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 January 28, 2015

News: Panel will propose new military retirement system - The long-awaited report on military compensation set to drop Thursday will propose fundamental changes to military retirement and health care benefits, according to several people familiar with the report. Source: DOD to request $585 billion for fiscal 2016 - The Department of Defense is preparing to submit a...
 
 

News Briefs January 28, 2015

Defense contractor to pay $2 million to settle claims A Northern California defense contractor will pay the federal government $2 million to settle claims about its manufacturing of parts for remote-controlled aircraft. The U.S. Attorney’s Office in Sacramento says Sacramento-based Composite Engineering Inc. agreed to pay the money to end allegations that it artificially inflated...
 
 
Navy photograph

USS Roosevelt marks 200,000 trap

Navy photograph An F/A-18F Super Hornet flown by Capt. Daniel Grieco, commanding officer of the aircraft carrier USS Theodore Roosevelt (CVN 71), and Capt. Benjamin Hewlett, deputy commander of Carrier Air Wing (CVW) 1, complet...
 

 
Navy photograph by PO1 William Larned

USS California returns from maiden deployment

Navy photograph by PO1 William Larned The Virginia-class attack submarine USS California (SSN 781) returns from its maiden deployment to its homeport at Naval Submarine Base New London. Under the command of Cmdr. Shawn Huey, Ca...
 
 
Army photograph

Army proves new watercraft capabilities

Army photograph Marine Corps assets are loaded onto the USNS Sgt. Matej Kocak (T-AK 3005), from an U.S. Army Landing Craft Utility, or LCU, USAV Port Hudson during port operations, at White Beach Naval Base, Jan. 22, 2015. Sold...
 
 

Orbital stockholders approve merger with ATK’s aerospace, defense groups

Orbital Sciences Corporation announced Jan. 27 that at a special meeting, the company’s stockholders voted overwhelmingly to approve the proposed merger with the Aerospace and Defense Groups of Alliant Techsystems Inc., pursuant to the definitive transaction agreement dated April 28, 2014. Approximately 99 percent of the votes cast at the special meeting voted in favor...
 




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>