INNOVATIVE CERAMIC MANUFACTURING FOR SPACE APPLICATIONS - EXPRO+

Objective:To develop and optimise additive manufacturing techniques for ceramic components, as well as developing post-processing,improving crack detection and establishing a robust European supply chain.Description:Ceramics play a crucial role in spacecraftfor their unique properties, namely high thermal stability/resistance, low density and high strength. Ceramics like silicon carbide(SiC) and silicon nitride (Si3N4) are employed in structural components, delivering high stiffness with relatively low mass. They are vital for optical applications for a stable and accurate placement of sensors and mirrors. They are also used for thermal protectionsystems, microwave and radio-frequency equipment. Recently, additive manufacturing (AM) has further expanded the applications ofceramics in spacecraft, enabling the production of unprecedented complex shapes. Overall, ceramics are becoming indispensable for modern spacecraft.Nevertheless, ESA recognises the need to enhance several key aspects of the ceramic manufacturing chainto supportindustrialisation and establish a robust supply. Despite the advancements in AM, specific challengespersist, particularly when attempting to achieve thin walls, improving surface finish or enabling more intricatelattice geometries with high reliability and precision. The feasibility of assembling larger structures from smallerceramic parts is a way to overcome AM equipment size and processlimitations. In parallel, there is a need toimprove data for crack analysis and damage tolerance, coupled with the development of viableNon-Destructive Testing (NDT) solutions for crack detection. Downstream operations are critical, including precisionmachining formounting interfaces, coatings and polishing. Additionally, exploration of alternatives to SiC and Si3N4 may yield new opportunities. The use of ceramics poses challenges for spacecraft demisability, which can limit their suitability for satellites in large constellations adhering to the zero-debris charter. This constraint must be considered early in the design phase and accounted for in mission architecture.The aim of this activity is to further develop AM processes for ceramics. It can be expected that this will involve the use of novel materials, achieving higher geometric complexity, improved surface finish, larger part size and/or thinner walls.This activity encompasses the following tasks:- Trade-off potential use cases (e.g. parts, AM processes and materials) whichwould allow further developingceramic manufacturing technologies for space applications.- Select the most promising application and develop the corresponding AM processes, progressing towards arepresentative part prototype. This will likely involve complementary steps such as surface treatments, joining, coating, polishing and NDT.- Develop numerical simulation tools to support design formanufacturing, for example by predictingdeformation and crack formation during fabrication or sintering.- Manufacture and test the prototype under relevant conditions.- Define end-of-life strategies.Deliverables: Breadboard, Prototype part, Report