High temperature catalysts for decomposition of liquid monopropellants and methods for producing the same

Ceramic catalyst carriers that are mechanically, thermally and chemically stable in a ionic salt monopropellant decomposition environment, high temperature catalysts for decomposition of liquid high-energy-density monopropellants and ceramic processing techniques for producing spherical catalyst carrier granules are disclosed. The ceramic processing technique is used to produce spherical catalyst carrier granules with controlled porosities and desired composition and allows for reproducible packing densities of catalyst granules in thruster chambers. The ceramic catalyst carrier has excellent thermal shock resistance, good compatibility with the active metal coating and metal coating deposition processes, melting point above >2300° C., chemical resistance to steam, nitrogen oxides and nitric acid, resistance to sintering to prevent void formation, and the absence of phase transition associated with volumetric changes at temperatures up to and beyond 1800° C.