Multi-material applications were once trending topics at the last Formnext. Now the Advanced Manufacturing Division (QAMD) of Quadrus Corporation has produced a bimetallic injection nozzle for a rotating detonation engine for the rocket technology sector for the first time.
The development, which was produced using selective laser melting (SLM), comes from a series of SBIR (Small Business Innovation Research) projects led by engineers at the NASA Marshall Space Flight Center.
Due to the intense heat generated by the rotating detonation waves, RDRE (Rotating Detonation Rocket Engine - RDRE) injection nozzles face considerable challenges. This is why QAMD has developed a solution with a thin front plate made of a thermally conductive copper alloy GRCop-42 and a manifold made of an oxidation-resistant nickel-based superalloy (Monel K500). Using GRCop-42, the injection surface can be effectively cooled by the fuels, while Monel K500 enables thinner walls in the manifold and thus a lighter design.
Thermal management for combustion injectors
Quadrus Corporation, based in Huntsville, Alabama, is using multi-material development to overcome hurdles previously associated with bimetallic SLM manufacturing, such as precise geometric alignment, reducing the risk of material contamination and forming a high-strength multi-material bond. The attention to detail of QAMD is evident, among other things, in the smallest 1 mm fine holes in the bimetallic area.
NASA's multi-year SBIR project focuses on thermal management for combustion injectors. In addition to the bimetallic injector, "Quad Mesh" was also developed, a novel approach to transpiration cooling for injector faceplate applications.
In the next step, the bimetallic injection nozzle will be tested under real conditions in the summer of 2024 at NASA's Marshall Space Flight Center together with a monolithic GRCop-42 nozzle containing Quad Mesh technology.
