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Metal Matrix Composite LOX Turbopump Housing Via Novel Tool-Less Net-Shape Pressure Infiltration Casting TechnologyMetal matrix composites (MMC) offer relatively higher specific strength, specific stiffness, lower coefficient of thermal expansion (CTE) and lower density as compared with conventional alloys. These unique properties make them very attractive for aerospace turbomachinery applications where there is ever increasing emphasis to reduce weight and cost, and to increase engine performance. Through a joint effort between NASA and Metal Matrix Cast Composites, Inc., a complex liquid oxygen (LOX) compatible turbopump housing is being redesigned and manufactured from hybrid (particulate and fibers) Aluminum MMC. To this end, a revolutionary tool-less pressure infiltration casting technology is being perfected. Ceramic preforms for the composite are 3-dimensionally printed using a stereolithography file, acquired from a CAD model. The preforms are then invested into a refractory material and pressure infiltrated with liquid metal. After casting, the refractory material is washed away leaving behind a near net-shape composite part. Benefits of this process include increased composite uniformity, no mold machining, short time from design to part, properties matching traditional methods, ability to make previously impossible to manufacture parts and no size limitations with a newly developed joining technology. The results of materials, manufacturing and design optimizations, preform joining, and sub-element tests will be presented.
Document ID
20010021180
Acquisition Source
Marshall Space Flight Center
Document Type
Preprint (Draft being sent to journal)
Authors
Shah, Sandeep
(NASA Marshall Space Flight Center Huntsville, AL United States)
Lee, Jonathan
(NASA Marshall Space Flight Center Huntsville, AL United States)
Bhat, Biliyar
(NASA Marshall Space Flight Center Huntsville, AL United States)
Wells, Doug
(NASA Marshall Space Flight Center Huntsville, AL United States)
Gregg, Wayne
(NASA Marshall Space Flight Center Huntsville, AL United States)
Marsh, Matthew
(NASA Marshall Space Flight Center Huntsville, AL United States)
Genge, Gary
(NASA Marshall Space Flight Center Huntsville, AL United States)
Forbes, John
(NASA Marshall Space Flight Center Huntsville, AL United States)
Salvi, Alex
(Metal Matrix Cast Composites, Inc. Waltham, MA United States)
Cornie, James A.
(Metal Matrix Cast Composites, Inc. Waltham, MA United States)
Sung, Michael
(Metal Matrix Cast Composites, Inc. Waltham, MA United States)
Zhang, Shi-Yu
(Metal Matrix Cast Composites, Inc. Waltham, MA United States)
Gentz, Steven
Date Acquired
August 20, 2013
Publication Date
January 1, 2001
Subject Category
Composite Materials
Meeting Information
Meeting: Aeromat
Location: Long Beach, CA
Country: United States
Start Date: June 11, 2001
End Date: June 14, 2001
Distribution Limits
Public
Copyright
Work of the US Gov. Public Use Permitted.

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