Tech

August 31, 2013

NASA tests limits of 3-D printing with powerful rocket engine check

The largest 3-D printed rocket engine component NASA ever has tested blazed to life Aug. 22 during an engine firing that generated a record 20,000 pounds of thrust.

This test is a milestone for one of many important advances the agency is making to reduce the cost of space hardware. Innovations like additive manufacturing, or 3-D printing, foster new and more cost-effective capabilities in the U.S. space industry.

The component tested during the engine firing, an injector, delivers propellants to power an engine and provides the thrust necessary to send rockets to space. During the injector test, liquid oxygen and gaseous hydrogen passed through the component into a combustion chamber and produced 10 times more thrust than any injector previously fabricated using 3-D printing.

“This successful test of a 3-D printed rocket injector brings NASA significantly closer to proving this innovative technology can be used to reduce the cost of flight hardware,” said Chris Singer, director of the Engineering Directorate at NASA’s Marshall Space Flight Center in Huntsville Ala.

The component was manufactured using selective laser melting. This method built up layers of nickel-chromium alloy powder to make the complex, subscale injector with its 28 elements for channeling and mixing propellants. The part was similar in size to injectors that power small rocket engines. It was similar in design to injectors for large engines, such as the RS-25 engine that will power NASA’s Space Launch System (SLS) rocket for deep space human missions to an asteroid and Mars.

“This entire effort helped us learn what it takes to build larger 3-D parts — from design, to manufacturing, to testing,” said Greg Barnett, lead engineer for the project. “This technology can be applied to any of SLS’s engines, or to rocket components being built by private industry.”

One of the keys to reducing the cost of rocket parts is minimizing the number of components. This injector had only two parts, whereas a similar injector tested earlier had 115 parts. Fewer parts require less assembly effort, which means complex parts made with 3-D printing have the potential for significant cost savings.

“We took the design of an existing injector that we already tested and modified the design so the injector could be made with a 3-D printer,” explained Brad Bullard, the propulsion engineer responsible for the injector design. “We will be able to directly compare test data for both the traditionally assembled injector and the 3-D printed injector to see if there’s any difference in performance.”

Early data from the test, conducted at pressures up to 1,400 pounds per square inch in a vacuum and at almost 6,000 degrees Fahrenheit, indicate the injector worked flawlessly. In the days to come, engineers will perform computer scans and other inspections to scrutinize the component more closely.

The injector was made by Directed Manufacturing Inc., of Austin, Texas, but NASA owns the injector design. NASA will make the test and materials data available to all U.S. companies through the Materials and Processes Information System database managed by Marshall’s materials and processes laboratory.

NASA seeks to advance technologies such as 3-D printing to make every aspect of space exploration more cost-effective. This test builds on prior hot-fire tests conducted with smaller injectors at Marshall and at NASA’s Glenn Research Center in Cleveland. Marshall engineers recently completed tests with Made in Space, a Moffett Field, Calif., company working with NASA to develop and test a 3-D printer that will soon print tools for the crew of the International Space Station. NASA is even exploring the possibility of printing food for long-duration space missions.

NASA is a leading partner in the National Network for Manufacturing Innovation and the Advanced Manufacturing Initiative, which explores using additive manufacturing and other advanced materials processes to reduce the cost of spaceflight. For more information about the National Network for Manufacturing Innovation, visit: http://manufacturing.gov/nnmi.html.

 




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


 
 

 

Headlines August 28, 2015

Business: Rafale, Mistral on agenda for Le Drian in Malaysia, India¬†– French Defense Minister Jean-Yves Le Drian is due to visit Malaysia Aug. 30, with talks expected to cover the Rafale fighter jet and Mistral helicopter carrier, website La Tribune reported. U.S. Army to choose new landing craft next year¬†– In line with the Pentagon’s...
 
 

News Briefs August 28, 2015

Boeing plans to lay off some Southern California workers Boeing has announced that it plans to lay off employees at its Southern California-based satellite division. The Los Angeles Times reports that the aerospace giant said Aug. 25 that it will lay off as many as several hundred employees at the El Segundo factory. Boeing says...
 
 

Special tactics Airmen killed in hostile incident

Two special tactics airmen, who were deployed in support of Operation Freedom’s Sentinel, were killed near Camp Antonik, Afghanistan, Aug. 26. Capt. Matthew D. Roland, 27, and SSgt. Forrest B. Sibley, 31, were at a vehicle checkpoint when two individuals wearing Afghan National Defense and Security Forces uniforms opened fire on them. NATO service members...
 

 

Hurricane Hunters to fly Tropical Storm Erika

The Air Force Reserve Hurricane Hunters are operating out of Homestead Air Reserve Base, Fla., flying their state-of-the-art WC-130J Super Hercules into Tropical Storm Erika in support of the National Hurricane Center in Miami. The 53rd Weather Reconnaissance Squadron flew four missions into the tropical storm from their deployed location at St. Croix in the...
 
 
LM-MUOS

U.S. Navy, Lockheed Martin ready to launch MUOS-4 Aug. 31

The U.S. Navy and Lockheed Martin are ready to launch the fourth Mobile User Objective System secure communications satellite, MUOS-4, from Cape Canaveral Air Force Station, Fla., Aug. 31 aboard a United Launch Alliance Atlas V...
 
 

Pentagon probing alleged distorting of war intelligence

The Pentagon’s inspector general is investigating an allegation that the military command overseeing the anti-Islamic State campaign distorted or altered intelligence assessments to exaggerate progress against the militant group, a defense official said Aug. 26. The official was not authorized to discuss the probe publicly and so spoke on condition of anonymity. The investigation was...
 




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=""> <s> <strike> <strong>