A new technology for production of high thickness carbon/carbon composites for launchers application

Carbon–Carbon (C/C) composites are known for their extraordinary stability and excellent mechanical properties, almost unchanged at high temperatures. Among the several advanced applications, C/C based materials can be used in engines as nozzle throat section for launchers. In particular, the main feature for such employment is the material high resistance in extreme thermal environment. On the other hand, large-size items are required for this kind of purposes, thus introducing criticalities in terms of material uniformity and final overall properties. Up to now, there no standard for the production of high thickness C/C structures. In this paper a novel manufacturing method is analyzed, following each phase of the process, from the carbon fiber preform design and preparation to the carbon densification by chemical vapor infiltration method. Five preforms of large dimensions with different characteristics have been manufactured and infiltrated. The realized prototypes have been then analyzed by means of mechanical, physical and morphological tests. Aim of the results of this preliminary work is to establish a set of guidelines for a well-defined high thickness C/C production method.