Integrated Ceramic Matrix Composite-Carbon/Carbon Structures for Large Rocket Engine Nozzles and Nozzle Extensions

Low-cost access to space demands durable, cost-effective, efficient, and low-weight propulsion systems. Key components include boost and upper stage rocket engine nozzles and extensions. Nozzle material options include ablatives, actively cooled alloys, and radiation-cooled composites and metals, each of which has known limitations. Metallic nozzles have high density and limited temperature capability. Carbon/carbon (C/C) is an attractive alternative, but has manufacturability, oxidation resistance, and joining ability concerns.