Cold Spray Additive Manufacturing (CSAM) Process to Produce Large-Scale Parts for the Next Generation Rocket Engines – Industrialization Challenges

Cold Spray Additive Manufacturing Process to Produce Large-Scale Parts for the Next Generation Rocket Engines – Industrialization Challenges Dr. Steffen Beyer, ArianeGroup Munich (Germany) An ultra-low cost reusable rocket engine is under development to power Europe’s future launchers. Constructed using 3D printing technology, the core of the engine is the thrust chamber and in particular the combustion chamber. Cold Spraying (CS) was selected to spray-form the copper chamber liner and to deposit In625 for the load bearing structure (jacket). In cooperation with external specialists and technology leaders, intensive work has been done in recent years on the powder and process optimization, process monitoring as well as on a solution for so-called nozzle clogging. The presentation will give an overview of the challenges from technology maturation to the industrialization of a Cold Spray process as production technology for rocket engines.