Redesign Approach
The catalyst bed support structure was redesigned using a high-temperature nickel-based superalloy with reinforcement ribs. The previous design used stainless steel in a simple grid configuration. The new geometry includes ribs to prevent buckling and maintains strength at high temperature.
Analysis and Verification
Finite element analysis modeled the catalyst bed under expected operating conditions: 50 bar chamber pressure, 900°C temperature, and dynamic vibration. The analysis showed the new design has a safety factor of at least 3—acceptable for a development program and conservative enough to provide confidence in structural integrity.
Test Results
The new design was fabricated and tested on the test stand. A 30-second burn with standard catalyst formulation showed flawless performance. Chamber pressure was steady, thrust was consistent, and no anomalies occurred. The catalyst bed support showed no signs of damage or stress. Several additional tests with the new design were all successful.
Program Impact
The robust new design enables more aggressive testing—higher pressures, longer burn times, and new catalyst formulations without concern for structural failure. The test stand failure forced more careful design consideration, resulting in a much more reliable and robust thruster. The program can now proceed with confidence in structural integrity.