Rapid Analysis and Manufacturing Propulsion Technology (RAMPT)

The RAMPT project developed and advanced multi-metallic freeform manufacturing, composite overwrap techniques, and analysis capabilities required to implement them to reduce design and fabrication cycles for large scale lightweight regeneratively-cooled liquid rocket engine components. RAMPT reduced design, fabrication, assembly schedules while allowing for reduced parts, increased reliability, significant weight reduction and creating a healthy American supply chain. Four technology areas that were developed include: 1) Composite over-wrap technology for regen-cooled TCA with specialty manufacturing vendor; 2) Large-scale freeform laser directed energy deposition (DED) technology for forming regen-cooled nozzle components with specialty manufacturing vendor; 3) Bimetallic joints for integration of the manifolds to a copper-alloy chamber with specialty manufacturing vendor; and 4) Modeling and analysis tools for additive and closed out regeneratively cooled designs. RAMPT advanced state-of-the-art bimetallic and multi-alloy GRCop-alloy to superalloy AM for liquid rocket engine components. The advancements were made through evaluations of various multi-alloy AM processes, material characterization, and successful component manufacturing and hot-fire testing for various combustion devices. The RAMPT team manufactured 2k-lbf through 40k-lbf bimetallic chambers and hot-fire tested various configurations using both radial and axial multi-metallic joints with 73 accumulated starts and 2,512 seconds of hot-fire time across multi-alloy AM chambers. RAMPT addressed the longest lead, highest cost and heaviest component in rocket engines. The technology developed is applicable to Lunar Lander Engines, Booster Engines, Upper Stage Engines, and space nuclear power. The project has developed public-private partnerships with specialty industry vendors, worked with government partners and commercial crew, and emphasized infusion of the technologies into commercial space companies and manufacturers. RAMPT supported the STMD Strategic Framework

RAMPT benefits include: Reduced cost, manufacturing schedule, scale and improved performance of a regeneratively-cooled thrust chamber assembly (combustion chamber and nozzle) for government and industry propulsion applications. Freeform blown powder nozzle: The first key technology that was matured under RAMPT is the freeform blown pow­der DED additive manufacturing of the large scale regen­-cooled nozzle structure. The goal of this process development was to advance the blown powder DED for large ­scale thin-­walled structures to net shape or near-net shape to significantly reduce the time required for nozzle fabrication. Composite overwrap structural jacket: The second key technology developed under RAMPT is the com­posite overwrap of the thrust chamber assembly (TCA). The TCA includes the combustion chamber liner manufactured from a GRCop­-42 copper­-alloy based material and the freeform nozzle manufactured using super alloy materials. This technology offers the potential to substan­tially decrease weight up to 70 percent over metallic jacket structural supports. Bimetallic radial deposition for manifolds: The third key technology area was the development of the bimetallic deposition for manifold land and/or integrated manifold to the GRCop­-42 combustion chamber. Modeling and analysis tools for additive and regenerative design: The supporting key technology area was the develop­ment of congruent design and analysis tools that help optimize the overall design and fabrication process. This includes tools for process modeling and design tools that integrate various codes and analysis subroutines to allow for optimization of complex regenerative­-cooled combustion devices components.

This is early/mid-stage (TRL 3) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

None of these are guaranteed paths for this specific project — TechPort itself doesn't have an "apply" button. Reaching out to the contact(s) above with a specific question is usually the fastest way to find out what's actually open.