Abstract: A thrust chamber liner includes a metallic combustion chamber having an annular protrusion extending radially away from an exterior surface of the combustion chamber adjacent to its injector opening. A metallic nozzle is coupled to the combustion chamber at its throat opening. A composite material encases the exterior surface of the combustion chamber, but is only bonded to the annular protrusion.

Abstract: A method and system are provided for mapping a melt pattern of material created during directed energy fabrication. An infrared camera and a video camera are provided to record images of the pattern of melted material. Each frame of the infrared camera's images is processed to generate a first map of pixels identifying pixels indicative of a highest temperature greater than or equal to a liquidus temperature of the meltable material. Each frame of the video camera's images is processed to generate a second map of pixels identifying pixels indicative of a highest temperature greater than or equal to the liquidus temperature of the meltable material. The first map of pixels and said second map of pixels are overlaid on each other wherein a third map of pixels is generated and is indicative of a hybrid image of the pattern of melted material.

Abstract: A base structure is clad and coolant channels are formed through the cladding and into the base structure. A line of tangency relative to the outer clad surface is defined for each point thereon. Linear rows of a metal feedstock are directed towards and deposited on the outer clad surface as a beam of weld energy is directed to the metal feedstock so-deposited. The metal feedstock is the same material as the cladding or one that is weld compatible therewith. A first angle between the metal feedstock so-directed and the line of tangency is maintained in a range of 20-90°. The beam is directed towards a portion of the linear rows such that less than 30% of the cross-sectional area of the beam impinges on a currently-deposited one of the linear rows. A second angle between the beam and the line of tangency is maintained in a range of 5-65°.

Abstract: A thrust chamber liner includes a main combustion chamber (MCC) with MCC coolant channels extending axially there along. Each MCC coolant channel has a port at an outside surface of the MCC. A nozzle is integrated with the MCC. The nozzle has nozzle coolant channels extending axially there along. A coolant-supply manifold, integrated with one of the MCC and the MCC and nozzle, is in fluid communication with each port in the MCC coolant channels.

Abstract: A method for fabricating a thrust chamber liner for a rocket engine commences with a ring made from a first material on a build plate. A base layer of a second material in powder form is deposited on the exposed axial end of the ring. A laser beam is directed towards the base layer and the ring such that energy associated with the laser beam melts the base layer and a portion of the ring adjacent to the base layer. A melted portion of the base layer intermixes with a melted portion of the ring. Following this step, additional layers of the second material are deposited on the base layer. The first axial end of the ring is then exposed and additional layers of the first material are deposited on the first axial end of the ring.

Abstract: A thrust chamber liner for a rocket engine includes a main combustion chamber (MCC) and a nozzle. A composite wrap covers the outside surface of the MCC and the outside surface of the nozzle.

Abstract: A method is provided for fabricating a coolant channel closeout jacket on a structure having coolant channels formed in an outer surface thereof. A line of tangency relative to the outer surface is defined for each point on the outer surface. Linear rows of a metal feedstock are directed towards and deposited on the outer surface of the structure as a beam of weld energy is directed to the metal feedstock so-deposited. A first angle between the metal feedstock so-directed and the line of tangency is maintained in a range of 20-90°. The beam is directed towards a portion of the linear rows such that less than 30% of the cross-sectional area of the beam impinges on a currently-deposited one of the linear rows. A second angle between the beam and the line of tangency is maintained in a range of 5-65°.

Abstract: A Dynamically Variable Spot Size (DVSS) laser system for bonding metal components includes an elongated housing containing a light entry aperture coupled to a laser beam transmission cable and a light exit aperture. A plurality of lenses contained within the housing focus a laser beam from the light entry aperture through the light exit aperture. The lenses may be dynamically adjusted to vary the spot size of the laser. A plurality of interoperable safety devices, including a manually depressible interlock switch, an internal proximity sensor, a remotely operated potentiometer, a remotely activated toggle and a power supply interlock, prevent activation of the laser and DVSS laser system if each safety device does not provide a closed circuit. The remotely operated potentiometer also provides continuous variability in laser energy output.