Material properties and manufacturing feasibility of Cold Spray Additive Manufactured (CSAM) launcher propulsion system components

In space applications, materials with high strength to weight ratios along with properties such as excellent tensile strength, fatigue strength and fracture toughness in combination with low density are needed. However, there are specific parts such as launcher propulsion system components, where the focus of the properties are also on heat conductivity, mechanical strength at elevated temperatures and dissimilar material combination.

Present work escribes the mechanical, thermal and fatigue properties of the specific materials such as In625, In718, Ti-6-4, CuCrZr used in single or multi-material combination and report the feasibility of CSAM of components with large dimensions and specific geometrical complexity to demonstrate the potential of the CSAM process as an innovative process for additive manufacturing in space applications.