High Performance Components and Assemblies
Plasma manufactures a wide range of advanced propulsion components leveraging our additive manufacturing technologies including Electroforming (El-Form), Plasma Spray deposition, precision 3D printing, and also conventional CNC machining, Electrical Discharge Machining (EMD, including rotary), and 5-axis. We produce high-performance aerospace and missile components utilized in solid rocket motors (SRMs), divert and attitude control systems (DACS), rotating detonation engines (RDEs), ramjets, scramjets, satellites, commercial airplanes, and more.
Our product portfolio includes critical elements such as nozzles, thrust chambers, pintles, non-eroding throats, crucibles, igniters, electrodes, bulkheads, structural brackets, thrusters, and even fully integrated propulsion assemblies through our dedicated propulsion division, Rubicon Space Systems. We collaborate closely with customers to define optimal material systems and manufacturing processes that meet stringent performance, cost, and schedule objectives.
Whether you require precision-engineered components for production or quick turnaround prototypes, Plasma can assist you with these needs.
Liquid Rocket Engine Subcomponents
- Radiation Cooled Combustion Chambers
- Non-toxic Green Propellant Combustion Chambers
- Regeneratively Cooled Combustion Chambers
- Injector and Faceplate Coatings
- Catalyst Beds and Igniters
- Nozzle Extension Coatings
- Preburners
- Valves
- Reaction Control Systems (RCS)
- Rotating Detonation Engines (RDE)
- Divert and Attitude Control Systems (DACS)
Solid Rocket Motor Subcomponents (SRM)
- Refractory Metal Subcomponents
- Ultra High Temperature Ceramic (UHTC) Subcomponents
- Composite Material Subcomponents
- Divert and Attitude Control System (DACS) Subcomponents
- Non-Eroding Rocket Nozzles
- Structural Insulators
- Case Insulators
Through our Additive Manufacturing or Machining capabilities, we can provide a variety of components. Some examples are crucibles, for high-temperature controls, pintles for controls, non-eroding and other forms of throats, combustion chambers, nozzles, electrodes, ignitors, catalysts, and more.
PRODUCTS
Catalyst Products
Plasma Processes is producing refractory and noble metal foams for a variety of applications. The foams are available in various porosities from 30 to 100 PPI (pores per inch) configurations, in Tungsten, Rhenium, Molybdenum, Niobium, Tantalum, Hafnium, Zirconium, Iridium, Ruthenium, Rubidium, and Platinum; as well as alloys such as Iridium-Rhodium and Iridium-Platinum. The foams have an open cell structure consisting of a regular matrix of connecting ligaments.
Surface area of foam samples was measured using BET gas absorption analysis to average 0.450 m2/g for 60 PPI high-temperature monolithic foams to 0.815 m2/g for 60 PPI Ruthenium foam. The foams have a high compressive strength, which can be tailored by adjusting the density of the foam and the thickness of the ligaments.
High-temperature monolithic foams developed by Plasma Processes have been used successfully for the catalytic ignition of AF-M315E and LMP-103S monopropellants in thrusters. In this application, high-temperature monolithic foam has operated at very high temperatures of approximately 1850 °C (3362 °F). The high temperature strength of the foam allowed the foam to operate without the need for a catalyst bed plate required by granular catalysts. The monolithic structure of the foam increases the durability and service life of the catalyst.
Because of the varied selection of materials and porosities in which these foams can be produced, as well as Plasma Processes’ ability to tune mechanical and material properties of these foams allows for a there is a wide range of applications for these foams that include catalysts, biomedical and biomaterial applications, anodes in electrochemical processes, among many other industries and uses.
Finishing and Assembly
Plasma is fully equipped to provide additional product services such as final finishing, assembly, or integration per Build-to-Print (B2P) instructions or specifications on components or assemblies for our customers. We can fabricate, surface prep, coat, deburr, machine finish, assemble/integrate, braze, vacuum heat treating, grit blast, mask, furnace treat, and more utilizing our newly acquired capabilities. Plasma can provide an entire assembly back to our customers from a clean sheet drawing. If you would like these services, or want to know more, please request a quote below. Our team is ready to provide full end-to-end assemblies to our customers vs. only one process.
APPLICATIONS
What it’s used for
Plasma Processes offers innovative products and services for highly demanding markets and is dedicated to providing customers with advanced materials solutions and enabling capabilities. We drive technology with engineered products and coatings for emerging technologies through the implementation of unique materials and processes.