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Rapid Fabrication Techniques for Liquid Rocket Channel Wall NozzlesThe functions of a regeneratively-cooled nozzle are to (1) expand combustion gases to increase exhaust gas velocity while, (2) maintaining adequate wall temperatures to prevent structural failure, and (3) transfer heat from the hot gases to the coolant fluid to promote injector performance and stability. Regeneratively-cooled nozzles are grouped into two categories: tube-wall nozzles and channel wall nozzles. A channel wall nozzle is designed with an internal liner containing a series of integral coolant channels that are closed out with an external jacket. Manifolds are attached at each end of the nozzle to distribute coolant to and away from the channels. A variety of manufacturing techniques have been explored for channel wall nozzles, including state of the art laser-welded closeouts and pressure-assisted braze closeouts. This paper discusses techniques that NASA MSFC is evaluating for rapid fabrication of channel wall nozzles that address liner fabrication, slotting techniques and liner closeout techniques. Techniques being evaluated for liner fabrication include large-scale additive manufacturing of freeform-deposition structures to create the liner blanks. Abrasive water jet milling is being evaluated for cutting the complex coolant channel geometries. Techniques being considered for rapid closeout of the slotted liners include freeform deposition, explosive bonding and Cold Spray. Each of these techniques, development work and results are discussed in further detail in this paper.
Document ID
20160009709
Document Type
Conference Paper
Authors
Gradl, Paul R. (NASA Marshall Space Flight Center Huntsville, AL, United States)
Date Acquired
August 1, 2016
Publication Date
July 25, 2016
Subject Category
Spacecraft Propulsion and Power
Report/Patent Number
M16-5368
Meeting Information
AIAA Propulsion and Power 2016 Conference(Salt Lake City, UT)
Distribution Limits
Public
Copyright
Work of the US Gov. Public Use Permitted.

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