Tech

July 12, 2013

NASA, industry test additively manufactured rocket engine injector

NASA and Aerojet Rocketdyne of West Palm Beach, Fla., recently finished testing a rocket engine injector made through additive manufacturing, or 3-D printing.

This space technology demonstration may lead to more efficient manufacturing of rocket engines, saving American companies time and money.

NASA’s Glenn Research Center in Cleveland conducted the successful tests for Aerojet Rocketdyne through a non-reimbursable Space Act Agreement.

A series of firings of a liquid oxygen and gaseous hydrogen rocket injector assembly demonstrated the ability to design, manufacture and test a highly critical rocket engine component using selective laser melting manufacturing technology. Aerojet Rocketdyne designed and fabricated the injector by a method that employs high-powered laser beams to melt and fuse fine metallic powders into three dimensional structures.

“NASA recognizes that on Earth and potentially in space, additive manufacturing can be game-changing for new mission opportunities, significantly reducing production time and cost by ‘printing’ tools, engine parts or even entire spacecraft,” said Michael Gazarik, NASA’s associate administrator for space technology in Washington. “3-D manufacturing offers opportunities to optimize the fit, form and delivery systems of materials that will enable our space missions while directly benefiting American businesses here on Earth.”

This type of injector manufactured with traditional processes would take more than a year to make but with these new processes it can be produced in less than four months, with a 70 percent reduction in cost.

“Rocket engine components are complex machined pieces that require significant labor and time to produce. The injector is one of the most expensive components of an engine,” said Tyler Hickman, who led the testing at Glenn.

Aerojet Rocketdyne’s additive manufacturing program manager, Jeff Haynes, said the injector represents a significant advancement in application of additive manufacturing, most often used to make simple brackets and other less critical hardware. “The injector is the heart of a rocket engine and represents a large portion of the resulting cost of these systems. Today, we have the results of a fully additive manufactured rocket injector with a demonstration in a relevant environment.” he said.

Glenn and Aerojet Rocketdyne partnered on the project with the Air Force Research Laboratory at Edwards Air Force Base, Calif. At the Air Force lab, a unique high-pressure facility provided pre-test data early in the program to give insight into the spray patterns of additively manufactured injector elements.

“Hot fire testing the injector as part of a rocket engine is a significant accomplishment in maturing additive manufacturing for use in rocket engines,” said Carol Tolbert, manager of the Manufacturing Innovation Project at Glenn. “These successful tests let us know that we are ready to move on to demonstrate the feasibility of developing full-size, additively manufactured parts.”




All of this week's top headlines to your email every Friday.


 
 

 

Headlines April 21, 2014

News: Former Ranger breaks silence on Pat Tillman death: I may have killed him - Almost 10 years after the friendly fire death of former NFL star turned Army Ranger Pat Tillman, a fellow ranger admits that he may have been the one who fired the fatal shot.   Business: Ship study should favor existing designs -...
 
 

News Briefs April 21, 2014

Navy OKs changes for submariners’ sleep schedules The U.S. Navy has endorsed changes to submarine sailors’ schedules based on research into sleep patterns by a military laboratory in Connecticut. With no sunlight to set day apart from night on a submarine, the Navy for decades has staggered sailors’ working hours on schedules with little resemblance...
 
 

NASA cargo launches to space station aboard SpaceX resupply mission

Nearly 2.5 tons of NASA science investigations and cargo are on the way to the International Space Station aboard SpaceX’s Dragon spacecraft. The spacecraft launched atop a Falcon 9 rocket from Space Launch Complex 40 at Cape Canaveral Air Force Station in Florida at 3:25 p.m., EDT, April 18. The mission is the company’s third...
 

 

Second series of CASIS-sponsored research payloads launch to ISS

The Center for the Advancement of Science in Space is proud to announce several sponsored research payloads have launched to the International Space Station onboard the Space Exploration Technology Corporation’s Dragon cargo capsule. This marks the second series of investigations headed to the station that are sponsored by CASIS, the nonprofit responsible for managing research...
 
 

Boeing to give California workers $47 million in back pay

PALMDALE, Calif. – Boeing will pay $47 million to hundreds of current and former Southern California employees who are owed back pay and benefits, a union announced April 18. An arbitrator ruled against the aerospace giant in January and laid down guidelines for the payments and interest, but it took months to cull through records...
 
 

NASA selects commercial crew program manager

NASA has selected Kathy Lueders as program manager for the agency’s Commercial Crew Program. Lueders, who has served as acting program manager since October 2013, will help keep the nation’s space program on course to launch astronauts from American soil by 2017 aboard spacecraft built by American companies. “This is a particularly critical time for...
 




0 Comments


Be the first to comment!


Leave a Reply

Your email address will not be published. Required fields are marked *

You may use these HTML tags and attributes: <a href="" title=""> <abbr title=""> <acronym title=""> <b> <blockquote cite=""> <cite> <code> <del datetime=""> <em> <i> <q cite=""> <strike> <strong>