Purdue University's PSP-AC team has made significant strides in rocketry by collaborating with Elementum 3D to create the innovative TADPOLE propulsion system. This cutting-edge project utilizes laser powder bed fusion technology to manufacture an integrated aluminum combustion chamber, cooling circuit, and nozzle, all produced as a single component.
By harnessing the power of additive manufacturing, the students are pushing the boundaries of vertical take-off and landing technology. Their work is part of the Collegiate Propulsive Lander Challenge, which encourages student teams to design rockets capable of self-landing. The TADPOLE propulsion system has emerged as a standout innovation from this initiative.
Dr. Jacob Nuechterlein, Founder and President of Elementum 3D, expressed pride in contributing to the project, stating, "We are thrilled to share our team's expertise in additive manufacturing to inspire students in the Purdue Space Program to challenge conventional thinking and achieve the milestone of printing the first A6061-RAM2 thrust chamber assembly."
Overview of the TADPOLE Propulsion System
The TADPOLE propulsion system represents a pivotal advancement in the development of a bipropellant hopper vehicle by PSP-AC. This vehicle requires a propulsion system capable of extended burn durations, a regenerative cooling mechanism, and precise thrust vector control. To fulfill these specifications, PSP-AC collaborated with Elementum 3D to create the thrust chamber assembly.
Operating at a chamber pressure of 250 psi and delivering a thrust of 550 lbf, the team recognized the importance of Elementum 3D's advanced RAM technology. The selection of the aluminum alloy A6061-RAM2 was strategic, as its yielding characteristics align perfectly with the operational needs of TADPOLE. This choice not only enhanced the durability of the thrust chamber assembly but also facilitated extensive testing, enriching the team's educational experience.
Advantages of Aluminum
The choice of aluminum for the thrust chamber assembly stemmed from its superior thermal properties, lightweight design, and cost-effectiveness. The PSP-AC team was particularly impressed that Elementum 3D's aluminum alloy addressed common issues found in other additive manufacturing aluminum powders, such as rough surface finishes. The thrust chambers crafted from A6061-RAM2 showcased smooth surfaces that promote efficient heat transfer and exhibit excellent thermal and mechanical properties.
Overcoming Challenges
Throughout the 3D printing process, the PSP-AC team encountered challenges, especially in post-processing and the removal of powder from internal channels. By collaborating closely with engineers from Elementum 3D, they developed effective strategies and optimized dimensions to facilitate proper powder removal.
Moreover, the team gained access to detailed material property data for the alloy, marking a significant milestone in their project. This in-depth understanding enabled them to model and predict the performance of the thrust chamber assembly, allowing for comparisons between theoretical predictions and experimental results from engine testing.
Andrew Radulovich, Chief Engineer at PSP-AC, remarked, "This entire process has been a remarkable engineering challenge and a valuable learning experience, made possible by the support of Elementum 3D. The simulations and results we gather will inform the design of our next engine."