Fabrication of Composite Combustion Chamber/Nozzle for Fastrac Engine

The Fastrac Engine developed by the Marshall Space Flight Center for the X-34 vehicle began as a low cost engine development program for a small booster system. One of the key components to reducing the engine cost was the development of an inexpensive combustion chamber/nozzle. Fabrication of a regeneratively cooled thrust chamber and nozzle was considered too expensive and time consuming. In looking for an alternate design concept, the Space Shuttle's Reusable Solid Rocket Motor Project provided an extensive background with ablative composite materials in a combustion environment. An integral combustion chamber/nozzle was designed and fabricated with a silica/phenolic ablative liner and a carbon/epoxy structural overwrap. This paper describes the fabrication process and developmental hurdles overcome for the Fastrac engine one-piece composite combustion chamber/nozzle.