Possible Applications of Metal Additive Manufacturing in Aerospace Vaporizers
Open Access
- Author:
- Canby, Charles
- Area of Honors:
- Aerospace Engineering
- Degree:
- Bachelor of Science
- Document Type:
- Thesis
- Thesis Supervisors:
- Sven G Bilen, Thesis Supervisor
Robert G. Melton, Thesis Honors Advisor - Keywords:
- resistojet
vaporizer
additive manufacuring
3d printing
selective laser melting - Abstract:
- Many aerospace components are complex, they must meet challenging requirements, and require extensive fabrication processes. For vaporizer systems such as resistojets or heat pipes, their internal chambers and duct work have meant they are difficult to fabricate and also not fully optimized. Metal additive manufacturing methods offer a solution to these complex production challenges. In this work, current methods of metal additive manufacturing are evaluated for possible use in producing vaporizer systems, namely resistojets. Material compatibility, cost, and feasibility are considered to suggest which method should be employed. After evaluating several methods of metal additive manufacturing, selective laser melting (SLM) was chosen as the most promising for resistojet development. SLM is readily available from numerous companies for on-demand part printing. SLM also has a sizable catalog of materials that can be used. For resistojets, the most important evaluation factors are strength, maximum operating temperature, and the ability to form and sustain thin-walled structures. Two materials were selected for use in SLM: a cobalt–chrome alloy, Co-28Cr-6Mo, and nickel alloy, Inconel 718. Two different resistojet design concepts were evaluated. One was a single-component heat chamber and nozzle made entirely of the cobalt–chrome alloy, the other was a cobalt–chrome heat chamber welded to an Inconel 718 nozzle. These two design concepts are the basis for future work on model development, procurement, and evaluation.