Embedded catalytic channels in low temperature co-fired ceramics

The trend towards ever smaller satellites increases the need for miniaturized propulsion devices to control these satellites and the reduced propellant needs to maintain them in low earth orbits. The LTCC medium is fast becoming a product of choice for a variety of different products due to it flexibility in applications. With recent advances in fabrication techniques allowing us to embed micro-channels within monolithic ceramic devices, we believe we can provide inexpensive and reliable micro-propulsion systems. This work will describe the design and fabrication of catalytic micro-channels 0.75mm in width embedded in multi-layered devices. These devices consist of silver paste applied to the surface of the channels which allows for decomposition of 90% hydrogen peroxide. The decomposed hot gas is then passed through a micro-nozzle to produce the needed thrust to control the satellite. This work will describe the design and fabrication of these multi-layered devices with channel sizes 0.75mm in width. Three fabrication processes will be detailed including: channel construction using a LASER milling machine, silver paste deposition using a CNC Direct Write tool as well as the use of a sacrificial carbon tape to maintain the channel integrity during lamination. Several images will be used to illustrate these processes. Each of the completed devices will be tested for leakage and pressure losses by flowing non-reactive water through the channels. The catalytic performance of each device will be tested using hydrogen peroxide. This performance will be described using thermocouple measurements on the outer surface of the ceramic device and in the exhaust plume.