| METALS AND METAL MATRIX COMPOSITES |
|
|
|
|
|
| Overview of Manufacturing Technologies for Cu-Cr-Nb Combustion Chamber Inner Wall in Liquid Rocket Engine |
| XUE Yujie, MA Mingyue, YU Gaofeng*, LI Lei, ZHANG Hang, WANG Wenbin
|
| Shaanxi Sirui Advanced Materials Co., Ltd., Xi’an 710076, China |
|
|
|
|
Abstract With the growing demand for space launches, increasingly stringent requirements are imposed on the material performance and manufactu-ring processes of the combustion chamber inner wall. These advancements aim to meet the design needs of next-generation liquid rocket engines, which demand high thrust, exceptional reliability, reusability, low cost, and short production cycles. Due to their superior thermal conductivity properties, copper alloys are the preferred material for the inner wall of the combustion chamber. Conventional copper alloys do not meet the stringent stability requirements for materials in high-thrust, reusable rocket engines due to their significant high-temperature softening beha-vior. The Cu-Cr-Nb alloy has emerged as a promising candidate material due to its unique Cr2Nb precipitate strengthening mechanism and exceptional thermal stability. However, conventional manufacturing processes for this alloy are hindered by low material utilization, high costs, and prolonged production cycles, which significantly prevent its rapid verification and practical application. This paper reviews the development of copper alloys for the inner wall of combustion chambers, with particular emphasis on the key properties of next-generation Cu-Cr-Nb alloys. It systematically presents manufacturing technologies for Cu-Cr-Nb inner wall, including raw material preparation, billet production, conventional machining processes, and additive manufacturing techniques. Finally, future research directions for Cu-Cr-Nb materials and combustion chamber fabrication technologies are discussed.
|
|
Published:
Online: 2026-04-16
|
|
|
|
|
1 Gradl P, Protz C, Park A, et al. In:1st International Conference on Advanced Manufacturing for Air, Space and Land Transportation. US, 2022. 2 Vafadar A, Guzzomi F, Rassau A, et al. Applied Sciences, 2021, 11(3), 1213. 3 Blakey-Milner B, Gradl P, Snedden G, et al. Materials & Design, 2021(12), 110008. 4 Cooke S, Ahmadi K, Willerth S, et al. Journal of Manufacturing Processes, 2020, 57, 978. 5 Hou Y J, Bi K, Dong L, et al. Tool Technology, 2021, 55(3), 72(in Chinese). 侯亚娟, 毕凯, 董礼, 等. 工具技术, 2021, 55(3), 72. 6 Dai J Q, Yang K. Space Exploration, 2023(6), 52(in Chinese). 戴佳桥, 杨开. 太空探索, 2023(6), 52. 7 Zhang Z C, Wang R C, Peng C Q, et al. Transactions of Nonferrous Metals Society of China, 2021, 31(12), 3772. 8 Iii H C D G, Ellis D L, Loewenthal W S. Journal of Materials Engineering and Performance, 2008, 17(4), 594. 9 Wu X, Wang R C, Peng C Q, et al. Journal of Alloys and Compounds, 2019, 803, 1037. 10 Lv G, Feng Y, Wang R, et al. Materials Science and Engineering A, 2021, 800, 140198. 11 Wu X, Wang R, Peng C, et al. Materials Science and Engineering A, 2020, 773, 138829. 12 Wang Y J, Qu J P, Wang X L, et al. Journal of Alloys and Compounds, 2022, 902, 163816. 13 Zhu Z, Lu Y, Lu X. Materials Letters, 2024, 366, 136412. 14 Murugesan S K, Natarajan J, Yang C H. International Journal of Advanced Manufacturing Technology, 2024, 133, 1845. 15 Li J Z, Ding H, Li B M, et al. Materials Science and Engineering A, 2021, 819, 141464. 16 Li J Z, Ding H, Li B M. Materials Science and Engineering A, 2021, 802, 140413. 17 Ellis D L. GRCop-84:a high temperature copper-based alloy for high heat flux applications,Technical Memorandum (TM), 2005. 