S. Schmidt et al./ Acta Astronautica 55(2004)409-420 Fig. 19. 3D braiding facility EADS Research Ottobrunn. production methods for processing carbon fibres developed further and innovative concepts elaborated for making special semifinished products. New braiding techniques offer extremely roductive methods for making contoured fibre pre- Fig. 20. Robot stitching machine forms such as combustion chambers or nozzles Thus the 3D braiding technique offers quite a few technology) become manufactured bya and cross section and are characterized by high struc- (AEROTISS material)and the above mer F ural integrity and tolerance, as the braiding threads can be led laterally through the component wall, thus low-cost LSI process representing a reinforcement in thickness direction Thanks to using sewing threads made of carbon fibre, 4. Summary cost effective. tailor-made 3D reinforcements for ten sile and shear loads can be created. the actual inn New, innovative approaches must be followed in vation with this material development is the combina- the area of material development in order to addi- tion of an extremely cost-effective infiltration method tionally create, besides the customary one-way engine with the textile technique for making multidirectional components, reusable propulsion technologies for the fibre-composite ceramics. Within the scope of a re- future. In this context, using fibre-reinforced ceramics, gionally sponsored development programme, inten- in particular C/SiC ceramics, is becoming increasingly sive work is being carried out, in addition to material obvious--thanks to their outstanding thermophysical and process development, on metal/ceramic joining and mechanical characteristics-as being the optim techniques based on the active soldering method and solution. electroplating. Fig 19 shows the 3D braiding facility Within the framework of hot-firing testing, funded at EADS Research(Ottobrunn)and Fig. 20 depicts in-house, C/SiC nozzle extensions for upper- and the robot-assisted stiching machine lower-stage engines as well as C/SiC combustion In frame of a common development progran chambers for small thrusters(400 N) were designed of MBDA-France, EADS ST France, EADS ST manufactured and successfully subjected to hot-firing Germany and EADS Common Research Center Ger- testing any, fuel cooled combustion chamber structures The components were manufactured corresponding for hypersonic Dual-Mode Ramjets(PTAH-SOCAR to the laminating technique from CFRP technologyS. Schmidt et al. /Acta Astronautica 55 (2004) 409 – 420 419 Fig. 19. 3D braiding facilityEADS Research Ottobrunn. production methods for processing carbon 3bres have been developed further and innovative machine concepts elaborated for making special semi3nished products. New braiding techniques o;er extremely productive methods for making contoured 3bre pre￾forms such as combustion chambers or nozzles. Thus the 3D braiding technique o;ers quite a few advantages. 3D braided pro3les can be varied in shape and cross section and are characterized byhigh struc￾tural integrityand tolerance, as the braiding threads can be led laterallythrough the component wall, thus representing a reinforcement in thickness direction. Thanks to using sewing threads made of carbon 3bre, cost e;ective, tailor-made 3D reinforcements for ten￾sile and shear loads can be created. The actual inno￾vation with this material development is the combina￾tion of an extremelycost-e;ective in3ltration method with the textile technique for making multidirectional 3bre-composite ceramics. Within the scope of a re￾gionallysponsored development programme, inten￾sive work is being carried out, in addition to material and process development, on metal/ceramic joining techniques based on the active soldering method and electroplating. Fig. 19 shows the 3D braiding facility at EADS Research (Ottobrunn) and Fig. 20 depicts the robot-assisted stiching machine. In frame of a common development program of MBDA-France, EADS ST France, EADS ST Germanyand EADS Common Research Center Ger￾many, fuel cooled combustion chamber structures for hypersonic Dual-Mode Ramjets (PTAH-SOCAR Fig. 20. Robot stitching machine. technology) become manufactured by a combi￾nation of textile techniques of EADS-ST France (AEROTISSJ material) and the above mentioned low-cost LSI process. 4. Summary New, innovative approaches must be followed in the area of material development in order to addi￾tionallycreate, besides the customaryone-wayengine components, reusable propulsion technologies for the future. In this context, using 3bre-reinforced ceramics, in particular C/SiC ceramics, is becoming increasingly obvious—thanks to their outstanding thermophysical and mechanical characteristics—as being the optimal solution. Within the framework of hot-3ring testing, funded in-house, C/SiC nozzle extensions for upper- and lower-stage engines as well as C/SiC combustion chambers for small thrusters (400 N) were designed, manufactured and successfullysubjected to hot-3ring testing. The components were manufactured corresponding to the laminating technique from CFRP technology