thon printed air inlet for solid fuel ramjet - secretariat · unclassified. unclassified....
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UNCLASSIFIED
UNCLASSIFIED
Distribution Statement A. Approved for Public Release. Distribution is unlimited.
FY17 Department of Navy Additive Manufacturing PrintFY17 Department of Navy Additive Manufacturing Print--aa--ThonThon
Printed Air Inlet for Solid Fuel RamjetPrinted Air Inlet for Solid Fuel Ramjet
Project Description—This NAWCWD internally funded
demonstration effort aims to accelerate the development of Solid
Fuel Ramjet (SFRJ) technology. The SFRJ air inlet design is
critical to system performance and conventional manufacturing
methods limit the part geometry that can be affordably achieved
to less than optimum designs. Utilizing metal additive
manufacturing, this effort explores the feasibility & performance
impact of a DMLS (Direct Metal Laser Sintering) steel printed air
inlet for a SFRJ test vehicle.
Transition:
AM parts currently undergoing ground test as
part of in-house R&D efforts with flight test
planned in FY17
Inlet development is critical to the success of
next generation high speed strike weapons
AM enables significant cost and schedule
savings positioning SFRJ technology to provide
the warfighter with increased range weapons
systems
Business Case:
SFRJ technology enables a 3x increase in delivered range
compared to a similar size solid rocket motor
Inert fuel grain and no moving parts
Inlet performance critical for high efficiency and
delivered impulse
Traditional machining requires multiple components to
create a high performance inlet
Interfaces have undesirable tolerance stack-up
Fasteners, welding, threading all incur additional
machine time and cost
Additive manufacturing enables single piece inlet design
Complex geometries to improve inlet performance
Free volume to reduce weight and improve packaging
Minimal post print machining
Design, print, ground test, and flight test at NAWCWD The Technology:
Process: Direct Metal Laser Sintering (DMLS)
Machine: EOS M290
Material: Maraging Steel MS1
Post-print heat treatment & minimal machining
required
Challenges:
Lack of sufficient material property database for
printed materials
As-printed surface roughness not ideal
Design to limit post-print machining
High speed (Mach 2-4) flight induces aerodynamic
heating and high localized temperatures
Uncertain mechanical properties at elevated
temperatures
Enhanced Capability ConceptEnhanced Capability Concept