Rocket Nozzle Transpiration Cooling With Permeable 3D-Printed Walls
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Solution Overview
Problem
Existing methods for forming parts with both permeable and non-permeable features face challenges in integrating different materials and result in suboptimal cooling efficiency and increased manufacturing complexity.
Innovation Solution
The use of 3D printing technologies, specifically laser powder bed fusion (LPBF) additive manufacturing, to integrate permeable and non-permeable portions in a single step, allowing for controlled coolant flow and improved cooling efficiency by forming parts with permeable and non-permeable layers from a single material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional methods using multiple materials and complex manufacturing steps are used to form parts with porous media, then the parts can be manufactured, but the manufacturing process becomes complex and material integration is difficult
Solution Approach 1:
The patent combines multiple materials (metal and ceramic) into a single integrated part using selective laser melting technology. The manufacturing process merges the formation of permeable porous media sections and non-permeable structural sections into one continuous process, eliminating the need for separate manufacturing steps and reducing assembly complexity.
Solution Approach 2:
The invention employs composite materials consisting of metal and ceramic phases within a single part structure. The selective laser melting process creates a composite material structure where ceramic particles are embedded in a metal matrix, providing both structural integrity and cooling functionality without requiring multiple separate components.
2Reliability
If traditional methods using multiple materials are used, then different functional requirements can be met, but material mismatch issues arise and cooling efficiency is suboptimal
Solution Approach 1:
The patent applies different material properties to different sections of the part based on local functional requirements. The permeable porous media sections use ceramic particles for cooling functionality, while the non-permeable structural sections use metal for mechanical strength. This localized material selection optimizes both cooling efficiency and structural performance.
Solution Approach 2:
The invention creates a composite material structure where ceramic particles are distributed within a metal matrix. This composite approach allows simultaneous achievement of cooling functionality (through ceramic permeable sections) and structural integrity (through metal non-permeable sections) without material mismatch problems that would occur with separate components.
3Adaptability or versatility
If numerous materials are used to form parts with both permeable and non-permeable portions, then functional requirements are met, but manufacturing cost increases
Solution Approach 1:
The patent merges multiple functional sections (permeable cooling sections and non-permeable structural sections) into a single manufactured part using selective laser melting. This consolidation eliminates the need for multiple separate components and their associated manufacturing processes, reducing overall manufacturing cost while maintaining all required functions.
Solution Approach 2:
The invention uses a single composite material system (metal and ceramic particles) that can be processed into different functional sections within one part. This approach replaces the need for multiple separate materials and manufacturing processes, reducing material costs and manufacturing expenses while fulfilling all functional requirements.
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 enhances cooling efficiency, reduces manufacturing costs, and minimizes material mismatch issues while providing structural integrity and controlled coolant flow, resulting in improved heat flux management.
Implementation Method 1
at least a portion of the permeable layer is configured to be permeated by the fluid
Implementation Method 2
The permeable layer is spaced a distance from the non-permeable outer layer. The plurality of colling channels are formed between the permeable layer, the non-permeable outer layer, and a set of adjacent walls of the plurality of walls
Data Source
AI summary
Transpiration-cooled systems having permeable and non-permeable portions are provided. In one aspect, a nozzle for a rocket engine includes a non-permeable outer layer, a plurality of walls, a permeable layer, and a plurality of cooling channels. The non-permeable outer layer forms a predetermined shape of the nozzle and defines an interior space. The plurality of walls extend generally orthogonal to the non-permeable outer layer and into the interior space. The permeable layer is disposed between each set of adjacent walls of the plurality of walls. The permeable layer is spaced a distance from the non-permeable outer layer. The plurality of cooling channels are formed between the permeable layer, the non-permeable outer layer, and a set of adjacent walls of the plurality of walls. The plurality of cooling channels are configured to transport a fluid.