Freeform Fabrication of Cost & Weight Efficient Hot Gas Valves

The proposed work addresses limitations in current methods used to fabricate fluidic hot gas valve bodies for divert propulsion. Fluidic valves are preferred over more conventional valves because of their extremely fast response time, on the order of several milliseconds. Fluidic valve bodies however, present significant fabrication challenges due to the complicated internal flow channels and cavities in the multistage amplifier designs. The proposed fabrication approach is based on stereolithography, a solid freeform fabrication method that Ceramic Composites, Inc has adapted to the direct fabrication of metal and ceramic components. The fabrication approach enables consideration of several innovative lightweighting options which will also be pursued in Phase I. The proposed work seeks to develop photocurable rheniun resins and demonstrate their use in stereolithography fabrication of hot gas valve bodies. In addition, lightweight rhenium composite materials will be fabricated and tested. Density reductions approaching 50% are expected with limited loss, and some enhancement, of key properties relative to solid rhenium.