SBIR-STTR Award

The goal of the proposed effort is to demonstrate feasibility of using selective laser melting (SLM, an emerging manufacturing technique) to manufacture a subscale combustion chamber liner that features an advanced regenerative cooling technique that combines high performance with low pressure drop. SLM enables the ability to "print" the advanced regenerative liner in mere hours, despite the liner's inherent flow passage complexity. This reduction in manufacturing lead time, combined with the fact that SLM manufacturing costs are driven almost exclusively by the amount of raw powder used during fabrication, results in a substantial cost reduction for future regeneratively-cooled rocket engines. Considering that the proposed regenerative cooling approach features heat transfer coefficients 3-10 times higher and pressure drops 2-10 times lower than traditional axial channels, the proposed effort demonstrate one of the highest performing, lowest cost combustion chambers in the world.

The goal of the proposed effort is to use selective laser melting (SLM, an additive manufacturing technique) to manufacture a hot fire-capable, water-cooled spool piece that features an advanced regenerative cooling technique that combines high heat flux performance with low pressure drop. SLM enables us to "print" the spool piece in days, despite the complexity of the regenerative liner's inherent flow passage complexity. This reduction in manufacturing lead time, combined with the fact that SLM manufacturing costs are driven in large part by the amount of raw powder used during fabrication, results in a substantial cost reduction for future regeneratively-cooled rocket engines. Additionally, the proposed advanced regenerative cooling approach features a heat-pickup efficiency that is at least two orders of magnitude higher than traditional milled channel liners and/or brazed tube bundle chambers.