The Korea Institute of Machinery and Materials has successfully created 3D printed parts for space launch vehicles and passed pressure tests at cryogenic temperatures, proving the reliability of the parts under actual operation conditions in space launch vehicles. The large metal pressure vessel developed through joint research with the Korea Aerospace Research Institute (KARI), KP Aerospace Industry Co., Ltd., AM Solutions Co., Ltd., and Hanyang University is reportedly the world’s first to pass high-pressure tests in a cryogenic environment.
High-pressure vessels used in space launch vehicles or satellites are core components that maintain high-pressure states for storing and supplying liquid fuels and propellants, as well as for gas used in attitude control. They must be strong yet lightweight and maintain stable performance in the cryogenic environment of propellant tanks, which is why titanium alloys are primarily used. However, manufacturing titanium alloy vessels through traditional casting or forging methods poses challenges in material supply when producing large products, and cost and lead times increase due to design constraints.
The research team implemented a custom production system without restrictions on shape and size to enhance material efficiency and reduce post-processing and manufacturing expenses by introducing AM processes. First, a team led by Senior Researcher Lee Hyup at the Korea Institute of Machinery and Materials’ 3D Printing Manufacturing Innovation Center produced a titanium alloy high-pressure vessel of 640 mm in diameter and 130L in size using the Directed Energy Deposition (DED) method with lasers and metal wires.
The Korea Aerospace Research Institute conducted the cryogenic tests. The pressure performance was assessed by gradually pressurizing the vessel to a verified pressure of 330 bar after cooling the interior with liquid nitrogen at minus 196 degrees Celsius.
“The demonstration proved that the reliability of large additive manufacturing structures can be secured even under cryogenic and high-pressure conditions that mimic actual operation conditions,” said Senior Researcher Lee Hyup, adding that it is significant that a foundation has been established for the active application of AM technology in various aerospace application fields.
