Fabrication of a Multi-Material Rocket Nozzle via a Hybrid MELD Process

In this presentation the MELD process (additive friction stir deposition) is used to produce a multi-material nozzle with integrated cooling channels in support of demonstrating the applicability of this technology for space applications. Specifically, this component combines the solid-state additive manufacture of a fully-dense pure copper (Cu110) conical nozzle via the MELD process, deployment of a 4th axis (rotary), subtractive machining, and encapsulation of nickel alloy cooling channels. Each of these key aspects used in the production of the multi-material nozzle will be presented, including deposition process parameters, a discussion of the resultant metallurgy and mechanical performance, a summary of the build and fabrication strategy, a discussion of technical approach used in the encapsulation of the nickel-alloy cooling channels, and finally an overview of the motivation behind the component. The MELD process is a large-scale metal additive technology that utilizes a rotating non-consumable tool to plastically deform wrought metal feedstock in order to print metal components. The information contained within this presentation will provide a detailed look at how industry users of the MELD process are currently deploying this solid-state technology. Over the last several years the primary focus of MELD related research has focused on the qualification of light weight alloys for the manufacture of large-scale components. In this presentation we will review the fabrication of a smaller component with internal complications.