Rocket Engine Metal AM with In-Process Cooling and Stress Relief
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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 and unfavorable microstructure formation, particularly in thin section materials.
Innovation Solution
The method involves simultaneously applying heat to melt a work piece, depositing metallic material, and continuously cooling it while stress-relieving the layer, allowing for the integration of these steps into a continuous process to mitigate distortion and refine the internal microstructure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional additive layer manufacturing processes use sequential heating, depositing, cooling, and stress-relieving steps, then the manufacturing process is simpler to implement, but distortion increases and microstructure formation becomes unfavorable
Solution Approach 1:
The patent combines multiple sequential operations (heating, depositing, cooling, and stress-relieving) into a single integrated apparatus that performs all functions simultaneously. The apparatus includes a heat source for melting material, a deposition system for adding material, a cooler for solidification, and a stress-relieving mechanism, all coordinated to operate together during the additive manufacturing process. This integration resolves the contradiction by maintaining manufacturing simplicity through a unified system while eliminating distortion through simultaneous multi-functional operation.
Solution Approach 2:
The patent implements continuous operation where heating, depositing, cooling, and stress-relieving occur simultaneously and continuously throughout the additive manufacturing process, rather than as discrete sequential steps. This continuous multi-functional action maintains process simplicity while preventing distortion by ensuring that stress-relieving and cooling occur concurrently with deposition and heating, eliminating idle time and thermal gradients that cause distortion.
2Device complexity
If conventional additive layer manufacturing processes use sequential operations, then the equipment requirements are fewer, but unfavorable microstructure formation occurs
Solution Approach 1:
The patent merges multiple functional systems into a single integrated apparatus that performs heating, depositing, cooling, and stress-relieving simultaneously. This consolidation maintains equipment simplicity in terms of system integration while achieving superior microstructure quality through the coordinated action of all functions during material deposition and solidification.
Solution Approach 2:
The patent utilizes real-time parameter changes in temperature, deposition rate, and cooling rate through the integrated apparatus to control microstructure formation. By dynamically adjusting these parameters simultaneously during the manufacturing process, the system achieves favorable microstructure quality without requiring complex post-processing equipment or multiple separate operational stages.
3Duration of action of moving object
If conventional additive layer manufacturing processes are used, then the manufacturing time for each step is shorter individually, but the total manufacturing time increases due to sequential operations
Solution Approach 1:
The patent implements continuous simultaneous operation where heating, depositing, cooling, and stress-relieving occur concurrently throughout the additive manufacturing process. This eliminates the sequential waiting time between operations, maintaining short individual step durations while dramatically improving total manufacturing efficiency by performing all functions in parallel rather than sequence.
Solution Approach 2:
By merging multiple operational functions into a single integrated apparatus that works simultaneously, the patent reduces total manufacturing time while maintaining the effectiveness of each individual function. The coordinated operation of all systems during material deposition eliminates idle time and accelerates the overall manufacturing process.
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 more efficient manufacturing by reducing distortion and improving mechanical properties through refined microstructure control, allowing for the production of components with enhanced structural integrity, such as those for 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
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.