Project Title:

Improved Electroformed Structural Copper and Copper Alloys for Rocket Components

92-1-11.05-4707                                                   NAS03-26918
Improved Electroformed Structural Copper and
     Copper Alloys for Rocket Components
Electroformed Nickel, Inc.
283 Winfield Circle
Corona, CA  91720
Glenn Malone                                         (714-371-4707)

Abstract:

     Because of high thermal conductivity requirements, OFHC
(oxygen-free, high-conductivity) copper and certain copper alloys
are primarily used as the liner materials for regeneratively
cooled rocket engines. Unfortunately, the wrought alloys and
electroformed pure metal do not exhibit the structural strengths
of electroformed nickel or wrought nickel alloys having less than
desired thermal conductivity. This project offers a new way to
improve the "as deposited" structural properties of a pure,
electroformed OFHC equivalent. Preliminary test results have
indicated that unusually high yield strengths in copper can be
obtained (while maintaining low oxygen content) using less
conventional deposition techniques. Once the optimum deposit
parameters and deposition current manipulation cycles are
established, further enhancement of yield strength (with suitable
ductility) may be obtained by minor alloying and/or dispersion
strengthening through co-deposition so that these improved
properties are retained over a fairly wide thermal range and
stress-strain cycling service.

Potential Commercial Application:

Potential Commercial Applications:  This material can be used for
rocket engine thrust chambers, barrier layers for prevention of
hydrogen embrittlement, high-performance heat exchangers subject
to high coolant pressures, and high-energy eximer laser
components. A possible military application is for anti-armor-
shaped charge devices.

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