Rocket Engine ALM With In-Process Cooling and Peening
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Solution Overview
Problem
Conventional additive layer manufacturing (ALM) processes face challenges in efficiently combining heating, depositing, cooling, and stress-relieving steps, often requiring sequential operations that can lead to distortion, residual stresses, and unfavorable microstructures, particularly in the production of complex components like orbital and launch vehicle parts.
Innovation Solution
The method involves simultaneously performing heating, depositing metallic material, and cooling layers while applying stress-relieving techniques, such as peening, to form continuous layers with controlled microstructures, allowing for the integration of machining operations during the manufacturing process, using a system comprising a heat source, applicator, cooler, and stress-reliever, which can include peening modules and cooling systems like gas or cryogenic coolers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional ALM processes perform heating, depositing, cooling, and stress-relieving steps sequentially, then each step can be optimized individually, but the overall process time increases and distortion/residual stresses worsen
Solution Approach 1:
The patent combines multiple sequential operations (heating, depositing, cooling, and stress-relieving) into a single integrated ALM process that performs these functions simultaneously or in overlapping sequences, thereby reducing total process time while maintaining control over distortion and residual stresses through coordinated parameter management
Solution Approach 2:
The patent implements continuous deposition and cooling operations without interrupting the manufacturing process, allowing the ALM system to maintain productive action throughout the build process while managing thermal gradients and residual stresses through continuous monitoring and adjustment of process parameters
2Manufacturing precision
If conventional ALM processes use simple cooling methods, then the process is simpler, but unfavorable microstructures and residual stresses result
Solution Approach 1:
The patent applies localized cooling strategies where different cooling rates and methods are applied to different regions of the deposited material based on their specific geometric and thermal characteristics, enabling precise control over microstructure formation and residual stress distribution throughout the component
Solution Approach 2:
The patent utilizes controlled phase transitions during cooling, managing the transformation from austenite to martensite or other microstructures through precise temperature control and cooling rate management, thereby achieving desired material properties while minimizing harmful residual stresses
3Manufacturing precision
If conventional ALM processes do not integrate stress-relieving techniques, then the process is simpler, but distortion and residual stresses increase
Solution Approach 1:
The patent applies stress-relieving techniques such as peening during or immediately after the deposition process, before residual stresses can cause significant distortion, thereby proactively managing stress accumulation and preventing dimensional instability in the final component
Solution Approach 2:
The patent converts the potentially harmful effect of rapid cooling (which generates thermal stresses) into a beneficial outcome by simultaneously applying stress-relieving techniques that induce compressive residual stresses to counterbalance the tensile stresses from rapid solidification, thereby improving overall component stability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the production of components with reduced distortion and improved mechanical properties by controlling microstructure and residual stresses, enhancing the efficiency and quality of additive layer manufacturing for complex parts like those used in orbital and launch vehicles.
Implementation Method 1
applying an amount of heat to a portion of a work piece sufficient to melt the portion of the work piece
Implementation Method 2
cooling said layer of deposition material on the work piece to a crystallization state of the deposition material
Implementation Method 3
cooling said layer of deposition material on the work piece to a crystallization state of the deposition material
Implementation Method 4
the stress-relieving apparatus comprises a peening module
Data Source
AI summary
Systems and methods for additive layer manufacturing of metallic components, such as rocket engines and propellant supply systems, are provided. Methods include melting the surface of a work piece to form a weld pool; adding wire to the weld pool and moving a heat source relative to the work piece to progressively form a new layer of metallic material on the work piece; cooling the formed layer; stress relieving (e.g., peening) the cooled layer; applying a secondary operations either sequentially or simultaneously; and repeating the above steps as required to form components layer by layer. Systems and methods of supplying a first propellant to the rocket engine of a launch vehicle are also provided, where the first propellant is supplied through a heat exchanger for generating mechanical energy to pump the first propellant into the rocket engine, and electrical energy to pump a second propellant into the rocket engine.