<b>Investigation of Additively Manufactured Silver Plated Stainless Steel Monolith Catalyst Beds</b>
Creators: name: Farquharson, Amelia Jane
Publisher: name: Purdue University Graduate School
Year: 2024
Subjects: classificationCode: 400106
subject: Hypersonic propulsion and hypersonic aerothermodynamics
classificationCode: 400107
subject: Satellite, space vehicle and missile design and testing
classificationCode: 400101
subject: Aerospace materials

description: Additive manufacturing has introduced new possibilities for the design and manufacturing of monolith catalyst beds. Many hydrogen peroxide monolith catalyst beds are made of ceramics and washcoated through a complex process. However, creating a metal monolith bed with the tried-and-true silver catalyst could provide an alternative decomposition method for 90 wt.% hydrogen peroxide with easier manufacturing methods and similar or better decomposition efficiency. 91.2 wt.% hydrogen peroxide was decomposed with a lattice-type monolithic catalyst bed additively manufactured out of 316L stainless steel that was electroplated with pure silver. The variables investigated included the catalyst bed’s mass loading, chamber pressure, pressure drop, and length-to-diameter ratio (L/D). The catalyst bed had loadings of 0.1 lb<sub>m</sub>/s/inch<sup>2</sup>, 0.25 lb<sub>m</sub>/s/inch<sup>2</sup>, and 0.4 lb<sub>m</sub>/s/inch<sup>2</sup>. One catalyst bed configuration had an L/D of 2.6, while the other configuration had an L/D of 0.85. A modular throat controlled the chamber pressures for each catalyst bed loading case. The decomposition efficiency was calculated with the theoretical and expected characteristic velocity (c*) of the catalyst beds. The chamber pressures for the lowest bed loading and highest L/D ratio varied from 52 psia to 202 psia. The hydrogen peroxide decomposition efficiency was approximately 85% for the lowest chamber pressure and approximately 100% for the highest chamber pressure. The chamber pressures for the middle and highest bed loading and high L/D were 193 psia at the lowest to 325 psia at the highest. The decomposition efficiencies for all middle and highest bed loading tests with high L/D were 90% or higher for all tests. For all of the highest L/D tests, decomposition was also confirmed by observing videos of the exhaust plume, which was clear and showed no sign of flow channeling. For all of the highest L/D tests, the pressure drops in all of the middle bed loading cases were at or below 30% of the chamber pressure. The high chamber pressure, highest bed loading cases also had a pressure loss below 30% of the chamber pressure. The smallest L/D configuration performed significantly worse than expected, with efficiencies between 15-25% at chamber pressures between 33-75 psi. The silver electroplated on the stainless steel survived the 143 s of lifetime on the catalyst bed during testing with minimal to no silver loss determined by weight and visual inspection with a microscope post-test. The higher L/D catalyst bed tests prove that silver electroplated on to an additively manufactured stainless steel monolith is a viable method for creating a catalyst bed. More research is required to determine the lowest L/D possible, which resides somewhere between the two L/D cases studied, and higher bed loadings also require investigation.