Highly Compatible, Additively Manufactured LOX Injectors

Our Phase II efforts included the development of the SLM process for generating organized, high strength meshes in GRCop-84 and NASA HR-1 alloys. The meshes are meant to provide a cost-effective alternative to Rigimesh, with the injector face and imbedded elements built as a monolithic part. The method used to produce the mesh includes a modification of the parameters intrinsic to the SLM process, so the corresponding components are easily manipulated in CAD and preprocessing programs with small file sizes. Our efforts include developing the SLM parameter sets for building high quality meshes in both materials. Meshes with a wide range of porosities have been characterized by air and water flow testing. Both showed increased flow resistance with lower mesh porosities. Efforts were made to match individual flow curves using orifice, Ergun’s, and microfluidic channel equations by solving for the respective discharge, viscous, and inertial coefficients. The Ergun’s and microfluidic channel equations best predicted realistic pressure drops for flow with gaseous hydrogen in a transpiration-cooled faceplate application. Tensile and bend test samples were built for meshes made from GRCop-84, showing decreased strength with increases in mesh porosity. Using the modeled flow and strength data, multiple 2,000 lbf LOX/GH2 injectors with transpiration cooled faceplates were designed with shear coaxial and swirl elements, respectively. The injectors were successfully built by SLM and delivered to MSFC for future hot fire testing. Continued Phase IIE efforts will focus on developing the SLM process for GRCop-42, and building lander and RDRE components with integrated, monolithic meshes for transpiration cooling.

Artemis program Lunar Lander main propulsion Mars ascent vehicle main propulsion Rotating Detonation Rocket Engines (RDRE)

Commercial launch main propulsion Valve and fluid control devces Heat exchanger components Catalyst Beds

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