U.S. patent application number 13/977103 was filed with the patent office on 2014-01-09 for method for manufacturing inner structure of regenerative cooling type combustion chamber.
This patent application is currently assigned to KOREA AEROSPACE RESEARCH INSTITUTE. The applicant listed for this patent is Kyu Bok Ahn, Hwan Seok Choi, Jong Gyu Kim, Mun Ki Kim, Keum Oh Lee, Byoung Jik Lim, Chul Sung Ryu. Invention is credited to Kyu Bok Ahn, Hwan Seok Choi, Jong Gyu Kim, Mun Ki Kim, Keum Oh Lee, Byoung Jik Lim, Chul Sung Ryu.
Application Number | 20140007412 13/977103 |
Document ID | / |
Family ID | 46383657 |
Filed Date | 2014-01-09 |
United States Patent
Application |
20140007412 |
Kind Code |
A1 |
Ryu; Chul Sung ; et
al. |
January 9, 2014 |
METHOD FOR MANUFACTURING INNER STRUCTURE OF REGENERATIVE COOLING
TYPE COMBUSTION CHAMBER
Abstract
The present invention relates to a method for manufacturing an
inner structure of a regenerative cooling type combustion chamber,
and more specifically to a method for manufacturing the inner
structure of the regenerative cooling type combustion chamber,
including the steps of: manufacturing a cylinder structure by
performing a vacuum casting process or an air casting process for a
copper alloy; manufacturing a circular plate having a constant
thickness by forging and rolling the cylinder structure; thermally
and mechanically processing the circular plate; spinning the
circular plate to manufacture the shape of the regenerative cooling
type combustion chamber; and thermally processing the shape of the
regenerative cooling type combustion chamber. The method for
manufacturing the inner structure of the regenerative cooling type
combustion chamber can prevent necking and damage of the structure
and can improve reliability during a bulging process for assembling
the inner structure with an outer structure of the combustion
chamber by uniformizing and miniaturizing the grain size of the
inner structure of the combustion chamber.
Inventors: |
Ryu; Chul Sung; (Daejeon,
KR) ; Choi; Hwan Seok; (Daejeon, KR) ; Lee;
Keum Oh; (Daejeon, KR) ; Kim; Jong Gyu;
(Daejeon, KR) ; Lim; Byoung Jik; (Daejeon, KR)
; Ahn; Kyu Bok; (Daejeon, KR) ; Kim; Mun Ki;
(Daejeon, KR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Ryu; Chul Sung
Choi; Hwan Seok
Lee; Keum Oh
Kim; Jong Gyu
Lim; Byoung Jik
Ahn; Kyu Bok
Kim; Mun Ki |
Daejeon
Daejeon
Daejeon
Daejeon
Daejeon
Daejeon
Daejeon |
|
KR
KR
KR
KR
KR
KR
KR |
|
|
Assignee: |
KOREA AEROSPACE RESEARCH
INSTITUTE
Daejeon
KR
|
Family ID: |
46383657 |
Appl. No.: |
13/977103 |
Filed: |
December 23, 2011 |
PCT Filed: |
December 23, 2011 |
PCT NO: |
PCT/KR11/10042 |
371 Date: |
September 13, 2013 |
Current U.S.
Class: |
29/527.7 |
Current CPC
Class: |
F23M 5/08 20130101; B21D
51/16 20130101; B21D 22/16 20130101; B22D 25/02 20130101; C22F 1/08
20130101; B22D 21/025 20130101; B22D 18/06 20130101; Y10T 29/49991
20150115; B21K 21/02 20130101; C22C 9/00 20130101 |
Class at
Publication: |
29/527.7 |
International
Class: |
F23M 5/08 20060101
F23M005/08 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 31, 2010 |
KR |
10-2010-0139744 |
Claims
1. A method of manufacturing an inner liner of a regenerative
cooling combustion chamber, the method comprising: manufacturing a
cylinder structure with copper alloy through a vacuum or atmosphere
casting process; manufacturing a circular plate having a certain
thickness by forging and rolling the cylinder structure; and
thermally treating, working and spinning the circular plate to have
a shape of a regenerative cooling combustion chamber.
