schorr

  3. Air Force Research Laboratory, Edwards Air Force Base, CA, 93524, USA

    W. P. Hoffman

  4. ERC Inc., Air Force Research Laboratory, Edwards, CA, 93523, USA

    P. G. Wapner

Authors
  1. M. B. Dickerson
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  2. P. J. Wurm
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  3. J. R. Schorr
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  4. W. P. Hoffman
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  5. P. G. Wapner
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  6. K. H. Sandhage
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Dickerson, M.B., Wurm, P.J., Schorr, J.R. et al. Near net-shape, ultra-high melting, recession-resistant ZrC/W-based rocket nozzle liners via the displacive compensation of porosity (DCP) method. Journal of Materials Science 39, 6005–6015 (2004). https://doi.org/10.1023/B:JMSC.0000041697.67626.46

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  • DOI: https://doi.org/10.1023/B:JMSC.0000041697.67626.46

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