Modern Manufacturing for Liquid Rocket Engine Components

Liquid Rocket Engine (LRE) component manufacturing process by conventional processes are comprised of multi steps, components are fabricated by conventional machining from a forged or rolled billet/sheet. As a result a long lead time is needed and part acquisition time is high. So a low cost fabrication process is needed to replace current traditional processes. Low cost, rapid fabrication of this component can be done by Additive Manufacturing (AM) where parts are fabricated by successive melting of layers of metal powder. By AM each layer is melted to the exact geometry defined by a 3D CAD model and the same part could be fabricated within hours. In this AF STTR Phase I program teaming with system integrator APS will develop innovative different AM machine compatible engineered copper alloy powders with high laser absorptivity and will demonstrate step by step fabrication process of porosity free rocket engine component by additive manufacturing with excellent high temperature strength, high thermal conductivity, creep resistant and low cycle fatigue property. This program will reduce the time required to fabricate parts for AF. Phase II will continue to develop this materials and will fabricate more specific components for AF