The Cool Parts Show, Episode 1: This Rocket Fuel Injector Is a Solid Part That Contains a Working Motor
Our new video series debuts with a look at a solid metal part made through additive manufacturing that was built with a motor embedded inside. The motor sealed within the part adjusts the rocket’s fuel mixture while the rocket is in flight.
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Welcome to the first episode ofAdditive Manufacturing’s new video series,The Cool Parts Show!
In this episode, hosts Stephanie Hendrixson and I look at rocket fuel injector made by Fabrisonic for TGV Rockets & Propulsion Systems using ultrasonic additive manufacturing, a type of sheet lamination. The solid-state metal AM process (no high heat, no melting) made it possible to build a solid part to contain a motor without harming the motor during the build.
Transcript
Peter Zelinski.,Additive Manufacturing
Additive manufacturing will change what parts are possible! I'm Pete Zelinski
Stephanie Hendrixson.,Additive Manufacturing
而且我是斯蒂芬妮亨德里克斯森，带有additivemanufacturing.media。欢迎来到酷炫的零件秀！这是我们的新系列，在那里我们谈论由您喜欢的观众印刷的酷零件3D。所以皮特你有一部分，帮助我们被踢掉。
Peter Zelinski.
I have a way cool part! So Stephanie you know how one of the promises of additive manufacturing is internal features?
Stephanie Hendrixson.
确定格子，保形散热，那种东西。
Peter Zelinski.
正确的。所以现在认为内部对象。
Stephanie Hendrixson.
像传感器？
Peter Zelinski.
是的。但甚至需要它。想象一个固体部件，嵌入内部的完整工作电机。这就是这是什么。
Stephanie Hendrixson.
听起来像一个很酷的部分。但它是什么？
Peter Zelinski.
It is a cool part! This is a rocket fuel injector, designed by TGV. Fuel injector, mixing fuel and oxidizer during the rocket launch, usually a solid part. This one uses that motor that's inside to precisely control this pentil, controlling the openings of these orifices changing the mix of fuel and oxidizer in flight.
Stephanie Hendrixson.
所以这看起来很坚固，你说有一个嵌入的电机。你如何在那里获得电机，没有用金属3D打印损坏它？
Peter Zelinski.
这是使用固态添加剂制造方法制造的。没有融合综合，没有高热，电机从未处于危险之中。这是通过超声添加剂制造进行的。它是由Fabrisonic Ceo的Fabrisonic，Mark Norfolk描述的过程。
Mark Norfolk，Fabrisonic
So ultrasonic additive manufacturing is a type of 3d printing for metals. UAM is little bit different in that we're taking thin foils of metal on the order of five to 10 thousandths of an inch. And we're welding those together using ultrasound. The secret sauce there is we're not actually melting anything. This is all happening at room temperature. This part right here never got above about 200 F. So the lowest temperature on your oven at home, that's as hot as we ever get. Metals really like to stick to other metals. And if you take two pieces of metal here on Earth, they are always covered with an oxide layer. So if I take this sheet and I fold it over and I try to press it down, it doesn't bond. But with ultrasound, we can actually scrub away that oxide layer and put virgin metal on virgin metal. So what we do is we fold over the foil onto the material we want to bond and we roll over that with what we call an ultrasonic welder. As it rolls over, it's vibrating this sheet back and forth on the order of 20,000 times a second. That vibration actually scrubs off any impurities any oils and most importantly scrubs off the oxide layer. As soon as you have virgin metal touching virgin metal, mother nature takes over and you get a solid state bond.
Peter Zelinski.
所以真正袭击了我，并迷住了我的是氧化物层。世界上每个金属部分都基本上包裹在萨伦包装中。如果你做超声波擦洗，就像金属一样想要像金属一样粘合，他们想要糊涂在一起，只是那么相互咕噜声足以制作固体部分。
Stephanie Hendrixson.
Yeah, and so through that process, you're able to build things like this without damaging the motors or sensors or anything else that you might want to embed inside. Okay, so if fuel injectors are usually this static thing, why would you want to put a motor inside of one?
Peter Zelinski.
是的，所以如果它只是一个静态的固定部分，那么你就可以获得一个燃料和氧化剂。这是您可以控制的各种不同的混音。根据一个程序的路径，它现在可以缩小燃料混合燃料的混合，以便恰好推出您想要的推出。
Stephanie Hendrixson.
那么你为什么3D打印这样的东西？你不能汇集它吗？
Peter Zelinski.
是的，你可以。所以这就是你应该做的那样是这样的就是这样，这是在不同的部位，你把电机放在那里，把它拴在一起，它握着它。问题是，TGV决定，没有办法得到足够紧张的装配绝对保证，您不会因流体而受到意外混合。保持那些流体分开的唯一方法，保持溪流分开，是一个完全坚固的无缝部分。
Stephanie Hendrixson.
Alright, so one more question for you. All of this seems to be the same material except for this band right here. What is this?
Peter Zelinski.
这是正确的。这是所有铝，除了带是铜的铝。这种过程的另一个能力，超声添加剂制造，它使得在同一部分中具有不同材料的建筑物很容易。Mark Norfolk也有话要说。
马克诺福尔克
另一个有趣的功能是我们可以打印异种金属。因此，如果您查看设备，您实际上会看到一个薄的环铜，这实际上是印章。通过在非常具体的位置中打印更软的材料，该材料允许我们非常容易地将一个流体从另一个流体密封。我们正在寻找未来版本的其他事情实际上是用一些嵌入的嵌入线的结构加强，以便我们实际上可以取出一些质量。通过在铝基矩阵内添加高强度线，我们可以获得更高的强度，使我们能够缩小墙壁厚度，如果您愿意，这将可能允许储蓄储蓄。
Stephanie Hendrixson.
Alright, so to recap, this is a 3d printed fuel injector made with ultrasonic additive manufacturing. That process allows for a motor to be embedded inside, which controls this pintil on the top, which allows you to change the amount of fuel that's coming through and throttle your engine.
Peter Zelinski.
所以我认为这是一包。这是我们的第一个酷零件秀的集。告诉我们你的酷炫部分！请给我们发电子邮件coolparts@additivemanufacturing.media.。谢谢观看。别忘了订阅。
