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A new asbestos-free insulation mixture of Expanded Perlite (PExp) and Cork Powder (CP) was developed for rocket motors. This sustainable alternative offers reduced density and improved thermal protection, enhancing safety in space programs.

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Area of Science:

  • Materials Science
  • Aerospace Engineering
  • Chemical Engineering

Background:

  • Rocket motor insulations like Flexible Thermal Protections (FTPs) and Rigid Thermal Protection (RTPs) are crucial for managing extreme combustion environments.
  • Traditional asbestos-containing FTPs used in the Brazilian Space Program pose significant health risks.
  • There is a need for safer, high-performance alternatives to asbestos-based thermal protection materials.

Purpose of the Study:

  • To investigate a novel mixture of Expanded Perlite (PExp) and Cork Powder (CP) as a viable, non-hazardous replacement for asbestos in FTPs.
  • To evaluate the thermal and physical properties of the PExp and CP composite material for rocket motor applications.
  • To assess the suitability of this new composite for attenuating propellant contraction and extending RTP performance.

Main Methods:

  • Formulation and characterization of a composite insulation material using Expanded Perlite (PExp) and Cork Powder (CP).
  • Experimental testing to determine the density and ablative properties of the developed PExp and CP mixture.
  • Comparative analysis of the new material's performance against traditional asbestos-containing FTPs.

Main Results:

  • The PExp and CP mixture demonstrated a significant reduction in density by approximately 21%.
  • A notable increase of 13% in ablative properties was observed for the new composite material.
  • The mechanical properties of the PExp and CP mixture were found to be adequate for FTP applications, as they do not impede the attenuation of propellant contraction.

Conclusions:

  • The developed Expanded Perlite and Cork Powder mixture presents a promising, safer alternative to asbestos-based insulations for rocket motors.
  • This eco-friendly composite offers enhanced ablative performance and reduced density, crucial for advanced thermal protection systems.
  • The material's properties align with the functional requirements of FTPs, supporting propellant contraction attenuation and extending overall system performance.