Liquid rocket engine turbopump inducer assembly for furnace
The present invention relates generally to a centrifugal pump for a liquid rocket engine, and more specifically to a centrifugal pump manufactured with liquid rocket engine turbopump inducer assembly for furnace single piece housing using a metal additive manufacturing process and having a ceramic coating on specific sections to smooth surfaces and prevent damage from exposure to an oxidizer.
Metal additive manufacturing process is a form of 3D metal printing in which a part such as an impeller for a turbopump can be printed such as with a metal powder bed fusion process in which a layer of metal powder is laid down and a laser is used to fuse or melt the metal powder to form a solid metal.
The metal printing process does not produce a smooth surface as would be found in a casting, a metal machining, or metal removal process to form the part. Prior art manufacturing methods used to produce liquid rocket engine components have historically led to high manufacturing costs. A current challenge in the rocket propulsion industry base is lack of modernization in manufacturing processes and inefficiencies in production. With the low qualities inherent in space propulsion hardware, and an liquid rocket engine turbopump inducer assembly for furnace increasing drive toward reduced cost, there is an increased interest in design for manufacturability.
An optimal balance between commercial best practices and advanced manufacturing techniques could be implemented to meet the future requirements of the rocket propulsion industry. There is potential for significant advancement in cost reduction, design and manufacturing for turbopumps through the application of additive manufacturing AM.
A turbopump for a liquid rocket engine with an oxidizer pump and a fuel pump both driven by a turbine and common rotor shaft, where both pumps are formed from a strong base metal such as stainless steel, and where the oxidizer pump includes a protective coating. Liquid rocket engine turbopump inducer assembly for furnace high pressure pump or turbine that requires high strength base material that is used to pump oxygen will have a protective coating in order to prevent the reaction of oxygen with the base metal material.
In another embodiment, a substrate exposed to a high temperature such as in a rocket engine turbopump can include a composite coating made of a superalloy, such as MONDALOY, and enamel glass that is co-deposited using a thermal spray process.
A turbopump such as a liquid oxygen LOX turbopump for a liquid rocket engine is formed using a metal additive manufacturing process in which a single piece impeller is formed within a single piece housing, the impeller being trapped within the single piece housing. The housing is formed with a fluid inlet and a fluid outlet for example, a liquid oxygen inlet and a liquid oxygen outlet.
The impeller is formed with an axial bore in which a shaft is inserted after the impeller and housing have been formed. Forward and aft bearing support surfaces are machined on to the outer surfaces of the impeller and then two bearings are inserted into the housing and secured by a tie bolt fastened on one end of the shaft. A forward cover plate encloses a forward opening of the housing and a buffer seal encloses an aft opening of the housing.
The cover plate and the buffer seal form support surfaces for outer races of the two bearings. The single piece impeller is formed with forward and aft labyrinth seal teeth all as a single piece, and the housing is formed with seal surfaces for the labyrinth teeth that form forward and aft labyrinth seals between the impeller liquid rocket engine turbopump inducer assembly for furnace housing.
A more complete understanding of the present invention, and the attendant advantages and features thereof, will be more readily understood by reference to the following detailed description when considered in conjunction with the accompanying drawings wherein:. The present invention is liquid oxygen LOX turbopump used in a liquid rocket engine in which the rotor which may also be referred to as the impeller is formed by a metal additive manufacturing process and formed within a single piece housing that is also formed by a metal additive manufacturing process.
The LOX turbopump is formed from only eleven part numbers not including fasteners and is very compact. This reduces or eliminates rotor axial thrust imbalance. Liquid rocket engine turbopump inducer assembly for furnace is an inducer in front of each impeller 15 to improve cavitation performance and the impellers 15 are shrouded to minimize secondary flow leakage without requiring extremely tight tolerance.
The impeller 15 is rotatable within the housing due to bearings 12 that straddle the impeller 15, and the impeller 15 is cooled by recirculating the inlet LOX with the natural pumping of liquid rocket engine turbopump inducer assembly for furnace impeller The bearings 12 are axially held on the impeller 15 by identical spanner nuts To minimize assembly time and components, the impeller 15 is integral with the shaft.
In other words, the impeller 15 functions as both the impeller 15 and the shaft, and the turbopump does not include a separate shaft in addition to the impeller. To minimize cost, the two bearings 12 are the same, the spanner nuts 14 are the same, and the buffer seal 21 is the same as the fuel pump buffer seal. The housing 11 also includes a fluid inlet and a fluid outlet, such as a liquid oxygen inlet and a liquid oxygen outlet.