18 Gradl P, Mireles O, Katsarelis C, et al. Acta Astronautica, 2023, 211, 483. 19 Thomas S, Yazdanparast S, Hildreth O, et al. Physica B Condensed Matter, 2022, 637, 413909. 20 Ellis D L, Michal G M. Precipitation strengthened high strength, high conductivity Cu-Cr-Nb alloys produced by chill block melt spinning. Thesis, Case Western Reserve Univercity, USA, 1989. 21 Zhou S, Yang Y H, Lei Q, et al. Materials Science and Engineering A, 2022, 858, 144159. 22 Yang Y H, Lei Q, Huan L, et al. Materials & Design, 2022, 219, 110784. 23 Anderson K R. Dissertation Abstracts International, 2000, 60(10), 5189. 24 Mjali K V, Mkoko Z A. Manufacturing Letters, 2023, 35, 305. 25 Dutta A, Pal S K, Panda S K. Thin-Walled Structures, 2023, 193, 19. 26 Shi L, Dai X, Tian C, et al. Materials Science and Engineering A, 2022, 858, 15. 27 Ellis D L, RusselL C K, Goudy R. Research and Technology 2004, 2005. 28 Dhokey N B, Sarve S N, Lamsoge H A. Transactions of the Indian Institute of Metals, 2011, 425. 29 Li P Y. Aeronautical Manufacturing Technology, 2020, 63(7), 16(in Chinese). 李沛勇. 航空制造技术, 2020, 63(7), 16. 30 Li J Y. Technology and Market, 2016, 23(10), 1(in Chinese). 李嘉阳. 技术与市场, 2016, 23(10), 1. 31 Wang X, Lin Y, Liu Z, et al. Materials Science and Engineering A, 2022, 852, 8. 32 Neikov O D. Handbook of non-ferrous metal powders, Ukraine, 2009, pp.102. 33 Mathias L E T, Andreoli A F, Gargarella P. Journal of Alloys and Compounds, 2023, 960, 170696. 34 Bartzsch G, Scherbring S, Richter J, et al. Materials Today Communications, 2023, 34, 105388. 35 Jassim A K, Hammood A S. In:International Conference on Material Science and Material Engineering. USA, 2014. 36 Loewenthal W S, Ellis D L. In, Fabrication of GRCop-84 Rocket Thrust Chambers. MS and T 05, USA, 2005. 37 Liu Y, Jia Q M, Jiang L H, et al. New Chemical Materials, 2019, 47(5), 5(in Chinese). 刘洋, 贾庆明, 蒋丽红, 等. 化工新型材料, 2019, 47(5), 5. 38 Zhao P F, Zhou Y J, Song K X, et al. Journal of Plastic Engineering, 2012, 19(3), 5(in Chinese). 赵培峰, 周延军, 宋克兴, 等. 塑性工程学报, 2012, 19(3), 5. 39 Li D R, Cai Y X, Liu Z Y, et al. China Tungsten Industry, 2012, 27 (3), 4(in Chinese). 李达人, 蔡一湘, 刘祖岩, 等. 中国钨业, 2012, 27(3), 4. 40 Ma W T, Leng S, Shi Z X, et al. Aluminum Fabrication, 2021(5), 4(in Chinese). 马万太, 冷晟, 史志翔, 等. 铝加工, 2021(5), 4. 41 Wang X N, Zhu L P, Yu W, et al. Rare Metal Materials and Engineering, 2021(10), 12(in Chinese). 王湘宁, 朱郎平, 余稳, 等. 稀有金属材料与工程, 2021(10), 12. 42 Wang J, Liu W, Ma Y, et al. Journal of Materials Research and Techno-logy, 2023, 24, 971. 43 Tian X, Wu J, Lu Z, et al. Journal of Materials Research and Technology, 2022, 21, 84. 44 Loewenthal W S, Ellis D L. GRCop-84 rolling parameter study,Technical Memorandum (TM), 2008. 45 Wu J, Xu L, Cui X X, et al. Aerospace Manufacturing Technology, 2020, 63 (16), 6(in Chinese). 吴杰, 徐磊, 崔潇潇, 等. 航空制造技术, 2020, 63(16), 6. 46 Zhu L P. Near-net shaping and mechanical property control of thin-walled complex titanium alloy parts by powder hot isostatic pressing. Master’s Thesis, University of Science and Technology Beijing, China, 2021(in Chinese). 朱郎平. 复杂薄壁钛合金构件粉末热等静压近净成形与性能调控. 博士学位论文, 北京科技大学, 2021. 47 Xu L, Chen X, Tian X S, et al. Aerospace Manufacturing Technology, 2024, 67(17), 32(in Chinese). 徐磊, 陈晓, 田晓生, 等. 航空制造技术, 2024, 67(17), 32. 48 Yu C, Huang Z, Zhang Z, et al. Journal of Materials Research and Technology, 2022, 18, 29. 49 Lin Y Z, Liu W B. Powder Metallurgy Industry, 2023, 33(3), 120(in Chinese). 林毅贞, 刘文彬. 粉末冶金工业, 2023, 33(3), 120. 50 Mclean N, Bermingham M J, Colegrove P, et al. Journal of Materials Processing Technology, 2022, 310, 117769. 