Innovative Manufacturing Processes

Solid and liquid rocket propulsion systems including hot gas generators, liquid bi-propellant thrusters and Divert and Attitude Control Systems (DACS) are used in commercial space applications and by the department of defense. These propulsion systemsrequire components, such as for example hot gas valves and trust chambers, which must operate at high temperatures, pressures and often extremely oxidizing environments. Rhenium and Columbium alloys offer attractive high-temperature properties for use inthese aerospace applications. However, traditional methods of manufacturing with powder metallurgy and CVD are time consuming, have high production costs and rejection rates. The advanced manufacturing process that can offer net shape fabrication ofrocket engine components from rhenium and other refractory metals promises to revolutionize the cost and time of development of these complex components by eliminating the need for fixed tooling and high running costs associated with existing processes.The proposed PMD¿ low heat input flat metal wire laser deposition process shows promise in addressing issues with current technologies and has the potential for rapid net-shape manufacturing of refractory components with improved micro-structuralcharacteristics in exotic high temperature metals such as Rhenium or Columbium. The nation will benefit from a United States manufacturing base for an advanced process and a system capable of low heat and low distortion net shape rapid manufacturing.Such a system will enhance capabilities for manufacturing of components, with high temperature properties, for use in missile, rocket, space vehicle and satellite propulsion systems.