Use of controlled atmosphere plasma spray combined with electrodeposition to fabricate a rocket engine chamber
An electrodeposition process is used to manufacture a thin layer of iridium ( 212 ) on a mandrel. A Controlled Atmosphere Plasma Spray (CAPS) process is used to fabricate a rhenium, rhenium containing alloy, or refractory alloy layer ( 210 ) on the electrodeposited iridium layer ( 212 ). After deposition of rhenium, rhenium containing alloy, or refractory alloy, the process uses a second CAPS process to apply a transition refractory material ( 214, 216 ), such as niobium, at each end of a rocket engine chamber ( 200 ). The electrodeposited iridium layer ( 212 ) provides a highly purified, highly ductile, uniform iridium layer ( 212 ).
1 . A method, comprising:
forming an oxidation resistant material from an electrodeposition process, and
forming a structural refractory material on the oxidation resistant material from a controlled atmosphere plasma spray process.
2 . The method of claim 1 , wherein the electrodeposition process includes depositing the oxidation resistant material from a molten salt electrolyte.
3 . The method of claim 1 , wherein the electrodeposition process includes depositing the oxidation resistant material from a chemical bath solution electrolyte.
4 . The method of claim 1 , wherein the controlled atmosphere plasma spray process includes depositing the structural refractory material at pressures from 0 to 14:7 psia.
5 . The method of claim 1 , further comprising forming a transitional refractory material on the structural refractory material.
6 . The method of claim 5 , wherein the transitional refractory material comprises niobium or tantalum.
7 . The method of claim 1 , wherein the oxidation resistant material comprises iridium.
8 . The method of claim 1 , wherein the structural refractory material is at least one of rhenium, molybdenum, alloys of rhenium, alloys of molybdenum, tungsten, alloys of tungsten, tantalum, alloys of tantalum or combinations thereof.
9 . A method for manufacturing a combustion chamber, comprising:
forming an oxidation resistant material from an electrodeposition process, and
forming a structural refractory material on the oxidation resistant material from a controlled atmosphere plasma spray process, wherein the oxidation resistant material and the structural refractory material are deposited in a shape representative of the combustion chamber.
10 . The method of claim 9 , wherein the electrodeposition process includes depositing the oxidation resistant material from a molten salt electrolyte.
11 . The method of claim 9 , wherein the electrodeposition process includes depositing the oxidation resistant material from a chemical bath solution electrolyte.
12 . The method of claim 9 , wherein the controlled atmosphere plasma spray process includes depositing the structural refractory material at a pressure from 0 to 14.7 psia.
13 . The method of claim 9 , further comprising forming a transitional refractory material on the structural refractory material.
14 . The method of claim 13 , wherein the transitional refractory material comprises niobium or tantalum.
15 . The method of claim 9 , wherein the oxidation resistant material comprises iridium.
16 . The method of claim 9 , wherein the structural refractory material is at least one of rhenium, molybdenum, alloys of rhenium, alloys of molybdenum, tungsten, alloys of tungsten, tantalum, alloys of tantalum, or combinations thereof.
17 . A method for making a combustion chamber, comprising:
obtaining a layer comprising an oxidation resistant material deposited via an electrodeposition process;
forming a structural refractory material on the oxidation resistant material from a controlled atmosphere plasma spray process,
wherein the oxidation resistant material and the structural refractory material are deposited in a shape representative of the combustion chamber.
18 . The method of claim 17 , wherein the electrodeposition process includes depositing the oxidation resistant material from a molten salt electrolyte.
19 . The method of claim 17 , wherein the electrodeposition process includes depositing the oxidation resistant material from a chemical bath solution electrolyte.
20 . A method for attaching a material comprising titanium to a structural refractory material comprising rhenium, the method comprising, applying a transitional refractory material comprising niobium or tantalum, and a structural refractory material comprising rhenium in a functionally graded manner onto the structural refractory material comprising rhenium.