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Completed TRL 3 (started at 2, targeting 3)
This project investigated the feasibility of processing GRCop-42 using a near-Infrared (IR) laser as part of the DED process for complex channel geometry. Initial development was explored using a DED system with a build volume of 200 x 200 x 200mm. The system demonstrated capability to process with copper alloys and refined the process parameters for a spot size near 1mm made from GrCop42 and provided test and metallurgical samples to NASA-MSFC. This material is of particular interest for large-scale combustion chambers and heat exchangers due to its high conductivity and high strength capabilities at extended duration elevated temperatures. The DED system used for the project is scalable to a large-format system with a build volume of 1 x 1 x 1m or greater, which can be used for potential future projects for full-scale parts.
The major tasks completed included the following:
• Developed process parameters for a 1mm spot size for GRCop-42 (Cu-Cr-Nb).
• Test and documented process parameters for GRCop-42 (Cu-Cr-Nb) builds to include laser
power, spot size, build speed, and powder flow.
• Built and provided to NASA-MSFC small racetracks for mechanical testing.
• Demonstrated feasibility of the process for increased scale copper-alloy components with complex coolant channel geometry.
• Provided final report detailing the process parameters and results of the project.
The DED system's deposition speed, in-process monitoring, and the unique capabilities for copper-alloy processing and gradient materials enabled the fabrication of GRCop-42 (Cu-Cr-Nb) tensile and channel simulated geometry samples. Process parameters were successfully developed with a 1.1mm spot size, resulting in a wall thickness of approximately 1.6mm. “Racetracks” were built for metallurgical and mechanical testing, as well as a sample component with internal cooling channels to demonstrate feasibility.
This project confirmed initial feasibility for a scalable, high quality metal additive manufacturing process capable of processing large-scale copper-alloy components for the aerospace industry. Specifically, initial studies have shown that DED is a viable technology for producing full-scale components from copper alloys such as GRCop-42 (Cu-Cr-Nb). Next steps include completion of a large format system that will enable adoption for full-size production applications.
Copper alloys are of great interest to the commercial space sector for use as combustion chambers, nozzles and heat exchangers for boost and upper-stage engines and nuclear thermal propulsion systems. High conductivity copper-alloys are necessary within these applications to efficiently cool the walls of the combustor without structural failure. However, it is this same thermo-physical property along with high reflectivity that causes significant challenges in additive manufacturing of this material. Copper alloys have been successfully built using Selective Laser Melting (SLM) powder-bed systems, but those systems are very limited in scale and do not address the larger-scale needs of commercial space combustion chamber and heat exchanger applications. By completing development of parameters for copper alloy GRCop-42 (Cu-Cr-Nb), providing tensile samples and sample geometry components, the use of directed energy deposition (also known as laser metal deposition) for large-scale components can be studied for feasibility.
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