Chinese 3D metal printer manufacturer Bright Laser Technologies (BLT) has used metal powder laser fusion technology to produce piping components and turbopumps for a 100-ton liquid oxygen methane engine known as “JD-2”. The project was carried out for i-Space (Beijing Star Glory Space Science & Technology Company). In the first days of March 2023, the JD-2 engine achieved a significant milestone by successfully passing two semi-system connector tests in real operating conditions. The engine is currently undergoing intensive research and engineering development, with plans for comprehensive testing and evaluation on the horizon.
Engine components, known for their delicate, thin-walled and complex designs, have historically suffered from deformation during production. Additionally, traditional manufacturing methods were associated with extended production cycles and wastage of raw materials. BLT developed a customized process solution that delivered benefits in reducing production costs, speeding up iteration, and improving part quality and accuracy.
Turbine pump components are typically divided into two key sections: the propeller jacket section and the guide vane section. Within the screw shell there is an internally designed rotary flow channel with a variable cross-section, requiring high requirements in terms of the surface roughness of the flow channel. The guide vane section consists of many elements, requiring a high degree of deflection and surface roughness. Thanks to BLT technology, integrated creation of complex guides and effective deformation control during production were achieved. The finished part is characterized by high transition speed, dimensional accuracy and roughness to meet the needs of use. The thinnest part of the blade is only 0.3 mm, which shortens the production cycle of parts while maintaining quality.
The parts were manufactured by BLT from self-produced TC4 superalloy and nickel after careful analysis of the parts’ service requirements. Key part forming parameters were also determined based on the part process characteristics. The project used BLT-S515 and BLT-S600 3D printers, and the strength and performance of the parts after inspection met the requirements of the “JD-2” liquid engine.
Source: BLT press materials
