Work

GRCop-42 Development and Hot-fire Testing Using Additive Manufacturing Powder Bed Fusion for Channel-cooled Combustion Chambers

Year: 2019

Type: conference-paper

Abstract: GRCop-42 is a high conductivity, high-strength dispersion strengthened copper-alloy for use in high heat flux applications such as liquid rocket engine combustion devices.This alloy is part of the family of NASAdeveloped GRCop, copper-chrome-niobium alloys.GRCop alloys were developed for harsh environments specific to regeneratively-cooled combustion chambers and nozzles with good oxidation resistance.Significant development was completed on the GRCop-84 and GRCop-42 alloys in the extruded wrought form demonstrating feasibility for combustion chambers.NASA has recently developed a process for additive manufacturing, specifically Powder Bed Fusion (PBF) or Selective Laser Melting (SLM), of GRCop-42 to establish parameters, characterize the material, and complete testing of components with complex internal features.This evolution of the GRCop-42 was based on the successful predecessor development work using GRCop-84 with the motivation of establishing a new copper-alloy option for use in NASA, government, and industry programs with SLM.A few advantages have been shown with the GRCop-42 that include higher conductivity and faster build speeds over the GRCop-84, and a simplified powder supply chain.Initial property development has shown that it is possible to produce high density builds with strengths equivalent to wrought GRCop-42 and a conductivity greater than GRCop-84.The GRCop-42 has completed process development and initial properties have been established.Several demonstrator combustion chambers have also been fabricated with the SLM GRCop-42 that include integral channels and closeouts.Additional test units have been fabricated and are completing substantial hot-fire testing to demonstrate performance of the material, process, and design.

Source: AIAA Propulsion and Energy Forum

DOI: 10.2514/6.2019-4228

Authors: Paul R. Gradl, Christopher S. Protz, Kenneth Cooper, David Ellis, Laura J. Evans, Chance Garcia

Institutions: Marshall Space Flight Center, National Aeronautics and Space Administration, Glenn Research Center

Language: English

Topic: Additive Manufacturing Materials and Processes

Subfield: Mechanical Engineering

Field: Engineering

Domain: Physical Sciences

SDG: Industry, innovation and infrastructure

Open Access status: bronze

Funder: Marshall Space Flight Center