Thrust Chamber Liner Monolithic Additive Manufacturing

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Solution Overview

Problem

Traditional rocket engine thrust chamber assemblies face design complexities and weight issues due to separate components and tight tolerances, leading to potential leakage and material erosion, especially at the downstream end of the main combustion chamber and upstream end of the nozzle.

Innovation Solution

A thrust chamber liner with a metallic combustion chamber and nozzle integrated using a novel fabrication process, where a composite overwrap is bonded only to an annular protrusion, eliminating the need for seals and bolts at the interface and allowing for a seamless transition between materials, and incorporating additive manufacturing techniques like Selective Laser Melting to create integrated coolant channels and manifolds.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If separate components with joints are used to fabricate the thrust chamber assembly, then manufacturing flexibility and material selection are improved, but device complexity, weight, and leakage risk increase

Engineering Contradiction:

Improvematerial selection flexibilityVSAvoidjoint complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges the combustion chamber and nozzle into a single monolithic component fabricated using additive manufacturing. This eliminates the need for separate joints, seals, and bolting mechanisms while maintaining the ability to use different materials for different sections of the chamber through multi-material additive manufacturing processes.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If tight tolerances and polished surface finishes are applied at joint locations, then leakage prevention is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improveleakage preventionVSAvoidsurface finish requirements

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

By combining the combustion chamber and nozzle into a single monolithic component, the patent eliminates all joint locations that would require tight tolerances and polished surface finishes. The seamless integration removes seal interfaces entirely, preventing leakage through design rather than through manufacturing precision.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of manufacture

If separate manifolds are fabricated for combustion chamber and nozzle, then manufacturing ease is improved, but weight and sealing complexity increase

Engineering Contradiction:

Improveseparate fabricationVSAvoidjoint weight

Core Design Contradiction:

Ease of manufactureVSWeight of moving object

Solution Approach 1:

The patent integrates the manifolds into the monolithic thrust chamber assembly, eliminating separate manifold components. This integration removes the need for additional joints, seals, and bolting hardware, thereby reducing overall weight while maintaining manufacturing feasibility through additive manufacturing processes.

Inventive Principle:

Principle #5Merging (Combining)

4Strength

If bolts and seals are used at the combustion chamber-nozzle interface, then structural integrity is improved, but weight and leakage risk increase

Engineering Contradiction:

Improvejoint strengthVSAvoidjoint weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent creates a monolithic structure where the combustion chamber and nozzle are fused into a single continuous piece. This eliminates the need for bolts, seals, and other joint mechanisms, reducing weight while maintaining structural integrity through the inherent continuity of the additive manufacturing process.

Inventive Principle:

Principle #5Merging (Combining)

5Reliability

If multiple bolt-hole patterns are added for joint compression, then sealing reliability is improved, but device complexity and weight increase

Engineering Contradiction:

Improveseal compressionVSAvoidbolt-hole pattern complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

By integrating the combustion chamber and nozzle into a monolithic structure, the patent eliminates all bolt-hole patterns and joint compression mechanisms. The seamless fusion provides inherent sealing without requiring additional structural features or fastening elements.

Inventive Principle:

Principle #5Merging (Combining)

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 solution reduces weight, eliminates leak points, enhances structural integrity, and optimizes coolant fluid distribution, providing improved thermal management and load handling capabilities without the need for complex sealing and bolting.

Implementation Method 1

A composite material encases the exterior surface of the combustion chamber, but is only bonded to the annular protrusion

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

incorporating additive manufacturing techniques like Selective Laser Melting to create integrated coolant channels and manifolds

Methodology Applied

Scientific EffectLaser melting: Laser Beam Welding

Data Source

PatentUS11333105B1Thrust chamber liner and fabrication method therefor

Publication Date: 2022.05.17 UNITED STATES OF AMERICA AS REPRESENTED BY THE ADMINISTRATOR NAT AERONAUTICS & SPACE ADMINISTRATION

AI summary

A thrust chamber liner includes a metallic combustion chamber having an annular protrusion extending radially away from an exterior surface of the combustion chamber adjacent to its injector opening. A metallic nozzle is coupled to the combustion chamber at its throat opening. A composite material encases the exterior surface of the combustion chamber, but is only bonded to the annular protrusion.