Liquid rocket engine turbopump inducer assembly for furnace, since the size is so small and the discharge pressure is low, the rotor design speed is low so the stresses on the parts will be extremely low. The double suction impeller 25 is manufactured within the housing 29 and the impeller 25 is rotatable within the housing 29 due to bearings The housing 29 may include a fluid inlet and a fluid outlet, such as a liquid oxygen inlet and a liquid oxygen outlet, screws 20, and springs 22 as discussed above regarding FIG.
Forward and aft bearing support surfaces may be machined onto the outer surfaces of the impeller, which support a forward bearing and an aft bearing, respectively, to rotatably support the impeller Additionally, the forward liquid rocket engine turbopump inducer assembly for furnace 16, the aft seal 17, and the nut 18 of the FIG.
Put another way, the housing 29 has a minimum inner diameter DMini and the impeller 25 has a maximum outer diameter DMaxo, the maximum outer diameter DMaxo of impeller 25 being greater than the minimum inner diameter DMini of the housing This is achieved by printing the components simultaneously within a metal additive manufacturing process such as the selective laser melting SLM machine.
Then, powder and support structure if required removal is performed. The impeller 25 includes an axial bore 30 into which a shaft 26 is inserted once the impeller 25 is created within the housing The bearings 12 are installed on the ends of the shaft 26 and a shaft tie bolt is threaded on one end of the shaft 26 to secure the bearings 12 for example, a forward bearing and an aft bearing between the housing 29 and the impeller Conventional manufacturing is required for the bearings 12 due to high precision requirements needed.
The cover plate and buffer seal form support surfaces for outer races of the bearings The impeller 25 is formed with forward and aft labyrinth seal teeth all as a single piece, and the housing 29 is formed with seal surfaces for the labyrinth teeth that form forward and aft labyrinth seals 28 between the impeller 25 and the housing With the exception of the shaft tie-bolt and the shaft seal, all other components are printed on an SLM machine.
The single-piece housing 29 of FIG. Additionally, stress from internal pressure would be evenly spread throughout the housing 29 without having to pass from one section to another, such as through the two bolts 20 that connect the main housing 11 and aft housing 19 in FIG.
Rotor balancing is another critical area. Typically, an assembly balance of the rotor is performed for turbopump rotors. That is, the full rotor, such as the impeller 25 of FIG. Since the impeller 25 is printed inside the single -piece housing 29, this method cannot be used without special tooling. In the present invention, a method of trim balancing is used where the impeller 25 is spun up to various high speeds and accelerometers on the housing along with a proximity probe looking at the impeller 25 is used to determine the impeller imbalance.
The imbalance is corrected by grinding locations on each end of the shaft. The present invention is a LOX turbopump used in a liquid rocket engine in which the impeller 25 is formed by a metal additive manufacturing MAM process and formed within a single-piece housing 29 that is also formed by a metal additive manufacturing process. By printing the impeller 25 within a one-piece housing 29, a dramatic reduction in part count, procurement activities, and assembly time is achieved over the prior art, which directly translates into a reduction in recurring cost and lead time.
The turbomachinery for a typical rocket engine accounts for about one-third of the cost of the total engine. Thus, significant reductions in turbomachinery cost have large impacts on the overall cost of the engine. The metal printing process produces a relatively rough surface on the parts.
Thus, the present invention also applies a protective coating of 36 of one or more materials to form a smooth surface that functions to increase the efficiency of the pump. Because the impeller 25 is formed within a single -piece housing 29, a machining tool that would form a smooth surface cannot be used because of lack of space to insert the tool.
In one embodiment, an enamel glass coating can be applied over the required surfaces while the impeller and even the housing are rotating to form a smooth surface. The enamel glass protective coating 36 would also provide a burn resistance to the pump surfaces that would be exposed to the liquid oxygen. INCONEL is a nickel based superalloy which retains high strength at elevated temperatures and has high strength up to 1, degrees F, good cryogenic ductility, and good weldability.
The enamel glass coating 36 is an ambient temperature applied coating using a spray or a brush to apply to selected surfaces. Or, the entire turbopump with the impeller 25 and the housing 29 can be submerged within a slurry of the liquid coating material to apply the coating A liquid rocket engine turbopump inducer assembly for furnace tape can be used to mask surfaces 35 where the coating 36 is not to be applied.
