Flexible Production of Geometrically Complex Rocket Propulsion Components

ABSTRACT: In order to design and manufacture complex, one-of-a-kind to limited quantity liquid rocket engine (LRE) components, while shortening the development cycle time and reducing the associated costs, an innovative method must be developed that expands upon current manufacturing technologies. A flexible manufacturing system that can handle the production of such parts in short time periods is desirable. Today"s near-net fabrication technologies are extremely limited in design flexibility due to the use of injection molding. Considering the need for design flexibility as well as shorter development cycles, reduced costs, and minimized variance in making one-of-a-kind components, an innovative manufacturing technology will be demonstrated in this work to eventually fabricate geometrically complex titanium LRE components. BENEFIT: Potential DoD and commercial applications of this technology include rocket and airbreathing propulsion system components, especially those requiring sophisticated internal passageways. Other possible applications are components and structures for industrial gas tubines, industrial pump and valve for corrosion resistance (petrochemical industry), and biomedical implants.