Process Development and Hot-fire Testing of Additively Manufactured NASA HR-1 for Liquid Rocket Engine Applications

Gradl, Paul R.; Teasley, Thomas W.; Protz, Christopher S.; Katsarelis, Colton; Chen, Po

doi:10.2514/6.2021-3236

Cited by 23 publications

(6 citation statements)

References 11 publications

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“…There have been numerous attempts to describe the existing structure of additive manufacturing techniques. For instance, in studies [1,2], the following scheme is presented According to the scheme presented in Fig. 1, metal additive manufacturing can be roughly divided into three main categories, each characterized by the primary materialand the underlying process principle.In the study [3], the division is based on the method of delivering thermal energy: beam and beamless (see Fig.…”

Section: Review Of Methodsmentioning

confidence: 99%

Features of the Development of Additive Manufacturing Methods in Application to Liquid Propellant Rocket Engines

Векілов,

Ліповський

2023

Rocket-Sp. Tech.

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Abstract. Modern development of additive manufacturing methods makes it necessary to seriously consider an alternative type of production for the manufacture of liquid rocket engine structures. On the one hand, additive manufacturing has a number of undeniable advantages compared to classical methods traditionally used in the rocket and space industry. On the other hand, products obtained by this method have characteristic features that must be taken into account at the early stages of design: relatively high surface roughness, the need to adapt the geometry of existing technical solutions, material properties, etc. Moreover, a full-fledged quality control system for the resulting products is currently the moment is missing, and the standardization of the production class is just emerging. It is also important to understand the direction of development of additive manufacturing, which in the future can lead to a significant increase in the characteristics of the resulting products. This paper discusses options for classifying additive manufacturing methods, provides definitions and classification of metal 3D printing methods, according to the existing ISO/ASTM 52900 standard, as well as the main features of the technology. The main advantages and disadvantages of additive manufacturing methods are considered, and a structural decomposition of the typical design of a liquid propellant rocket engine chamber is carried out. The work aimed at manufacturing structural elements for further integration into the production cycle of liquid-propellant rocket engines is considered. The work is considered, the results of which were a combination of additive technology methods, which made it possible to apply the concept of bimetallic additive production. Such products were produced without the use of complex technological equipment and belong to the product of “evolving” additive manufacturing. Based on the results of the work, it was concluded that it is possible to use additive technologies to improve the performance of new liquid-propellant rocket engine designs.

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Section: Review Of Methodsmentioning

confidence: 99%

Features of the Development of Additive Manufacturing Methods in Application to Liquid Propellant Rocket Engines

Векілов,

Ліповський

2023

Rocket-Sp. Tech.

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“…Likewise, the A-CT7 engine mid-frame-once seven assemblies with 300 parts-is now a single piece without additional assembly, shedding five kilograms in return [6]. SpaceX has also achieved 40% reductions in production time and weight for their engines using metal AM [10,45]. The National Aeronautics and Space Administration (NASA) is planning similar applications for the Space Shuttle's main engine [45].…”

Section: Metal Additive Manufacturingmentioning

confidence: 99%

“…SpaceX has also achieved 40% reductions in production time and weight for their engines using metal AM [10,45]. The National Aeronautics and Space Administration (NASA) is planning similar applications for the Space Shuttle's main engine [45]. Astonishingly, the world's first printed metal bridge, a 10.5-m wonder spanning Amsterdam's Oudezijds Achterburgwal canal, is a testament to metal AM's versatility, even in the construction industry [46].…”

Section: Metal Additive Manufacturingmentioning

confidence: 99%

Advancements in 3D Printing: Directed Energy Deposition Techniques, Defect Analysis, and Quality Monitoring

Imran,

Che Idris,

De Silva

et al. 2024

Technologies

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This paper provides a comprehensive analysis of recent advancements in additive manufacturing, a transformative approach to industrial production that allows for the layer-by-layer construction of complex parts directly from digital models. Focusing specifically on Directed Energy Deposition, it begins by clarifying the fundamental principles of metal additive manufacturing as defined by International Organization of Standardization and American Society for Testing and Materials standards, with an emphasis on laser- and powder-based methods that are pivotal to Directed Energy Deposition. It explores the critical process mechanisms that can lead to defect formation in the manufactured parts, offering in-depth insights into the factors that influence these outcomes. Additionally, the unique mechanisms of defect formation inherent to Directed Energy Deposition are examined in detail. The review also covers the current landscape of process evaluation and non-destructive testing methods essential for quality assurance, including both traditional and contemporary in situ monitoring techniques, with a particular focus given to advanced machine-vision-based methods for geometric analysis. Furthermore, the integration of process monitoring, multiphysics simulation models, and data analytics is discussed, charting a forward-looking roadmap for the development of Digital Twins in Laser–Powder-based Directed Energy Deposition. Finally, this review highlights critical research gaps and proposes directions for future research to enhance the accuracy and efficiency of Directed Energy Deposition systems.

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“…During the build cycle, the platform on which the build is repositioned lowers by the thickness of one layer; the process continues until the build or model is completed [ 2 ]. Due to the possibility to produce parts with complex and/or personalized internal and external geometries along with other benefits of AM, LPBF attracts growing interest in various fields of engineering, including medical [ 3 ], aerospace and aviation [ 4 , 5 ], bridges [ 6 ], and tooling [ 7 ]. During the LPBF process, volume micro-elements of material experience rapid heating above their melting point and rapid solidification; moreover, material of the already synthesized volume is being reheated numerous times when further fusing of neighboring tracks and following layers is performed.…”

Section: Introductionmentioning

confidence: 99%

Fiber Laser Alloying of Additively Manufactured 18Ni-300 Maraging Steel Part Surface: Effect of Processing Parameters on the Formation of Alloyed Surface Layer and Its Properties

et al. 2023

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The development of new efficient, economical, and safe methods for strengthening the working surfaces of parts is an important task in the field of improving the reliability and resourcefulness of critical equipment and structures. In the present paper, laser boronizing is investigated as an alternative method for improving the wear resistance of maraging steel parts manufactured by laser powder bed fusion (LPBF). After LPBF, the specimens’ surface was covered with an amorphous boron paste (0.03–0.6 mm) and laser processed with a continuous-wave fiber laser in melting mode (λ—1070 nm; power—300 W; spot Ø—1.0 mm) at 500–1500 mm/min laser beam scanning speeds. Scanning electron microscopy, X-ray microanalysis, Knoop hardness, and dry sliding wear tests were applied to investigate the geometry, microstructure, hardness and its distribution, heat-affected zones, wear resistance, and wear mechanism of the alloyed layers. The boronized layers of thickness ~280–520 µm with microstructure from hypoeutectic to borides’ mixture were obtained, whose hardness varied from ~490 to ~2200 HK0.2. With laser boronizing, the wear resistance was improved up to ~7.5 times as compared with aged LPBF samples. In further method development, the problem of thermal cracking and softening of the heat-affected zone should be solved.

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Process Development and Hot-fire Testing of Additively Manufactured NASA HR-1 for Liquid Rocket Engine Applications

Cited by 23 publications

References 11 publications

Features of the Development of Additive Manufacturing Methods in Application to Liquid Propellant Rocket Engines

Features of the Development of Additive Manufacturing Methods in Application to Liquid Propellant Rocket Engines

Advancements in 3D Printing: Directed Energy Deposition Techniques, Defect Analysis, and Quality Monitoring

Fiber Laser Alloying of Additively Manufactured 18Ni-300 Maraging Steel Part Surface: Effect of Processing Parameters on the Formation of Alloyed Surface Layer and Its Properties

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