Channel Wall Nozzle Manufacturing and Hot-Fire Testing using a Laser Wire Direct Closeout Technique for Liquid Rocket Engines

Gradl, Paul R.; Brandsmeier, William; Greene, Sandy E.

doi:10.2514/6.2018-4860

Cited by 9 publications

(2 citation statements)

References 6 publications

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“…NASA has demonstrated GRCop-84 consolidation methods including direct extrusion, hot isostatic pressing (HIP) to form, and vacuum plasma spraying (VPS) into shape and densifying with HIP [2]. NASA has also demonstrated a variety of welding techniques including diffusion bonding, inertia welding, friction stir welding, electron beam welding, and brazing, but limited information on these techniques is available currently [2,83,84]. Combustion chamber liners of GRCop-84 have been produced by VPS, conventional wrought processing, and by powder bed additive manufacturing (AM), with AM proving to be the most versatile processing technique [82,85].…”

Section: Fabrication Of Grcop Alloysmentioning

confidence: 99%

Copper-based alloys for structural high-heat-flux applications: a review of development, properties, and performance of Cu-rich Cu–Cr–Nb alloys

Minneci

Lass

Bunn

et al. 2020

International Materials Reviews

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This review examines the development and current state of Cu-rich Cu-Cr-Nb alloys commonly referred to as GRCop or Glenn Research copper alloys with emphasis on Cu-8Cr-4Nb (at%), or GRCop-84, and Cu-4Cr-2Nb, or GRCop-42. Recent additive manufacturing efforts have increased interest in GRCop alloys, and full-scale hardware has been fabricated using AM techniques and practical hot-fire tests have been conducted, but structure-property relationships are still under development. The development, processing, and current microstructure-property relationships of GRCop alloys are reviewed along with comparisons to similar high-heat-flux Cu alloys including NARloy-Z, GlidCop Al-15, AMZIRC, Cu-1Cr-0.1Zr, and Cu-0.9Cr. The review concludes with an assessment of future prospects for GRCop alloys and overview of advantages provided by additive manufacturing.

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Section: Fabrication Of Grcop Alloysmentioning

confidence: 99%

Copper-based alloys for structural high-heat-flux applications: a review of development, properties, and performance of Cu-rich Cu–Cr–Nb alloys

Minneci

Lass

Bunn

et al. 2020

International Materials Reviews

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“…LWDC is an additive manufacturing wire-fed laser deposition process that eliminates the need for a tight tolerance structural jacket and plating operations. A small diameter wire is generally used and the low heat flux freeform wiredeposition process provides the ability to form the jacket in place while maintaining the geometry of the thin-walled channel lands or ribs minimizing overall distortion 15 .…”

Section: Laser Wire Depositionmentioning

confidence: 99%

Additive Manufacturing of Liquid Rocket Engine Combustion Devices: A Summary of Process Developments and Hot-Fire Testing Results

Gradl

Greene

Protz

et al. 2018

2018 Joint Propulsion Conference

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Additive Manufacturing (AM) of metals is a processing technology that has significantly matured over the last decade. For liquid propellant rocket engines, the advantages of AM for replacing conventional manufacturing of complicated and expensive metallic components and assemblies are very attractive. AM can significantly reduce hardware cost, shorten fabrication schedules, increase reliability by reducing the number of joints, and improve hardware performance by allowing fabrication of designs not feasible by conventional means. The NASA Marshall Space Flight Center (MSFC) has been involved with various forms of metallic additive manufacturing for use in liquid rocket engine component design, development, and testing since 2010. The AM technique most often used at the NASA MSFC has been powder-bed fusion or selective laser melting (SLM), although other techniques including laser directed energy deposition (DED), arc-based deposition, and laser-wire cladding techniques have also been used to develop several components. The purpose of this paper is to discuss the various internal programs at the NASA MSFC using AM to develop combustion devices hardware. To date at the NASA MSFC, combustion devices component hardware ranging in size from 100 lbf to 35,000 lbf have been designed and manufactured using SLM and deposition-based AM processes, and many of these pieces have been hot-fire tested. Combustion devices component hardware have included thrust chamber injectors, injector components such as faceplates, regeneratively-cooled combustion chambers, regeneratively-cooled nozzles, gas generator and preburner hardware, and augmented spark igniters. Ongoing and future developments for combustion devices have also included design of components sized for boost-class engines. Several design and hot-fire test iterations have been completed on these subscale and larger scale components, and a summary of these results will be presented as well.

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Additive manufacturing for space: status and promises

Enea

Moon

2019

Int J Adv Manuf Technol

105

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Additive Manufacturing (AM) or 3D printing is a manufacturing technique where successive layers of material are layered to produce parts. The design freedom afforded by AM is ideal for the space industry, where part production is low volume and highly customized. The objective of this paper is to review research in the area of Additive Manufacturing For Space (AMFS) in all areas, from propulsion to electronics to printing of habitats, and to identify the gaps and directions in the research. In this paper we investigate the AMFS research by splitting it into two domains: space and ground-based. Space-based AMFS has been performed on the International Space Station using polymers and we also discuss the future of in-space AM, a subject closely related to more general in-space manufacturing. The ground-based research is split into three categories based on the printing material: metal, polymer, and other. The last category includes regolith, cement, and ceramic. This paper explores AMFS by bringing together as much research information as possible using a combination of papers, presentations, and news articles. We expect that the paper will allow the reader to gain an understanding of the current status of AMFS research and will contribute to the field as a reference and research guidelines.

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Channel Wall Nozzle Manufacturing and Hot-Fire Testing using a Laser Wire Direct Closeout Technique for Liquid Rocket Engines

Cited by 9 publications

References 6 publications

Copper-based alloys for structural high-heat-flux applications: a review of development, properties, and performance of Cu-rich Cu–Cr–Nb alloys

Copper-based alloys for structural high-heat-flux applications: a review of development, properties, and performance of Cu-rich Cu–Cr–Nb alloys

Additive Manufacturing of Liquid Rocket Engine Combustion Devices: A Summary of Process Developments and Hot-Fire Testing Results

Additive manufacturing for space: status and promises

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