Farsoon and Deep Blue Aerospace collaborate on large-scale rocket combustion chamber manufacturing

ApplicationsEquipmentNews
February 21, 2024

February 21, 2024

Farsoon Technologies has collaborated with Deep Blue Aerospace to develop a combustion chamber for commercial launch projects (Courtesy Farsoon Technologies)
Farsoon Technologies has collaborated with Deep Blue Aerospace to develop a combustion chamber for commercial launch projects (Courtesy Farsoon Technologies)

Farsoon Technologies, based in Changsha, China, has collaborated with Deep Blue Aerospace, Nantong, Jiangsu, China, to additively manufacture a 600 x 780 mm rocket engine combustion chamber that has been developed for commercial launch projects.

Together, engineers from Farsoon and Deep Blue Aerospace’s R&D teams addressed key technical aspects, and dedicated months in testing and verification before the completion of the project. The achievements included the successful implementation of machine and process optimisations, targeting high productivity and enhanced quality.

THE WORLD OF METAL AM TO YOUR INBOX
Subscribe to our weekly newsletter
Sign up

The manufacturing process featured improved items such as the optical system, process parameters, scanning strategy, powder recoating, electrical engineering, and more. After the optimisation, the production time for this combustion chamber was reduced from 327 hours to the current 96.5 hours, representing a significant 338% increase in build efficiency.

The development of the combustion chamber (Courtesy Farsoon Technologies)
The development of the combustion chamber (Courtesy Farsoon Technologies)

The success of this joint R&D project holds significant importance for Farsoon as it aims to enhance the production efficiency in large-format metal Powder Bed Fusion (PBF) solutions. The key research and application innovations in the project included:

  • Scanning Strategy – Farsoon implemented advanced multi-laser scanning strategies and a fast-performing algorithm in overlapped areas, addressing challenges in laser power control, galvo system calibration, overlap consistency, and multi-laser task coordination. With optimised parameters, the advanced multi-laser scanning strategy achieves enhanced control of the scanner and galvo, significantly improving communication efficiency by 39% while ensuring internal metallurgical quality.
  • Gas Flow – Gas flow design was optimised for the large-format platform to enable smoke removal and smooth operation of multiple lasers, preventing energy dissipation during the down-wind side laser operation generated by smoke and dust during the metal laser sintering process.
  • Control System – To facilitate higher efficiency of multi-laser operation, Farsoon’s R&D team optimised the control system to reduce waiting between the lasers and minimise the downtime of the machine. As a result, the multi-laser platform is able to offer higher efficiency in laser output for significantly improved build efficiency.
  • Optimised parameters – Given the intricate internal cooling channels within the combustion chamber of the rocket engine, attaining a smooth surface is crucial to minimise flow resistance. Farsoon’s R&D team has customised the processing parameters to achieve the desired high-quality surface that the application requires.

www.farsoon.com

www.dbaspace.com

Download Metal AM magazine
ApplicationsEquipmentNews
February 21, 2024

About Metal Additive Manufacturing magazine

Metal AM magazine, published quarterly in digital and print formats, is read by a rapidly expanding international audience.

Our audience includes component manufacturers, end-users, materials and equipment suppliers, analysts, researchers and more.

In addition to providing extensive industry news coverage, Metal AM magazine is known for exclusive, in-depth articles and technical reports.

Our focus is the entire metal AM process from design to application.

Each issue is available as an easy-to-navigate digital edition and a high-quality print publication.

In the latest issue of Metal AM magazine

Download PDF
 

Extensive AM industry news coverage, as well as the following exclusive deep-dive articles:

  • BMW Group: Laying the foundations for the application of metal Additive Manufacturing in the automotive industry
  • Predicting the metal Additive Manufacturing market – and breaking the hype cycle
  • China’s thriving metal Additive Manufacturing industry: An outsider’s perspective
  • Enhancing the productivity of Additive Manufacturing facilities through PBF-LB automation
  • Award-winning metal AM parts from the MPIF’s 2024 Design Excellence Awards
  • Performance of eddy currents for the in-situ detection of defects during PBF-LB metal AM

The world of metal AM to your inbox

Don't miss any new issue of Metal AM magazine, and get the latest industry news. Sign up to our twice weekly newsletter.

Sign up

Looking for AM machines, metal powders or part manufacturing services?

Discover suppliers of these and more in our comprehensive advertisers’ index and buyer’s guide, available in the back of Metal AM magazine.

  • AM machines
  • Process monitoring & calibration
  • Heat treatment & sintering
  • HIP systems & services
  • Pre- & post-processing technology
  • Powders, powder production and analysis
  • Part manufacturers
  • Consulting, training & market data
View online

Discover our magazine archive…

The free to access Metal Additive Manufacturing magazine archive offers unparalleled insight into the world of metal Additive Manufacturing from a commercial and technological perspective through:

  • Reports on visits to leading metal AM part manufacturers and industry suppliers
  • Articles on technology and application trends
  • Information on materials developments
  • Reviews of key technical presentations from the international conference circuit
  • International industry news

All past issues are available to download as free PDFs or view in your browser.

Browse the archive

Share via
Copy link
Powered by Social Snap