3D printing helps the U.S. complete the construction of the first next-generation AR1 engine

AR1 is a 500,000-pound thrust-class liquid oxygen/kerosene engine. The United States hopes to use it to replace Russia’s RD-180 engine. According to CNBC January 13, 2021, Aerojet Rocketdyne has completed the construction of AR1, and the ignition test is scheduled to start in 2022. Aerojet Rocketdyne successfully completed the hot ignition test of key components of its AR1 supercharged engine in 2015.

AR1 engine © CNBC

Fierce competition for the next generation of rocket engines

When traditional manufacturing technology cannot meet the requirements,3D printingTechnology has opened up a whole new path for it.Metal3D printingThe technology is able to quickly produce parts and components with high material properties, special-shaped structures, and structural integration characteristics, which opens up an innovative approach for next-generation products.

This not only realizes the integrated structure of the parts, avoids the connection structure (flanges, welds, etc.) that exist when the original multiple parts are combined, but also helps the designer to break through the constraints and achieve functional optimization design. The realization of the integrated structure not only brings the advantages of light weight, but also reduces the need for assembly and opens up feasible space for enterprises to improve production efficiency.
AR1 engine

©CNBC

Aerojet Rocketdyne has invested a lot of time and resources in the past two decades3D printing/Additive manufacturing applications to meet the stringent requirements of rocket engines and defense system applications.According to the market research of 3D Science Valley, in recent years, Aerojet Rocketdyne has achieved many successes in the development of this technology, with a wide range of products, including prototypes of components, and complete ignition tests.3D printingTechnically manufactured engines and propulsion systems.

3D printingEjector technology

In 2015, NASA and Aerojet Rocketdyne completed the test of fuel injectors for their rocket AR1 supercharged engines, with the purpose of evaluating the design and manufacturing methods of various main fuel injection components.The ejector uses a selective laser to melt the metal3D printingTechnology made.The test was carried out at a pressure exceeding 2000 psi, which was one of the rocket engine applications at the time3D printingThe highest pressure hot ignition test of the component. The test results show that only one item in the main injector,3D printingThe delivery time of parts and components has been reduced by nearly 9 months, and the cost has been reduced by 70%.

3D printingMain injector © Aerojet Rocketdyne

3D printingCopper alloy

Aerojet Rocketdyne at3D printingThe copper alloy thrust chamber components have certain development experience. Compared with the traditional manufacturing process, laser melting is selected.3D printingTechnology has brought a higher degree of freedom to the design of the thrust chamber, allowing designers to try advanced structures with higher thermal conductivity. The enhanced heat transfer capability makes the design of the rocket engine more compact and lightweight, which is exactly what the rocket launch technology needs.

Laser melting through selection 3D printingTechnology manufactures optimized and upgraded thrust chamber components. Aerojet Rocketdyne’s copper alloy thrust chamber has a manufacturing cycle of one month, which is several months shorter than the previous manufacturing cycle.Due to3D printingThe characteristics of the technology have been improved in design, Aerojet Rocketdyne has reduced the complexity of the manufacturing process and achieved lower manufacturing costs.

The competition is currently losing to BE-4

R-1 is currently losing ground to Blue Origin’s BE-4 engine in winning market orders.And Blue Origin uses3D printingTechnology to print the shell, turbine, nozzle and rotor of BE-4 rocket engine. BE-4 is a new generation rocket engine fueled by liquefied natural gas. In addition to the thrust provided by the main pump, the BE-4 also mixes liquid oxygen and natural gas through several “boost” turbo pumps to provide 500,000 pounds of thrust.It can be said3D printingIt has played a key role in the production of Blue Origin’s engines and is even more eye-opening.

(Editor in charge: admin)