The turbopump is formed using a metal powder bed fusion process in which thin layers of powder are applied to a platen, and then a laser is used to fuse or melt the powder to form a solid metal material. Subsequent layers of the powder are laid down and then selectively fused by the laser to build the parts.
The turbopump is built up along the rotational axis of the turbopump in a vertical direction with surfaces between the impeller 25 and the housing 29 for the forward and aft bearings 12 to be placed.
This way both the housing 29 and the impeller 25 can be formed. After the impeller 25 and housing 29 have been formed by the powder bed fusion process, the turbopump is placed in a horizontal position and masking tape used over surfaces 35 that will not have the enamel glass protective coating 36 applied. The enamel glass coating 36 is formed over selected surfaces 35 by using a spray nozzle or a brush to apply the coating 36 while the liquid rocket engine turbopump inducer assembly for furnace 25 is slowly rotating within the housing 29 to spread the coating The housing 29 can also be rotated.
The turbopump is then fired to harden the glass coating. The coating 36 is applied over the rough surface of the printed part to not only smooth the surface, but to add protection against heat, against oxidation, against erosion, and even against damage from a foreign object damage FOD.
Any masking tape used can be removed before the liquid rocket engine turbopump inducer assembly for furnace process. After the coating 36 has been hardened, the two bearings 12 are inserted and the open ends of the housing 29 are enclosed with cover plates The impeller 25 and the housing 29 are formed with bearing support surfaces that can be machined afterwards because the bearing surfaces are located close to the two open ends of the single -piece housing Bearings 12 can then be inserted into position to rotatably support the rotor 25 within the housing 29 and the open end or ends of the housing closed by securing a cover plate The opposite end would be connected to a driving mechanism such as an input shaft from a turbine.
The rocket engine uses a turbopump to pump both a liquid fuel and a liquid oxidizer to a common combustion chamber. For example, the liquid oxidizer would be liquid oxygen and the liquid fuel would be liquid hydrogen.
A common shaft 31 is driven by a turbine 32 with the fuel pump 33 on one end and the oxidizer pump 34 on the opposite end as shown in FIG. The oxidizer pump 34 and the fuel pump 33 are typically centrifugal pumps because of the high pressures obtained. To prevent the combustion resistance in the presence of high temperature and high pressure liquid or gaseous oxygen, the surfaces liquid rocket engine turbopump inducer assembly for furnace of the turbopump that are exposed to the oxidizer are coated with a protective coating Thus, the liquid rocket engine turbopump inducer assembly for furnace can be constructed with the prior art metal materials for strength and light weight such as stainless steels or INCONEL, but have the combustion resistance to the high temperature and high pressure liquid or gaseous oxygen due to the MONDALOY coating on its surfaces on which the liquid or gaseous oxygen would make contact.
Because of the high pressure, the base metal material must be a high strength material such as stainless steel. Certain high strength materials are very liquid rocket engine turbopump inducer assembly for furnace to oxygen. If the pump or turbine is exposed to oxygen, then the MONDALOY protective coating 36 on the surfaces 35 that are exposed to the oxygen will provide for the high strength required while also protecting the base material from reacting to the oxygen.
When the glass powder is fired, it becomes an enamel. The powder would be made of the enamel glass composition. The two constituents can be pre- blended, independently injected into a thermal plumb to allow for functional grading of the coating, or co-deposited on the surface 35 using a thermal spray process.
Thus, use of the enamel glass constituent processed as a powder and deposited using thermal spray would enhance the burn resistance of the MONDALOY material in the coating. In another embodiment, a surface can be created by coating a multiple component surface coating of MONDALOY and an oxide that is co-deposited using a thermal spray process. The two constituents can be pre-blended or independently injected into the thermal plumb to allow for functional grading of the coating.
Thermal spraying in air creates oxides in the coating deposit due to the interaction of the metal powder with a thermal heating source.
Thermal spray parameters can be adjusted to regulate the oxide content of the coating deposit. Instead of the enamel glass powder, an oxide powder can be used to produce similar properties for the protective coating 36 containing MONDALOY to resist burning.
In still another embodiment of the present invention, a burn resistant protective coating 36 that uses enamel glass fired with MONDALOY powder can be produced that will allow for higher operating temperatures prevent thermal creep and better manage the coefficient of thermal expansion mismatch. The attributes of the coating are burn resistance, low cost, and easy application to complex geometry parts or internal passages such as in air cooled airfoils.
Further features of the invention are disclosed in the numbered Embodiments set forth below.
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