PROPELLANT COMPATIBLE COMPONENT FOR COMBUSTION DEVICE
This disclosure relates to a component formed using an additive manufacturing process. Further disclosed is a method for providing a component for use with a combustion device. In the method, a component formed using an additive manufacturing process is provided. The component is left with a plurality of powder particles only partially fused to an internal passage thereof as a result of the additive manufacturing process. The method further includes removing the partially fused powder particles from the internal passage with a thermal energy process.
1 . A method for providing a component for a combustion device, the method comprising:
providing a component formed using an additive manufacturing process, the additive manufacturing process leaving the component with a plurality of powder particles only partially fused to an internal passage thereof; and
removing the partially fused powder particles from the internal passage using a thermal energy process.
2 . The method as recited in claim 1 , wherein the partially fused powder particles are at least one of burrs and flash within the internal passage.
3 . The method as recited in claim 1 , wherein the internal passage is arranged to convey a propellant.
4 . The method as recited in claim 3 , wherein the component is an injector.
5 . The method as recited in claim 4 , wherein the propellant includes liquid oxygen.
6 . The method as recited in claim 1 , wherein the combustion device is selected from the group consisting of a rocket engine and a coal gasifier.
7 . The method as recited in claim 1 , wherein the powder particles are alloy particles.
8 . The method as recited in claim 1 , wherein the removing step includes providing the component in a chamber, pressurizing the chamber with a mixture or oxidizer and fuel, and igniting the contents of the chamber.
9 . The method as recited in claim 1 , wherein the additive manufacturing process leaves the internal passage with an organic contaminant, and wherein the removing step includes removing the contaminant with the thermal energy process.
10 . The method as recited in claim 9 , wherein the removed partially fused particles have a height to width ratio of about 2:1, and wherein the contaminant is reduced to a level of about 1 milligram of nonvolatile residue per square foot of surface area of the internal passage.
11 . A method for operating a combustion device, the method comprising:
providing a component formed using an additive manufacturing process, the additive manufacturing process leaving the component with asperities on an internal passage thereof, the internal passage having been treated with a thermal energy process to remove the asperities; and
establishing a flow of a propellant through the internal passage that has been treated with the thermal energy process.
12 . The method as recited in claim 11 , wherein the asperities include at least one of burrs and flash, the asperities including a plurality of powder particles only partially fused to the internal passage.
13 . The method as recited in claim 11 , wherein the combustion device is selected from the group consisting of a rocket engine and a coal gasifier.
14 . The method as recited in claim 13 , wherein the propellant includes liquid oxygen.
15 . The method as recited in claim 14 , wherein the component is an injector.
16 . The method as recited in claim 15 , wherein the internal passage is configured to direct liquid oxygen throughout the combustion device.
17 . A combustion device comprising:
an electron beam formed component having an internal passage, the internal passage configured to route a propellant within the interior of the component, the component treated with a thermal energy process to remove asperities on the internal passage remaining from the electron beam process such that the internal passage is substantially free of the asperities.
18 . The combustion device as recited in claim 17 , wherein the asperities include at least one of burrs and flash.
19 . The combustion device as recited in claim 17 , wherein the propellant includes liquid oxygen.
20 . The combustion device as recited in claim 17 , wherein the component is selected from the group consisting of an injector, a pump, a conduit, and a valve.