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Glenn Research Center 

Improved Electroformed Structural Copper and Copper Alloys for Rocket 
Components

Electroformed Nickel, Inc.

Huntsville, AL
 

Improvements in mechanical properties of electrodeposited copper by conversion of coarse columnar grains into fine equi-axed grain structures and use of secondary strengthening methods such as alloying and dispersion strengthening

• Mechanical properties of electroformed copper equivalent  to those of wrought nickel have been demonstrated (a 50% improvement over prior electroformed copper)
• Elevated temperature ductility of electroformed copper to 500°F has been improved three fold
• Copper-platinum and copper-silver alloys have been developed having potential for even higher temperature  use
• A full scale regeneratively cooled copper tube bundle thrust chamber was fabricated entirely by electroforming with the new copper to demonstrate that property degrading thermal joining methods could be eliminated

• Aerojet has employed ENI's fine grained copper in the fabrication of full-scale formed platelet thrusters for Aerojet's Rocket Based Combined Cycle engine in support of Marshall Space Flight Center's Advanced Reusable Technologies Program. Aerojet is also investigating the use of ENI's fine grained copper for forming hotgas walls for combustion chamber liners.
• NASA Tech Brief articles of the new materials have been written and approved for publication.
• Have signed a contract with Pratt & Whitney for $100K for test samples for potential use in light-weight, high-performance reusable launch vehicles
• To date $17K of these new materials have been sold to NASA Glenn Research Center

• Dialogue continues with Boeing's Rocketdyne Division where Space Shuttle Main Engine upgrades are in planning
• Potential market will include DOD where new, improved shaped charge liners for warheads is sought

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