51 Gradl P R, Mireles O R, Andrews N. In: JANNAF 13th Liquid Propulsion (LPS) and 12th Spacecraft Propulsion (SPS) Joint Subcommittee Meeting. USA, 2022. 52 Zhou J, Cheng S, Wang H L, et al. Journal of Shanghai Electric Technology, 2012, 5(1), 6(in Chinese). 周吉, 程松, 王浩林, 等. 上海电气技术, 2012, 5(1), 6. 53 Li S Y. Die & Mould Industry, 2002(8), 27(in Chinese). 厉善元. 模具工业, 2002(8), 27. 54 Tian H, Huang H Q, Chen G Q, et al. Aerospace Manufacturing Technology, 2009(5), 4(in Chinese). 田辉, 黄海青, 陈国清, 等. 航天制造技术, 2009(5), 4. 55 Nyamekye P, Nieminen P, Bilesan M R, et al. Applied Materials Today, 2021, 23, 101040. 56 Sanchez S, Smith P, Xu Z, et al. International Journal of Machine Tools and Manufacture, 2021, 165, 103729. 57 Lassegue P, Salvan C, Vito E D, et al. Additive Manufacturing, 2021, 39, 101888. 58 Tang X, Chen X, Sun F, et al. Materials & Design, 2022, 224, 111419. 59 Gabriel D, Baxter B, Paul G, et al. Materials & Design, 2022, 222, 111035. 60 Li Z, Sui S, Ma X, et al. International Journal of Machine Tools & Ma-nufacture, Design, Research and Application, 2022, 181, 103942. 61 Yi H, Wang Q, Cao H. Journal of Materials Research and Technology, 2022, 20, 23. 62 Li W, Cao C, Yin S. Progress in Materials Science, 2020, 110, 100633. 1. 63 Yin S, Cavaliere P, Aldwell B, et al. Additive Manufacturing, 2018, 21, 628. 64 Raj S V, Barrett C, Karthikeyan J, et al. Surface and Coatings Technology, 2007, 201, 7222. 65 Bharat K J, Terrence S K, Marius D E, et al. Additive Manufacturing, 2023, 61, 103354. 66 Gradl P R, Mireles O R, Andrews N. In: AIAA Propulsion and Energy Forum 2020. USA, 2020. 67 Gradl P R, Protz C, Greene S E, et al. In:AIAA/SAE/ASEE Joint Propulsion Conference. USA, 2017. 68 Yadroitsev I, Yadroitsava I, Smurov I. Proceedings of the SPIE, 2021, pp. 7921. 69 Liu Z, Zhao D, Wang P, et al. Journal of Materials Science and Technology, 2022, 100, 224. 70 Gradl P R, Protz C S, Cooper K, et al. In:AIAA Propulsion and Energy 2019 Forum. USA, 2019. 71 Seltzman A H, Wukitch S J. Materials Science and Engineering A, 2021, 827, 141690. 72 Hayes C, Brown E, Kappes B. In: AIAA/SAE/ASEE Joint Propulsion Conference 2018. USA, 2018. 73 Minneci R P, Lass E A, Bunn J R, et al. International Materials Reviews, 2020, 66(11), 1. 74 Svetlizky D, Das M, Zheng B L, et al. Materials Today, 2021, 49, 271. 75 Guan X, Zhao Y F. The International Journal of Advanced Manufacturing Technology, 2020, 107, 1959. 76 Gradl P, Mireles O, Katsarelis C, et al. Acta Astronautica, 2023, 211, 483. 77 Yuan Q L, Feng X D, Cao J J, et al. Materials Reports, 2010, 34(3), 112(in Chinese). 袁庆龙, 冯旭东, 曹晶晶, 等. 材料导报, 2010, 34(3), 112. 78 Zhao H C, Liang X B, Qiao Y L, et al. Journal of Materials Engineering, 2019, 47(10), 33(in Chinese). 赵海朝, 梁秀兵, 乔玉林, 等. 材料工程, 2019, 47(10), 33. 79 Du X Y, Xu J B, Song J, et al. Surface Engineering & Remanufacturing, 2020, 20(6), 18(in Chinese). 杜学芸, 许金宝, 宋健. 表面工程与再制造, 2020, 20(6), 18. 80 Liu J D. Research on key technology of shape control and performance control in laser cladding of complex curved surface parts. Master’s Thesis, Xinjiang University, China, 2021(in Chinese). 刘金朵. 复杂曲面零件激光熔覆控形控性关键技术研究. 博士学位论文, 新疆大学, 2021. 81 Gradl P R, Protz C S. Acta Astronautica, 2020, 174, 148. 82 Gradl P R, Protz C S, Fikes J, et al. In: AIAA Propulsion and Energy Forum 2020. USA, 2020. |
| [1] |
LI Tongyue, WANG Fangjun, MENG Gang, WU Wei, LIU Haiding, WANG Dongzhe, ZHOU Dadi, HUANG Haitang, XIAO Jun. Overview of Additive Manufacturing Technology for Invar Alloy[J]. Materials Reports, 2026, 40(7): 25030107-14. |
|
|
|
|