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 June 29, 2015

News: SpaceX Falcon 9 explodes moments after launch – A SpaceX rocket carrying supplies to the International Space Station blew up June 28 shortly after liftoff.   Business: How serious a setback is SpaceX rocket explosion? – Elon Musk had never come face to face with that rule before — at least not in space travel —...
 
 

News Briefs June 29, 2015

Iraqi pilot in Arizona plane crash found dead Officials say the body of an Iraqi pilot who had been training in the United States and crashed in southern Arizona has been located. Iraq’s Defense Ministry said June 26 that search teams found the body of Brig. Gen. Rasid Mohammed Sadeeq at the crash site five...
 
 
Huntington Ingalls Industries photograph

PCU John Warner delivered to Navy

Huntington Ingalls Industries photograph A dolphin jumps in front of the Virginia-class attack submarine Pre-Commissioning Unit (PCU) John Warner (SSN 785) as the boat conducts sea trials in the Atlantic Ocean. The U.S. Navy ac...
 

 
navair-helo

HX-21 completes first flight with developmental electronic warfare pod

On June 8, 2015, a UH-1Y from Air Test and Evaluation Squadron (HX) 21 completed the first test flight with a developmental electronic warfare pod.  The pod would represent a new tactical capability for U.S. Marine Corps rotar...
 
 

Northrop, Navy celebrate legacy of EA-6B Prowler

Northrop Grumman photograph by Edgar Mills The U.S. Navy’s last operational EA-6B Prowler, designed and built by Northrop Grumman, lifts off from Naval Air Station Whidbey Island, Wash. in a ceremonial fly-away June 27 from its long time operational base. The Navy is retiring the Prowler after nearly 45 years of service.   The U.S....
 
 
Air Force photograph by Capt. Tania Bryan

NORTHERN EDGE provides environment for testing new capabilities

Air Force photograph by Capt. Tania Bryan Aircraft from test and evaluation squadrons across the Air Force line up on the Joint Base Elmendorf-Richardson flightline. Northern Edge is Alaska’s premier joint training exercise d...
 




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>