2. The method according to claim 1, further comprising performing
thermal treatment to recrystallize the jacket manufactured to have
the shape of the regenerative cooling combustion chamber after
finishing the spinning work.
3. The method according to claim 1, wherein the copper alloy
comprises copper, chrome, iron, lead, zinc, magnesium, nickel, and
silicon.
4. The method according to claim 1, wherein the copper alloy
comprises chrome of 0.4.about.0.7 wt %, iron of 0.06 wt % or below,
lead of 0.005 wt %, zinc of 0.015 wt % or below, magnesium of 0.002
wt % or below, nickel of 0.02 wt % or below, silicon of 0.05 wt %
or below, phosphorus of 0.01 wt % or below, and a remnant of copper
in the total weight of copper alloy.
Description
TECHNICAL FIELD
[0001] The present invention relates to a method of manufacturing
an inner liner of a regenerative cooling combustion chamber, and
more particularly to a method of manufacturing an inner liner of a
regenerative cooling combustion chamber, which includes the steps
of manufacturing a cylinder structure with copper alloy through a
vacuum or atmosphere casting process; manufacturing a circular
plate having a certain thickness by forging and rolling the
cylinder structure; and performing thermal treatment after
thermally treating, machine work and spinning the circular plate to
have a shape of a regenerative cooling combustion chamber, so that
the inner liner of the combustion chamber can have uniform and fine
grains and thus the inner liner to be coupled to the outer jacket
of the combustion chamber can be prevented from necking or damage
during a bulging process, thereby having an effect on improving
reliability.
BACKGROUND ART
[0002] In general, an inner liner and an outer jacket made of
different materials are assembled into a regenerative cooling
combustion chamber for a liquid rocket combustor. The inner liner
is made of copper alloy showing high thermal conductivity and
strength to protect a chamber structure from high temperature
combustion gas generated in the combustion chamber, and worked to
have a cooling channel through which fuel can flow for cooling. The
outer jacket is generally made of high strength steel showing very
high strength coupled to an outside of the inner liner so that the
chamber can structurally stably operate against the high pressure
combustion gas generated inside the combustion chamber,
[0003] As a method of manufacturing the foregoing combustion
chamber, there are two major methods currently used all over the
world.
[0004] In a first method, the inner liner made of copper alloy is
worked to have a chamber shape with the cooling channel, and nickel
(Ni) layer is formed at the outside of the inner liner by
electroforming, thereby completing the regenerative cooling
combustion chamber. As a combustor manufactured by this method,
there is a VULCAIN thrust combustor.
[0005] In a second method, currently used in Russia and Korea, the
copper alloy inner liner and the outer jacket are worked. and then
assembled to undergo brazing. At this time, the copper alloy inner
liner and the high strength steel outer jacket are worked to have
desired shapes and then assembled for brazing.
[0006] FIG. 1 is a schematic view showing the shape of the
regenerative cooling combustion chamber, and FIG. 2 is a schematic
view of a bulging process.
[0007] As shown in FIG. 1, the present shape has difficulty in
assembling the inner liner and the outer jacket since a cylinder
section 20 and a nozzle section 30 have larger diameters than a
nozzle neck 10. Therefore, the copper alloy inner liner and the
outer jacket are designed/manufactured for easily assembling. After
both jackets are assembled, the bulging process is performed to
transform the inner liner from a cylinder shape to a nozzle shape
as shown in FIG. 2, thereby manufacturing the regenerative cooling
combustion chamber.
