GREENLAM · Lightweight, Cost-effective Composite and Green Bipropellant System for Space Transportation Applications

Lightweight, Cost-effective Composite and Green Bipropellant System for Space Transportation Applications

The project titled "Lightweight Cost-effective Composite and Green Bipropellant System for Space Transportation Applications" (GREENLAM) successfully addressed the critical need for innovative, sustainable, and cost-effective technologies in space transportation. Responding to strategic imperatives like the European Green Deal, the project's core mission was to develop and validate the foundational technologies for a next-generation propulsion system by pioneering advancements in both green propellants and the advanced materials required to contain them. Context and Motivation: The modern space sector faces a dual challenge: reducing the high cost and environmental impact of launches while simultaneously improving performance and reliability. Traditional propulsion systems frequently rely on highly toxic and carcinogenic hypergolic propellants, such as hydrazine and its derivatives, which pose significant safety risks and require costly handling procedures. Furthermore, the heavy metallic alloys used in thruster manufacturing limit payload capacity and overall mission efficiency. GREENLAM was conceived to directly tackle these issues by creating a synergistic system of non-toxic propellants and lightweight, ultra-durable composite materials, thereby paving a path toward cleaner and more economical European space access. Overall Objectives: The project's primary objective was to develop and validate the core components for a lightweight, 100 N-class thruster designed for upper-stage applications. This was accomplished through two parallel research streams: - Composite Material Innovation: The project successfully fabricated and characterized a novel Ultra-High Temperature Ceramic (UHTC) matrix made of Zirconium Diboride and Silicon Carbide (ZrB2–SiC) using Spark Plasma Sintering (SPS). Extensive experimental work identified a key manufacturing trade-off: high-energy milling with Tungsten Carbide (WC) media yielded superior material density (up to 99.2%) and flexural strength, while conventional milling with Zirconia (ZrO2) produced a cleaner composite with exceptional hardness (up to 17.08 GPa) and fracture toughness. This research provides a critical roadmap for tuning material properties based on specific performance requirements. - Green Bipropellant System: The project successfully engineered and experimentally validated a hypergolic "green" bipropellant system. By doping kerosene fuel with a Manganese Acetylacetonate (Mn(II/III)AA) catalyst, research team achieved reliable, spontaneous ignition upon contact with High-Test Peroxide (HTP). This breakthrough eliminates the need for a separate, complex ignition system. The experimental campaign mapped the complete operational envelope, achieving exceptionally short Ignition Delay Times (IDTs) as low as 25 milliseconds under optimal preheated conditions. Political and Strategic Context: This research aligns closely with the European Green Deal's emphasis on low-emission transport technologies and sustainable innovation. By integrating green propellants and lightweight composite materials, the project directly supports Europe's commitment to lowering carbon emissions in space transportation. The project also addresses European strategic interests in aerospace by reducing dependency on non-European sources for critical materials like carbon fibers, as demonstrated by earlier EU-funded projects like EUCARBON. Pathway to Impact: GREENLAM's pathway to impact was realized through a powerful integration of experimental science and high-fidelity computational modeling. The material properties determined experimentally in Work Package 1 and the thermal and pressure loads generated from the bipropellant combustion analysis in Work Package 2 were fed into a comprehensive thermo-structural Finite Element Model (FEM) of the thruster. This simulation-driven approach successfully de-risked the technology and validated the thruster's design viability. It precisely identified critical stress zones—the nozzle throat during initial thermal shock and the flange region during prolonged burns—and enabled the optimization of the thruster's wall thickness to a tapered 2 mm profile, minimizing mass while ensuring structural integrity. This work provides a validated "digital twin" of the thruster, which is essential for future development and manufacturing. Scale and Significance: The project has significantly advanced the state-of-the-art for green propulsion in Europe. By successfully demonstrating a viable catalyst for HTP/Kerosene hypergolicity and characterizing a custom UHTCMC for its construction, GREENLAM has advanced the key technologies needed for a new class of reusable, low-toxicity thrusters. The project's scientific success is underscored by its prolific output of over ten research publications, far exceeding the initial target and contributing valuable, publicly available knowledge to the aerospace community. The findings create a direct pathway for developing flight-ready hardware that aligns with Europe's goals for strategic autonomy and environmental leadership in space. Integration of Social Sciences and Humanities: While the project is primarily technical in nature, its broader socio-political and ethical dimensions, particularly about environmental sustainability and the transition to green technologies, are inherently tied to the social sciences. The project considers the social impact of green technologies, particularly how the reduction of toxic emissions contributes to public health and environmental well-being. Additionally, the commercialization and adoption of green propellants involve regulatory and policy considerations that will require interdisciplinary collaboration, including insights from political science, economics, and environmental studies.

Текст от CORDIS, на английски · Данни: CORDIS, © Европейски съюз