Method for Fabricating Seal-Free Multi-Metallic Thrust Chamber Liner
First Claim
1. A method for fabricating a thrust chamber liner for a rocket engine, comprising the steps of:
- positioning a ring made from a first material on a build plate, wherein a first axial end of said ring rests on said build plate and a second axial end of said ring is exposed;
depositing a base layer of a second material in powder form on said second axial end of said ring;
directing a laser beam towards said base layer and said ring, wherein energy associated with said laser beam melts said base layer and a portion of said ring adjacent to said base layer, and wherein a melted portion of said base layer intermixes with a melted portion of said ring;
depositing, following said step of directing, additional layers of said second material on said base layer;
exposing said first axial end of said ring; and
depositing additional layers of said first material on said first axial end of said ring.
1 Assignment
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Accused Products
Abstract
A method for fabricating a thrust chamber liner for a rocket engine commences with a ring made from a first material on a build plate. A base layer of a second material in powder form is deposited on the exposed axial end of the ring. A laser beam is directed towards the base layer and the ring such that energy associated with the laser beam melts the base layer and a portion of the ring adjacent to the base layer. A melted portion of the base layer intermixes with a melted portion of the ring. Following this step, additional layers of the second material are deposited on the base layer. The first axial end of the ring is then exposed and additional layers of the first material are deposited on the first axial end of the ring.
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Citations
17 Claims
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1. A method for fabricating a thrust chamber liner for a rocket engine, comprising the steps of:
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positioning a ring made from a first material on a build plate, wherein a first axial end of said ring rests on said build plate and a second axial end of said ring is exposed; depositing a base layer of a second material in powder form on said second axial end of said ring; directing a laser beam towards said base layer and said ring, wherein energy associated with said laser beam melts said base layer and a portion of said ring adjacent to said base layer, and wherein a melted portion of said base layer intermixes with a melted portion of said ring; depositing, following said step of directing, additional layers of said second material on said base layer; exposing said first axial end of said ring; and depositing additional layers of said first material on said first axial end of said ring. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. A method for fabricating a thrust chamber liner for a rocket engine, comprising the steps of:
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providing a ring made from a first material on a build plate, wherein a first axial end of said ring rests on said build plate and a second axial end of said ring is exposed, said first material being selected from the group consisting of stainless steel and a superalloy; depositing a base layer of a second material in powder form on said second axial end of said ring, said second material comprising a copper-alloy; directing a laser beam towards said base layer and said ring, wherein energy associated with said laser beam melts said base layer and a portion of said ring adjacent to said base layer, and wherein an integrated region is generated from a melted portion of said base layer intermixed with a melted portion of said ring, said integrated region having a gradient function associated therewith; depositing, following said step of directing, additional layers of said second material on said base layer; exposing said first axial end of said ring; and depositing additional layers of said first material on said first axial end of said ring. - View Dependent Claims (9, 10, 11, 12)
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13. A method for fabricating a thrust chamber liner for a rocket engine, comprising the steps of:
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providing a nozzle inlet made from a first material on a build plate, wherein a first axial end of said nozzle inlet rests on said build plate and a second axial end of said nozzle inlet is exposed; depositing a base layer of a second material in powder form on said second axial end of said nozzle inlet; directing a laser beam towards said base layer and said nozzle inlet, wherein energy associated with said laser beam melts said base layer and a portion of said nozzle inlet adjacent to said base layer, and wherein an integrated region is generated from a melted portion of said base layer and a melted portion of said nozzle inlet; building, following said step of directing, a main combustion chamber liner on said base layer, said main combustion chamber liner made from said second material; exposing said first axial end of said nozzle inlet; and building a nozzle liner on said first axial end of said nozzle inlet, said nozzle liner made from said first material. - View Dependent Claims (14, 15, 16, 17)
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Specification