Abstract: A method of producing a rocket thrust chamber in which cooling tubes are positioned within a structural jacket to form a tube bundle, and a liner is positioned within the tube bundle thereby sandwiching the tubes between the jacket and the liner. The tubes are then subjected to high internal pressure and inflated while the liner is simultaneously subjected to the same high pressure, thereby forcing the tubes into intimate contact with adjacent tubes, the liner and the jacket. The tubes, liner and jacket are then subjected to ultrasonic vibrations to bond the tubes and jacket into an integral structure.

Abstract: A method of producing a tubular thermal structure in which cooling tubes are sandwiched between first and second members which are in turn sandwiched between first and second fixtures which fix the relative relationship of the members. The tubes, members and fixtures are then heated to a temperature at which plastic or superplastic deformation of the tubes will occur, and each tube is then subjected to a pressure differential sufficient to cause each tube to expand into intimate contact with adjacent tubes and the first and second members. The pressure is maintained until each of the tubes bonds to the adjacent tubes and the first and second members.

Abstract: A method of producing a rocket thrust chamber includes positioning cooling tubes within a structural jacket to form a tube bundle, and positioning a mandrel within the tube bundle thereby sandwiching the tubes between the jacket and the mandrel. The tubes are then inflated at high temperature into intimate contact with adjacent tubes and the jacket, and the temperature is maintained until bonding has occurred between the tubes and jacket.

Abstract: A method of producing a rocket thrust chamber includes positioning sleeved cooling tubes within a structural jacket to form a tube bundle, and positioning a liner within the tube bundle thereby sandwiching the tubes between the jacket and the liner. The tubes are then subjected to high internal pressure and inflated at high temperature while the liner is simultaneously subjected to the same high pressure, thereby forcing the sleeved tubes into intimate contact with adjacent sleeved tubes, the liner and the jacket, and the temperature is maintained until bonding has occurred between the liner, sleeved tubes and jacket.