Chemical vapor deposition (CVD) has been used to fabricate rhenium liquid rocket combustion chambers since 1979. CVD iridium was first applied to rhenium chambers for high temperature oxidation protection in 1986. The addition of iridium permits chamber operation for long durations at temperatures around 2200°C and provides a specific impulse increase on the order of 3 to 5%. Since 1986, CVD iridium/rhenium (Ir/Re) chambers have been successfully hot-fire tested at various facilities in both nitrogen tetroxide/monomethyl hydrazine (NTO/MMH) and oxygen/hydrogen (02/H2) bipropellants, the latter at mixture ratios ranging from 4 to 17, for a total of nearly 200 hours. An alternate processing method being investigated is to form the rhenium by powder metallurgy (PM) and apply the iridium by electrodeposition (ED). To date, hot-fire testing of chambers produced by this ED/PM method includes 43 seconds in NTO/MMH and approximately 11 hours in 02/H2 at mixture ratios of 3 to 4, a range having an oxidizing potential that may actually be benign to unprotected rhenium. These processing methods and their relationship to fabricating Ir/Re combustion chambers, as well as test methods for evaluating their efficacy, have been evaluated and a means of comparing the severity of different tests has been developed.
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