The Ingenious Technique of Manufacturing Rocket Engine Combustion Chambers in the 1970s

🚀Engineers at NASA used wax as a secret weapon to manufacture rocket engine combustion chambers in the 1970s.

🔥The technique involved the use of wax to fill channels, which were then machined and electroplated with copper and nickel.

💪The resulting combustion chambers had internal conformal cooling channels and were made of a copper alloy known as narloy Z.

⏰This technique was a crucial method for creating high-performance rocket engine combustion chambers before the advent of 3D printing.

✨Despite its simplicity, the technique was an ingenious solution to the challenges of manufacturing rocket engine components.

What is the purpose of the main combustion chamber in a rocket engine?

—The main combustion chamber is where combustion takes place, releasing a great amount of energy. It is responsible for producing the thrust necessary for the rocket to propel forward.

Why was wax used in the manufacturing process?

—Wax was used to fill the channels in the combustion chamber, creating a smooth surface. It served as a temporary material, allowing for the formation of conformal cooling channels.

What materials were used for the combustion chamber?

—The combustion chamber was made of a copper alloy known as narloy Z, which was chosen for its strength, conductivity, and ability to withstand high temperatures.

How did engineers dissipate the heat inside the combustion chamber?

—The combustion chamber featured internal conformal cooling channels, through which cryogenic liquid hydrogen was pumped to extract heat and prevent overheating.

Was this technique used exclusively by NASA?

—While NASA and its contractors developed and utilized this technique, similar methods have been employed in the manufacturing of other rocket engines as well, such as the Vulcan on the Ariane 5.

00:00In the 1970s, engineers at NASA used a clever technique involving wax to manufacture rocket engine combustion chambers.

04:38A replica of the main combustion chamber of the RS-25 engine, used in the space shuttle, was created using this technique.

04:52The replica was made of copper and machined to resemble the original combustion chamber.

06:36The wax-filled channels were later electroplated with copper and nickel to provide strength and heat protection.

08:59The wax was dissolved, leaving behind a monolithic combustion chamber with internal conformal cooling channels.