Development of an embedded hydrogen peroxide catalyst chamber in low temperature co-fired ceramics

Advances in microelectronics have driven a move to smaller satellites in the range of 10 to 50 kg. These satellites require smaller propulsion devices with lower propellant requirements to perform pointing and station-keeping tasks in orbit. Recent advances in embedding micro-channels and catalytic surfaces in monolithic LTCC structures provide a unique platform to produce a reliable, low-cost micro-propulsion system. The proposed design uses micro-channels embedded in the ceramic substrate to create a nozzle and embedded catalyst chamber. A hydrogen peroxide monopropellant is injected into a silver coated catalyst chamber structure. The monopropellant decomposes into hot gas which is expelled through the nozzle producing thrust. This work will describe the development of an embedded micro-channel hydrogen peroxide catalyst chamber using LTCC materials. A thermal energy balance and a kinetic model of the reacting flow will be presented to indicate the predicted catalyst chamber performance. The performance testing of the catalyst chamber will be described. A water test was performed to check for structural integrity at high pressures and flow. Both 30% and 90% hydrogen peroxide solutions will be introduced to measure decomposition performance based on temperature measurements on the device surface and in the exit plume. These predictions will be used to validate the design and model predictions.