Development of design and technology solutions for additive manufacturing of prototype inner lining for combustion chamber of multifunctional liquid-propellant rocket engine

The paper presents results of a Research and Development (R&D) project «Development of Design and Technological Solutions for Manufacturing Prototype Parts of Engine11D58MF». The objectives of the R&D project were to study powdered material of a Russian-made refractory copper alloy, to study mechanical properties of standard samples obtained through Selective Laser Melting (SLM) of the powder of that alloy, manufacturing of two full-scale prototype units of inner lining for combustion chamber of the multi-functional engine 11D58MF. A process has been developed for domestic industrial manufacturing of powder of the Russian-made refractory copper alloy. Chemical composition and physical and manufacturing properties were determined for the powder of the refractory copper alloy (granulometric size composition, plasticity, shape and morphology of the surface of particles, bulk density); feasibility was demonstrated of growing full-sized sample units of inner lining for combustion chamber of liquid-propellant engine 11D58MF using the SLM additive process of manufacturing out of the domestically produced powder of the refractory copper alloy; the density of these samples and their microstructure were studied; the units were thermally treated and their microstructure after the thermal treatment was studied. Mechanical properties at ambient and higher temperatures were determined for samples that had been grown in horizontal and vertical directions; processing methods were developed for growing prototype inner lining for the combustion chamber of the engine 11D58MF using the SLM process; two full-scale units of the inner lining for the combustion chamber of the engine 11D58MF were manufactured.