Ariane 6 Propulsion Module: Simplified by Additive Manufacturing Components Cut from 248 to 1 with EOS Technology
Total Page：16
File Type：pdf, Size：1020Kb
Customer Reference – Aerospace Facts & Figures Challenge Production of an injection head for rocket engines with as few components as possible and lower unit costs. Solution An additively manufactured product that comprises a single element instead of 248 individual parts thanks to functional integration. Results • Simplified: One component instead of 248 • Cost-efficient: Thanks to EOS technology, ArianeGroup has succeeded in manufacturing the injector head of the Ariane 6 VINCI upper stage propulsion module with an all-in-one design (AiO). (Source: ArianeGroup) 50 % lower costs • Fast: Significant reduction in production time Ariane 6 propulsion module: Simplified by additive manufacturing Components cut from 248 to 1 with EOS Technology „Mission Critical“ perfectly describes the Class 1 components used in the aerospace industry. Brief Profile Missions costing hundreds of millions depend on these components. Accordingly, engineers are ArianeGroup formerly known constantly seeking to develop components of the highest quality, functionality, and robustness while as Airbus Safran Launchers – simplifying the manufacturing chain and reducing the number of individual elements. Thanks to EOS a joint venture by the technology, ArianeGroup has succeeded in taking this to a whole new level: Instead of 248 elements, European aerospace the injector head of a rocket engine of the type used in the VINCI upper stage propulsion module of company Airbus Group and the Ariane 6 has just one. The injector head has been simplified and reduced to what is literally an the French group Safran – all-in-one (AiO) design. is responsible for the development and production of the new European launch Challenge onwards. It is designed with the fuel mixture into the combustion vehicle, Ariane 6. The European Space Agency (ESA) intention of securing Europe‘s chamber. Its traditional design wishes to assume a strong and access to space at a competitive consists of 248 components, Further Information independent position in space price. The goal set for this project produced and assembled in various www.ariane.group/en transportation using efficient is to reduce costs by eliminating manufacturing steps. The different launch vehicle technology. In the need for public funding. The processing steps, such as casting, order to achieve this, ArianeGroup, focus is on the rocket’s upper brazing, welding, and drilling, a joint venture by the European stage module, which takes over result in weak points that can aerospace company Airbus Group propulsion after the vehicle leaves constitute a risk under extreme and the French group Safran, was orbit. loads. Moreover, it is a time- commissioned to construct consuming and complex process. Ariane 6. Ariane is a series of In a propulsion module, tremend- In the field of injector elements, European launch vehicles designed ous forces develop under extreme conventional production requires to enable heavy payloads, such as conditions. This demands maximum over 8,000 cross holes to be communications satellites, to be levels of reliability and precision in drilled in copper sleeves that are put into orbit around the earth. a small space. The injection head then precisely screwed to the Ariane 6 is scheduled to replace is one of the core elements of the 122 injector elements in order to the current version 5 from 2025 propulsion module, feeding the mix the hydrogen that streams through them with oxygen. A glance at these figures clearly shows that, from the perspective of risk one functionally integrated component combining all the elements is an obvious but ambitious goal. This could also release huge economic potential The additively manufactured and cut the number of processing baseplate of the injector steps as well as production time, head of a rocket engine with especially for a Class 1 component. 122 injection elements is made from EOS NickelAlloy IN718. (Source: EOS GmbH) Solution Production process Construction time for 1 injector head preparing tools, as is the case The solution for these challenges Casting & machining finishing 3 months when casting parts. Industrial 3D is provided by additive manufac- Additive manufacturing printing thus achieves a quantum 133 hours with EOS M 290 turing. “The production of the leap in terms of lead time. EOS M 400-4 65 hours injector head in one piece is only (1 laser for 1 component) Whereas each iteration generally possible using EOS technology,” EOS M 400-4 used to require around half a year, 35 hours says Dr.-Ing. Steffen Beyer, (4 lasers for 1 component) one iteration now only takes a few Head of Production Technology – days. On top of this, the entire Materials & Processes at propulsion module component to the hydrogen and oxygen fuels manufacturing chain now unfolds ArianeGroup, explaining why be manufactured up to four times as one integrated component. in-house on ArianeGroup’s industrial 3D printing was chosen. as fast. “Scaling up the construction Compared with single-laser premises. In a nutshell: “Only additive manufacturing can process to the high-productivity systems, the significantly higher Mission accomplished! combine integrated functionality, EOS M 400-4 system was an productivity of the EOS M 400-4 lightweight construction, a important step for us in order to multi-laser system was able to cut simpler design, and shorter lead advance the industrialization and construction time by a factor of 3 times in a single component.” competitiveness of the Ariane 6 and costs by 50 % in the example The project team again chose a project. The collaboration un- of the AiO injector head. heat- and corrosion-resistant folded very efficiently thanks nickel-based alloy (IN718) as the to the experience and industry The project team was able to clock material. This material provides expertise of EOS staff. The results up a whole series of additional excellent tensile, endurance, speak for themselves and are successes. The simplified design creep and fracture strength at proof of great team performance,” and the improved material prop- high temperatures and and will adds Dr. Steffen Beyer. erties compared with the quality also be used with the new of cast parts allowed the additive production technology. Results technology to reduce the wall The results of the new injector thickness considerably – without “On Ariane 6, we are combining “After successfully developing head produced using additive losing any strength. Cutting our innovative strength with the component, we turned our manufacturing are extremely weight by 25 % also meant a the expertise of EOS. Together, attention to cost efficiency,” impressive: Instead of 248 parts, further reduction in construction we have implemented the reports Dr. Fabian Riss, Production it consists of just one – with the time and, of course, costs. additive production of an Technology – Materials & Processes. same functionality, and cutting injector head for a rocket The key requirement from the required time down to a Last but not least, additive engine. The results are ArianeGroup was to reduce lead minimum. manufacturing processes allow impressive: Significant times and unit costs. Manufactu- innovation cycles to be sped up reduction in production time ring was initially performed by The powder bed-based, industrial significantly. Structural improve- and 50 % lower costs.” an incremental process with the 3D printing technology from EOS ments, design modifications, and EOS M 290. meant that it was possible, for the manufacture of test compo- Dr. Steffen Beyer, After successful pilot tests, example, to print the 122 injection nents in the development phase Head of Production Technology production was scaled up to the nozzles, the base and front plates, can be put directly into production – Materials & Processes at larger EOS M 400-4 system. and the distribution dome with based on CAD data without ArianeGroup. 4-laser technology allowed the the corresponding feed pipes for requiring engineers to spend time EOS GmbH Electro Optical Systems Corporate Headquarters Robert-Stirling-Ring 1 82152 Krailling/Munich Germany Phone +49 89 893 36-0 Fax +49 89 893 36-285 Further EOS Offices EOS France Phone +33 437 49 76 76 EOS Greater China Phone +86 21 602307 00 EOS India Phone +91 44 39 64 80 00 EOS Italy Phone +39 02 33 40 16 59 EOS Korea Phone +82 2 6330 5800 EOS Nordic & Baltic Phone +46 31 760 46 40 EOS of North America Phone +1 248 306 01 43 EOS Singapore Phone +65 6430 05 50 EOS UK Phone +44 1926 67 51 10 www.eos.info • [email protected] Think the impossible. You can get it. Status 06/2017. Technical data subject to change without notice. EOS is certified according to ISO 9001. EOS® is a registered trademark of EOS GmbH in some countries. For more information visit www.eos.info/trademarks..