(I) Propulsion Materials. Next-generation propulsion systems operate under extreme conditions which can exceed the physical limits of current engineering materials. Conventional superalloys, for example, are susceptible to ignition and combustion under the high-pressure oxygen environment in advanced staged combustion rocket engines. The Cordero Lab aims to overcome such challenges by developing new materials optimized to withstand these harsh environments. Our approach is to first elucidate the mechanisms that drive material degradation during engine operation, then leverage this understanding to tailor material chemistry, microstructure, and properties in order to mitigate failures. We focus specifically on developing materials amenable to additive manufacturing, since intricately designed modern engines often necessitate net-shaping processes. This work will enable more robust, higher-performance, and lower-cost launch vehicles and spacecraft.

(II) In-Space Manufacturing. There is an ever-growing demand for larger structures in space: Larger solar panels achieve greater power output, larger antennas achieve higher gain and resolution, and larger solar sails achieve faster propulsion. However, the state-of-the art approach for deploying such systems in space limits their size to tens of meters, due to issues with reliability, precision, and other challenges unique to the space environment. To overcome these challenges, we are developing a method for manufacturing large, thermally stable structures in space from raw feedstock. Our approach relies on deformation processing, solid-state joining, and electrostatic actuation to fabricate truss structures for various space applications. Our initial focus is to construct a large electrostatically-actuated RF antenna on orbit from hierarchical feedstock. This work will enable a new generation of spacecraft with increased sensing, communication, and power capabilities.