3D printed hypersonic engine combustor successfully tested

Orbital ATK has successfully tested a 3D-printed hypersonic engine combustor at NASA's Langley Research Centre. The combustor, produced through powder bed fusion (PBF), was subjected to a variety of high-temperature hypersonic flight conditions during a 20 day period which included one of the longest duration propulsion wind tunnel tests ever recorded for a unit of this kind. The researchers confirmed the unit met or exceeded all of the test requirements.

One of the most challenging parts of the propulsion system, a scramjet combustor, houses and maintains stable combustion within an extremely volatile environment. The tests were, in part, to ensure that the PBF-produced part would be robust enough to meet mission objectives.

“Additive manufacturing opens up new possibilities for our designers and engineers,” said Pat Nolan, general manager of Orbital ATK’s Missile Products division. “This combustor is a great example of a component that was impossible to build just a few years ago.

The test at Langley was an opportunity for Orbital ATK and its partners to challenge the combustor design, by exploring new manufacturing methods. Additive manufacturing is helping companies like these to move away from complex geometries and assemblies that require multiple components.

“This successful test will encourage our engineers to continue to explore new designs and use these innovative tools to lower costs and decrease manufacturing time,” Nolan added.