[0008] When the cylinder section of the copper alloy inner liner is
transformed into the nozzle shape by the bulging process, large
deformation occurs in the cylinder section. In general, necking or
damage may occur in a metallic material if it is transformed beyond
its forming limit. Also, even though the same metallic material is
used, the metallic material having large and non-uniform grains is
more likely to cause necking or damage than that having small and
uniform grains. In manufacturing regenerative cooling combustion
chamber for a liquid rocket, if the cylinder section of the copper
alloy inner liner is transformed to have a nozzle shape, the large
deformation occurs to thereby cause the necking or damage during
the bulging process. Therefore, to prevent the inner liner from
being damaged by the deformation occurring in the bulging process,
a degree of deformation occurring in the jacket has to be decreased
by shortening the length of the cylinder section to be bulged,
i.e., by reducing an enlarging ratio of the finally transformed
nozzle. In this case, an end of the nozzle transformed by the
bulging process is connected to a nozzle extending portion due to a
larger enlarging ratio. A region in the combustion chamber, where
the largest thermal load due to combustion gas is applied, is a
nozzle throat portion. When EBW (Electron Beam Welding) location of
bulged nozzle end with the larger nozzle section is performed at a
portion closer to the nozzle throat, the thermal load are gradually
increased. Therefore, EBW location should be far away from the
nozzle throat as possible because cooling performance of EBW
location is low. That's why the nozzle formed by the bulging
process is designed to have the maximum enlarging ratio by taking a
forming limit of a material into account. It is very important that
the cylinder shape of inner liner is transformed into the nozzle
shape by the maximum diameter enlarging ratio without the necking
or damage. The copper alloy inner liner undergoes the bulging
process in the state that the cooling channel is worked. To
precisely work the cooling channel, much time and costs are needed.
Thus, if the bulging process is failed, a serious loss occurs in
the time and costs. Accordingly, material characteristics are very
important to prevent the necking and damage while the copper alloy
inner liner is transformed to have a designed nozzle shape.
[0009] To manufacture such an inner liner of the regenerative
cooling combustion chamber, as shown in FIGS. 3 and 4, copper alloy
is conventionally casted to have a circular bar shape, and then
forged to work the inner liner. Specifically, it is general that
the copper alloy 1 is forged through hammering and then worked to
have the shape of the inner liner 2 (refer to FIG. 3), or that the
copper alloy 1 is pierced with a forging rod, forged through
hammering, and worked to have the shape of the inner liner 2 (refer
to FIG. 4).
[0010] However, after the inner liner is formed by the conventional
methods shown in FIGS. 3 and 4, a result from analyzing the
material microstructure of the inner liner shows that the grains
are very large and non-uniformly distributed. If the grains are
large and non-uniformly distributed, small deformation may cause
the necking or damage in the jacket when the nozzle shape is
manufactured by the bulging method. The reason why the necking or
damage occurs is because the shape of the chamber to be
manufactured is circular. The circular shape of the jacket to be
worked to have such a shape is difficult to uniformly give a
forging effect to the material.
[0011] Accordingly, there is needed a new manufacturing method for
preventing the necking and damaging problems due to the non-uniform
forging effect in the bulging process.
DISCLOSURE
Technical Problem
[0012] The present invention is conceived to satisfy the foregoing
requirements, and an aspect of the present invention is to provide
a method of manufacturing an inner liner of a regenerative cooling
combustion chamber, and more particularly to a method of
manufacturing an inner liner of a regenerative cooling combustion
chamber, which includes the steps of manufacturing a cylinder
structure with copper alloy through a vacuum or atmosphere casting
process; manufacturing a circular plate having a certain thickness
by forging and rolling the cylinder structure; and performing
thermal treatment after thermally treating, working and spinning
the circular plate to have a shape of a regenerative cooling
combustion chamber, so that the inner liner of the combustion
chamber can have uniform and fine grains and thus the inner liner
to be assembled to the outer jacket of the combustion chamber can
be prevented from necking or damage during a bulging process,
thereby having an effect on improving reliability.
Technical Solution
[0013] In accordance with one aspect of the present invention,
there is provided a method of manufacturing an inner liner of a
regenerative cooling combustion chamber, the method including:
manufacturing a cylinder structure with copper alloy through a
vacuum or atmosphere casting process; manufacturing a circular
plate having a certain thickness by forging and rolling the
cylinder structure; and thermally treating, working and spinning
the circular plate to have a shape of a regenerative cooling
combustion chamber.
