Additive Manufacturing of Actively Cooled Thermal Shields

Purpose and goal

High-temperature Thermal Protection Systems (TPS) that find use in applications including aerospace, energy generation etc. typically rely on ‘passive’ thermal insulation, which is limited by the oxidation/ablation resistance of their constituent materials. The AM-ACTS project aims to develop novel thermal shields that can be ‘actively’ cooled by circulating an appropriate fluid. The internal microchannel network of TPS elements needed for this purpose will be fabricated from ultra-high temperature ceramics and refractory metals using additive manufacturing.

Expected effects and result

Realizing actively cooled TPS systems via additive manufacturing will enable sustainable and environmentally friendly production of strategic components such as atmospheric re-entry shields for reusable spacecrafts, turbine blades, rocket engines, reactor walls and solar receivers. It will also result in improved maximum service temperature and/or service lifetime at high operating temperatures, which can boost energy efficiency and reduce maintenance costs in these and many other industrial applications.

Planned approach and implementation

AM-ACTS intends to translate active refrigeration strategies to the microstructural level for aerospace and energy-related applications. By employing both metallic and ceramic UHTMs in tandem with AM methods, a bioinspired internal microchannel network with all critical design features necessary to produce internal evaporative cooling will be realized at a scale never explored before. The intent is to greatly increase the specific surface area available for heat exchange to develop a unique TPS system combining complementary expertise among partners.