China3D printingNet February 8th, additive manufacturing (AM) brings new and important design and manufacturing opportunities for rocket engine components with complex internal features and thin walls. Many developments in additive manufacturing have focused on existing or monolithic alloys, which cannot fully optimize the application structure. The recent success of NASA’s Directed Energy Deposition (DED) has shown that AM cost savings and reduced schedules have brought considerable returns, while weight reduction and performance improvements have been optimized.
L-PBF GRCop-42 chamber with polished outer surface (left) and unpolished (right).
The National Aeronautics and Space Administration (NASA) has demonstrated the use of laser powder bed fusion (L-PBF) GRCop-84 copper alloy liquid rocket engine combustion chamber and AM electron beam free Inconel 625 structural sheath under low-cost advanced propulsion (LCUSP) A successful project for bimetallic additive manufacturing. The product has been successfully tested in 2018 at NASA Marshall Space Flight Center in Huntsville, Alabama, and has been further developed into a mature bimetal combustor through cooperation with the industry. Continue to conduct further research to commercialize GRCop-84 AM and promote the development and supply chain of GRCop-42. The GRCop series of copper alloys has been tested under multiple NASA projects (including the future lunar lander concept) using various propellants for more than 30,000 seconds of heat testing. GRCop alloy was developed by NASA’s Glenn Research Center in Cleveland, Ohio. It is a high-strength, high-conductivity copper-chromium-niobium alloy for high-performance rocket combustion chambers.
Bimetal 7k coupling chamber using L-PBF GRCop-42 and NASA HR-1 LP-DED integrated nozzle
(Right: equipped with manifold).
In addition to working with the GRCop-84 and GRC-42 chambers, the test of AM integrated channel nozzles made of high-strength iron-nickel-based superalloy (NASA HR-1) also pointed out that it can be used as a potential choice for high-pressure materials. environment. NASA HR-1 can be easily printed using L-PBF and laser powder directed energy deposition (LP-DED) process. Through heat treatment, both DED and L-PBF materials can obtain ideal microstructures. NASA is currently studying the microstructure, material properties and material properties of NASA HR-1 alloy. NASA’s Space and Technology Mission Division (STMD) Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project is part of the STMD game change development plan, and most of the project’s work is in progress. The RAMPT project previously reported that a large integrated channel nozzle with a diameter of 40 inches (1.016 meters) and a length of 38 inches (0.965 meters) was successfully printed. NASA recently used NASA HR-1 alloy and LP-DED process and a complete channel to successfully conduct a heat test. The channel has accumulated more than 40 starts and 500 seconds of high performance so far.
Bimetal 40k chamber made with L-PBF GRCop-42 lining and NASA HR-1 LP-DED jacket
(RPM Innovation/NASA)
The RAMPT team has successfully printed larger channels using the same LP-DED technology through a partnership with NASA Marshall’s Space Launch System (SLS) Liquid Engine Office and a public-private partnership with Auburn University in Alabama. Wall nozzle. The nozzle diameter is 60 inches (1.524 meters) and the length is 72 inches (1.828 meters), which is 65% of the nozzles of the RS-25 engine on the SLS rocket. The nozzle was printed at RPM Innovations in Rapid City, South Dakota within 90 days. This additive manufacturing process can reduce the number of nozzle parts from more than 1,100 to less than 10. This innovative process can quickly advance technological progress through nearly complete prototyping and manufacturing evaluation. The team quickly rolled out the technology to the large demonstrator in less than five months, thus verifying the printing of key features such as integral coolant channels and thin walls, while minimizing distortion.
Use LP-DED NASA HR-1 alloy (RPM Innovations / NASA) to make a 60-inch diameter, 72-inch length integral channel wall nozzle, the proportion of which is 65% of the RS-25 nozzle
The RAMPT project expands the advantages of AM nozzles and chambers and further refines these technologies to integrate AM processes to allow the use of integrated bimetal and multi-alloy components. NASA is studying the direct installation of the LP-DED of the NASA HR-1 channel cooling nozzle to the L-PBF GRCop-42 chamber to eliminate the bolt connection. Material characterization, testing and heat testing of these technologies are in progress. In addition to these major manufacturing developments, the modeling work also complements the AM process development to simulate the AM process to reduce construction failure and deformation.
L-PBF GRCop-42 and LP-DED NASA HR-1 nozzle long-life additive manufacturing assembly (LLAMA) hot fire test,> 50 starts and> 1,000 seconds (01-27-2021)
China3D printingNet Comments: NASA continues to conduct AM process development, material characterization and testing, and thermal testing to prove the suitability of GRCop-42 and GRCop-84 alloys for rocket combustion chambers and NASA HR-1 for nozzles and other components. The NASA team is actively involved in advancing the industrial supply chain of these materials and processes, and has cooperated with many commercial aerospace companies through the “Space Act Agreement” and released data and technical reports. The goal is to use these materials and processes for future NASA and commercial space missions to explore the Moon and Mars.
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