Large titanium alloy rocket components are usually manufactured using forging technology. Nowadays, 3D printing technology is expected to significantly shorten manufacturing time.A team of scientists from the Korea Institute of Production Technology (KITECH) announced that a large titanium alloy aerospace fuel tank manufactured through 3D printing has passed a critical durability test.According to reports, the fuel tank has withstood extreme temperatures and pressures in a world first test. The team responsible for this project believes that their new 3D printing method will be able to produce robust aerospace components faster and more customizable.
3D printing titanium alloy fuel tank
The KITECH team uses directed energy deposition (DED) 3D printing technology to manufacture their fuel tanks. This method uses laser to melt metal wires, and then according to digital design, the melted titanium alloy wires are stacked layer by layer to construct components.This 3D printed titanium alloy fuel tank has a diameter of 640 millimeters and is made of Ti64 titanium alloy. It is part of a collaborative project between the Korea Aerospace Research Institute (KARI), KP Aviation Industries, AM Solutions, and Hanyang University.In the test, the fuel tank withstood a pressure of 330 bar while being cooled to -196 ° C using liquid nitrogen. High voltage components are crucial for space flight; They can supply liquid fuel and control the attitude of the aircraft. They must also maintain performance while maintaining the cold temperature required for low-temperature propellants.Traditionally, manufacturers use forging methods to manufacture these components. This process requires a fixed mold, which is not suitable for manufacturing customized parts of various sizes.Dr. Lee Hyub, Chief Researcher of KITECH, explained in a press statement: "This test demonstrates that large-scale additive manufacturing (3D printing) structures can reliably withstand low temperature and high pressure conditions that simulate actual operating environments. This lays the foundation for the widespread application of 3D printing in the aerospace industry.
Through low-temperature pressure testing
To manufacture their fuel tank, the KITECH team first created two hemispheres separately. Then machine them and weld them together to form a container. The entire process took three days. According to the R&D team, the entire manufacturing cycle only takes a few weeks, which is significantly shorter than traditional methods.Scientists have pointed out that traditional casting and forging methods for manufacturing large titanium alloy containers face challenges in material supply, design limitations, as well as rising costs and delivery cycles.After manufacturing, the team conducted low-temperature pressure testing on its container at KARI. Test placing titanium alloy spheres in a facility enclosed by a concrete barrier. The container is cooled to -196 ° C and subjected to a pressure of 330 bar.
Tests have shown that the container can withstand extreme space environments. However, further testing is needed to verify whether it can withstand the harsh conditions of space flight repeatedly. As Kim Hyun joon of KARI pointed out, "We will continue to collaborate to conduct cyclic stress testing under work pressure and seek additional certifications required for spaceflight certification.
