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Process qualification, additive manufacturing, and postprocessing of a hydrogen peroxide/kerosene 6 kN aerospike breadboard engine
Fraunhofer Institute for Material and Beam Technology IWS, Dresden 01277, Germany.ORCID iD: 0009-0000-2470-0667
Fraunhofer Institute for Material and Beam Technology IWS, Dresden 01277, Germany.ORCID iD: 0000-0001-8516-9339
Institute of Aerospace Engineering, TUD Dresden University of Technology, Dresden 01602, Germany.
Institute of Aerospace Engineering, TUD Dresden University of Technology, Dresden 01602, Germany.ORCID iD: 0009-0008-9367-9820
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2024 (English)In: Journal of laser applications, ISSN 1042-346X, E-ISSN 1938-1387, Vol. 36, no 1, article id 012027Article in journal (Refereed) Published
Abstract [en]

This contribution addresses the complete process chain of an annular aerospike breadboard engine fabricated by laser powder bed fusion using the nickel-based superalloy Inconel® 718. In order to qualify the material and process for this high-temperature application, an extensive material characterization campaign including density and roughness measurements, as well as tensile tests at room temperature, 700, and 900 °C, was conducted. In addition, various geometric features such as triangles, ellipses, and circular shapes were generated to determine the maximum unsupported overhang angle and geometrical accuracy. The results were taken into account in the design maturation of the manifold and the cooling channels of the aerospike breadboard engine. Postprocessing included heat treatment to increase mechanical properties, milling, turning, and eroding of interfaces to fulfill the geometrical tolerances, thermal barrier coating of thermally stressed surfaces for better protection of thermal loads, and laser welding of spike and shroud for the final assembly as well as quality assurance. This contribution goes beyond small density cubes and tensile samples and offers details on the iterations necessary for the successful printing of large complex shaped functional parts. The scientific question is how to verify the additive manufacturing process through tensile testing, simulation, and design iterations for complex geometries and reduce the number of failed prints.

Place, publisher, year, edition, pages
Laser Institute of America , 2024. Vol. 36, no 1, article id 012027
Keywords [en]
additive manufacturing, aerospace, aerospike engine, laser powder bed fusion, nickel-based superalloys
National Category
Manufacturing, Surface and Joining Technology
Research subject
Manufacturing Systems Engineering
Identifiers
URN: urn:nbn:se:ltu:diva-104177DOI: 10.2351/7.0001121Scopus ID: 2-s2.0-85183453067OAI: oai:DiVA.org:ltu-104177DiVA, id: diva2:1834676
Funder
The European Space Agency (ESA), 4000130551/20/NL/MG
Note

Validerad;2024;Nivå 2;2024-04-08 (hanlid);

Full text license: CC BY 4.0

Available from: 2024-02-05 Created: 2024-02-05 Last updated: 2024-04-08Bibliographically approved

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Brueckner, Frank

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