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NASA's Space Launch System Using Futuristic Technology to Build the Next Generation of Rockets.Video.
NASA's Marshall Space Flight Center in Huntsville, Ala. is using a
method called selective laser melting, or SLM, to create intricate metal
parts for America's next heavy-lift rocket. Using this state-of-the-art
technique will benefit the agency by saving millions in manufacturing
costs.
NASA is building the Space Launch System or SLS -- a rocket managed at
the Marshall Center and designed to take humans, equipment and
experiments beyond low Earth orbit to nearby asteroids and eventually to
Mars.
SLM is similar to 3-D printing and is the future of manufacturing.
"Basically, this machine takes metal powder and uses a high-energy laser
to melt it in a designed pattern," says Ken Cooper, advanced
manufacturing team lead at the Marshall Center. "The laser will layer
the melted dust to fuse whatever part we need from the ground up,
creating intricate designs. The process produces parts with complex
geometries and precise mechanical properties from a three-dimensional
computer-aided design."
There are two major benefits to this process, which are major
considerations for the Space Launch System Program: savings and safety.
"This process significantly reduces the manufacturing time required to
produce parts from months to weeks or even days in some cases," said
Andy Hardin, the integration hardware lead for the Engines Office in
SLS. "It's a significant improvement in affordability, saving both time
and money. Also, since we're not welding parts together, the parts are
structurally stronger and more reliable, which creates an overall safer
vehicle."
The emerging technology will build parts for America's next flagship
rocket more affordably and efficiently, while increasing the safety of
astronauts and the workforce. Some of the "printed" engine parts will be
structurally tested and used in hot-fire tests of a J-2X engine later
this year. The J-2X will be used as the upper stage engine for the SLS.
The goal is to use selective laser melting to manufacture parts on the first SLS test flight in 2017.
The agency procured the M2 Cusing machine, built by Concept Laser -- a
division of Hoffman Innovation Group of Lichtenfels, Germany to perform
the selective-laser-manufacturing.
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