An actively-cooled, fiber-reinforced ceramic matrix composite thrust
chamber for liquid rocket propulsion systems is designed and produced
with internal cooling channels. The monocoque tubular structure consists
of an inner wall, which is fully integrated to an outer wall via radial
coupling webs. Segmented annular void spaces between the inner wall,
outer wall and adjoining radial webs form the internal trapezoidal-shaped
cooling channel passages of the tubular heat exchanger. The manufacturing
method enables producing any general tubular shell geometry ranging from
simple cylindrical heat exchanger tubes to complex converging-diverging,
Delaval-type nozzle structures with an annular array of internal cooling
channels. The manufacturing method allows for transitioning the tubular
shell structure from a two-dimensional circular geometry to a
three-dimensional rectangular geometry. The method offers the flexibility
of producing internal cooling channels of either constant or continuously
variable cross-sectional area, in addition to orienting the cooling
channels either axially, helically or sinusoidally (e.g., undulating)
with respect to the longitudinal axis of the tubular shell structure with
without significant added manufacturing complication.