The present invention relates generally to a centrifugal pump for a liquid rocket engine, and more specifically to a centrifugal pump manufactured with a 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 ever 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. The protective coating may include enamel glass and/or a superalloy, such as MONDALOYâ„¢ material (Pratt & Whitney Rocketdyne Corporation) such as MONDALOY 100 or MONDALOY 200 to form a reaction resistant surface on the base metal in areas of the base metal that are exposed to an oxidizer during pumping. Any 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. The MONDALOY coating provides a high strength base material with the properties of a MONDALOY material, while the enamel glass material mixed in with the MONDALOY material provides a burn resistance to the MONDALOY coating.
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 and 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 in
In the
The single-piece housing 29 of
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
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. These reductions are estimated to reduce the cost of the LOX turbopump by approximately 40%. 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.
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 impeller 25 is slowly rotating within the housing 29 to spread the coating 36. 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 firing 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 13.
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 29. 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 13. 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
In a second embodiment, the protective coating 36 may include a superalloy, such as a MONDALOY material such as at least one of the MONDALOY 100 or 200 materials. Thus, the turbo-pump 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. No MONDALOY coating is required on the liquid hydrogen fuel pumps. The MONDALOY material is disclosed in US 2010/0266442 A1 by Jacinto et al., published on Oct. 21, 2010, and entitled BURN-RESISTANT AND HIGH TENSILE STRENGTH METAL ALLOYS, the entire disclosure of which is incorporated herein by reference.
The MONDALOY coating can also be used on other high pressure pumps or turbine that are exposed to liquid or gaseous oxygen. 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 reactive 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.
In another embodiment of the present invention, an enamel glass powder is mixed in with the MONDALOY powder to produce a protective coating 36 formed from a composite of MONDALOY and enamel glass that will have properties of the MONDALOY material and with a burn resistance that is produced with the enamel glass material. When the glass powder is fired, it becomes an enamel.
In another embodiment, the MONDALOY and enamel glass each form a protective coating. The MONDALOY and an enamel glass are deposited using a thermal spray process. For example, the MONDALOY layer 36a may be on the surfaces 35 of the turbopump that are exposed to the oxidizer and the enamel glass layer 36b may be on the MONDALOY layer (put another way, the MONDALOY layer 36a may be located beneath the enamel glass layer 36b, as shown in
In another embodiment, the MONDALOY and enamel glass are combined to form a multi-component protective coating 36. 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. Use of the fired enamel glass coating with the MONDALOY material has been shown to arrest burning of the metal substrate. 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. The addition of the oxide would enhance the burn resistance of the MONDALOY coating.
In still another embodiment, a surface can be created with high oxide content MONDALOY coating 36 through adjustment of the thermal spray parameters. MONDALOY powder is produced with little or no oxide impurities. 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. The addition of the oxide content will enhance a burn resistance of the MONDALOY coating.
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. As a non-limiting example, aluminum oxide or yttria stabilized zirconia can be added as the oxide to the MONDALOY powder to create the coating. Combinations of these three materials (MONDALOY, enamel glass, and oxide powder) can be used to produce the coating. Thus, a coating can be produced from MONDALOY powder and glass powder, or from MONDALOY powder and oxide powder, or from MONDALOY powder and glass powder and oxide powder.
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. This embodiment will add MONDALOY powder after spraying on enamel slurry before firing the composition. 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.
A liquid rocket engine oxidizer turbopump comprising: a housing with a liquid oxygen inlet and a liquid oxygen outlet; an impeller rotatable within the housing; a forward bearing and an aft bearing to rotatably support the impeller within the housing; both the housing and the impeller are formed as a single piece with the impeller trapped within the housing; and surfaces of the oxidizer pump exposed to an oxidizer during pumping having a composite coating of enamel glass to prevent reaction of the oxidizer.
A liquid rocket engine oxidizer turbopump as recited in Embodiment 1, and further comprising: the surface of the oxidizer pump includes a coating of Mondaloy material below the enamel glass coating.
A liquid rocket engine oxidizer turbopump as recited in Embodiment 2, and further comprising: the Mondaloy coating is Mondaloy 100 or Mondaloy 200.
A liquid rocket engine oxidizer turbopump as recited in Embodiment 1, and further comprising: the oxidizer pump is a centrifugal pump.
A liquid rocket engine oxidizer turbopump as recited in Embodiment 2, and further comprising: the composite coating of Mondaloy material and enamel glass is a mixture of Mondaloy powder and enamel glass powder that is deposited using a thermal spray process.
A liquid rocket engine oxidizer turbopump as recited in Embodiment 2, and further comprising: the Mondaloy and glass includes an oxide in the coating.
A liquid rocket engine oxidizer turbopump as recited in Embodiment 2, and further comprising: the oxide is one of aluminum oxide or yttria stabilized zirconia.
A liquid rocket engine oxidizer turbopump comprising: a single piece housing with an oxidizer inlet and an oxidizer outlet and a forward opening and an aft opening; the single piece housing having an inner minimum diameter; a single piece impeller having a maximum outer diameter greater than the inner minimum diameter of the single piece housing; a forward bearing and an aft bearing to rotatably support the single piece impeller within the single piece housing; and surfaces of the oxidizer pump exposed to an oxidizer during pumping having a coating of enamel glass to prevent reaction of the oxidizer.
A liquid rocket engine oxidizer turbopump as recited in Embodiment 8, and further comprising: the single piece impeller includes an axial bore; a shaft is inserted within the axial bore; and a shaft tie bolt is threaded on one end of the shaft to secure the forward and aft bearings between the housing and the impeller.
A liquid rocket engine oxidizer turbopump as recited in Embodiment 8, and further comprising: a forward cover plate encloses a forward opening of the housing; and an aft buffer seal encloses an aft opening of the housing.
A liquid rocket engine oxidizer turbopump as recited in Embodiment 10, and further comprising: forward cover plate forms a support surface for the forward bearing; and the aft buffer seal forms a support surface for the aft bearing.
A liquid rocket engine oxidizer turbopump as recited in Embodiment 8, and further comprising: a Mondaloy coating is used below the enamel glass coating.
It will be appreciated by persons skilled in the art that the present invention is not limited to what has been particularly shown and described herein above. In addition, unless mention was made above to the contrary, it should be noted that all of the accompanying drawings are not to scale. A variety of modifications and variations are possible in light of the above teachings without departing from the scope and spirit of the invention, which is limited only by the following claims.
Filing Document | Filing Date | Country | Kind |
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PCT/US2017/014259 | 1/20/2017 | WO | 00 |
Number | Date | Country | |
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62286213 | Jan 2016 | US |
Number | Date | Country | |
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Parent | 15227031 | Aug 2016 | US |
Child | 16072087 | US |