[0014] The method may further include performing thermal treatment
to recrystallize the jacket manufactured to have the shape of the
regenerative cooling combustion chamber after finishing the
spinning work.
[0015] The copper alloy may include copper, chrome, iron, lead,
zinc, magnesium, nickel, and silicon. In more detail, the copper
alloy may include chrome of 0.4.about.0.7 wt %, iron of 0.06 wt %
or below, lead of 0.005 wt %, zinc of 0.015 wt % or below,
magnesium of 0.002 wt % or below, nickel of 0.02 wt % or below,
silicon of 0.05 wt % or below, phosphorus of 0.01 wt % or below,
and a remnant of copper in the total weight of copper alloy.
Advantageous Effects
[0016] In accordance with an aspect of the present invention, there
is provided a method of manufacturing the inner liner of the
regenerative cooling combustion chamber, in which copper alloy has
uniform and fine grains so that the jacket can be prevented from
necking or damage during a bulging process necessarily performed
when the combustion chamber is manufactured by a brazing method,
thereby decreasing a loss of time and coasts due to failed bulging
in manufacturing the regenerative cooling combustion chamber, and
increasing fatigue life of the regenerative cooling combustion
chamber under repetitive thermal, pressure load by combustion
tests.
DESCRIPTION OF DRAWINGS
[0017] FIG. 1 is a schematic view showing the shape of the
regenerative cooling combustion chamber.
[0018] FIG. 2 is a schematic view of a bulging process.
[0019] FIG. 3 is a schematic view of a conventional forging process
where a casted circular bar is worked into an inner liner.
[0020] FIG. 4 is a schematic view of a conventional forging process
where a center of a casted circular bar is formed with a hole and
then a forging rod is inserted therein to be worked into an inner
liner.
[0021] FIG. 5 is a flowchart of a manufacturing method of a
regenerative cooling combustion chamber according to an embodiment
of the present invention.
[0022] FIG. 6 is a schematic view showing that copper alloy
materials are fused, forged, rolled and machine-worked before
spinning work, as a part of the manufacturing method of a
regenerative cooling combustion chamber according to an embodiment
of the present invention.
[0023] FIG. 7 is a schematic view showing that spinning work is
applied to the cooper alloy product manufactured in FIG. 6 to have
a shape of a combustion chamber, as a part of the manufacturing
method of a regenerative cooling combustion chamber according to an
embodiment of the present invention.
BEST MODE
[0024] Hereinafter, exemplary embodiments according to the present
invention will be described to be easily embodied by a person
having an ordinary skill in the art to which the present invention
pertains.
[0025] Prior to this, terms or words used in this specification and
claims have to be interpreted as the meaning and concept adaptive
to the technical idea of the present invention rather than typical
or dictionary interpretation on a principle that an inventor is
allowed to properly define the concept of the terms in order to
explain his/her own invention in the best way.
[0026] Therefore, embodiments disclosed in this specification and
configurations illustrated in the drawings are nothing but
preferred examples of the present invention and do not fully
describe the technical idea of the present invention, and it will
be thus appreciated that there are various equivalents and
alterations replacing them at a filing date of the present
application.
[0027] Hereinafter, an embodiment of the present invention will be
described in detail with reference to accompanying drawings.
[0028] FIG. 5 is a flowchart of a manufacturing method of a
regenerative cooling combustion chamber according to an embodiment
of the present invention.
[0029] As shown in FIG. 5, a method of manufacturing an inner liner
of a regenerative cooling combustion chamber according to the
present invention includes manufacturing a cylinder structure with
copper alloy through a vacuum or atmosphere casting process;
manufacturing a circular plate having a certain thickness by
forging and rolling the cylinder structure; and thermally treating,
working and spinning the circular plate to have a shape of a
regenerative cooling combustion chamber.
[0030] FIG. 6 is a schematic view showing that copper alloy
materials are fused, forged, rolled and machine-worked before
spinning work, as a part of the manufacturing method of a
regenerative cooling combustion chamber according to an embodiment
of the present invention, and FIG. 7 is a schematic view showing
that spinning work is applied to the cooper alloy product
manufactured in FIG. 6 to have a shape of a combustion chamber, as
a part of the manufacturing method of a regenerative cooling
combustion chamber according to an embodiment of the present
invention. With reference to FIGS. 6 and 7, the method of
manufacturing the inner liner of the regenerative cooling
combustion chamber according to an embodiment of the present
invention will be described.
[0031] First, as shown in FIG. 6, copper, chrome, iron, lead, zinc,
magnesium, nickel, silicon and other metals are put into a smelting
furnace and made into casting 100 for manufacturing copper alloy.
Here, other metals used in manufacturing the copper alloy may
include chrome of 0.4.about.0.7 wt %, iron of 0.06 wt % or below,
lead of 0.005 wt %, zinc of 0.015 wt % or below, magnesium of 0.002
wt % or below, nickel of 0.02 wt % or below, silicon of 0.05 wt %
or below, phosphorus of 0.01 wt % or below in the total weight of
copper alloy.
[0032] The copper alloy casting 100 manufactured as above undergoes
a forging process where it is forged with pressure and shock under
plastic flow state, and cast structures thus become a uniform
organization. Therefore, the copper alloy forging 200 is
manufactured. Here, the forging process is obvious to those skilled
in the art, and therefore detailed descriptions thereof will be
omitted.
[0033] After the forging process is completed, the copper alloy
forging 200 is rolled while passing through a rolling mill and
being heated at a temperature higher or lower than a
recrystallization temperature. Through the rolling process, a cast
structure is uniformly deformed and thickness is decreased. Thus,
the rolled copper alloy 300 is manufactured. Here, the rolling
process is obvious to those skilled in the art.
[0034] After the rolling process is completed, the rolled copper
alloy 300 is thermally treated to make the grains fine, and the
inner liner manufactured to be shaped like a chamber through the
following spinning process is machine-worked to have an opening
portion 410, thereby manufacturing the copper alloy product
400.
[0035] When the thermal treatment and the machine work are
completed, the spinning process is performed. As shown in FIG. 7,
the copper alloy product 400 is first mounted to spinning equipment
X having a straight incline and then pushed with a roller Y,
thereby performing spinning work (refer to 7a). Here, the opening
portion 410 of the copper alloy product 400 is put in and fixed to
one end of the spinning equipment X in an axial direction, thereby
facilitating the work.
[0036] After the shear spinning work is completed, the copper alloy
product 400 is mounted to spinning equipment X' having a curved
slope shaped like the combustion chamber as shown in FIG. 7b, and
then undergoes spinning work.
[0037] In this case, the copper alloy product 400 is worked to have
the shape of the combustion chamber as shown in FIG. 7, and
thermally treated to have uniform and fine grains. At this time,
both hot and cold processes are possible for the spinning process.
However, the cold process is preferable to make the grains fine and
uniform through the following heat treatment. A processing
temperature at the hot process may be equal to or lower than the
recrystallization temperature of the material. If the processing
temperature is beyond the above temperature range, the grains of
the jacket become coarse after the final process
[0038] An embodiment of the present invention may further include
performing the thermal treatment for recrystallizing the inner
liner manufactured to have the shape of the regenerative cooling
combustion chamber after finishing the spinning work. Through this
thermal treatment, the grains of the copper alloy can get finer and
more uniform. The thermal treatment may be performed at a
temperature of 600.about.900.degree. C. If the thermal treatment is
performed beyond this temperature range, the recrystallization is
not performed or the grains become coarse
[0039] Although some embodiments have been described herein with
reference to the accompanying drawings, it will be understood by
those skilled in the art that these embodiments are provided for
illustration only, and various modifications, changes, alterations
and equivalent embodiments can be made without departing from the
scope of the present invention.
* * * * *