As part of the RAMFIRE initiative, NASA advanced a rocket engine nozzle crafted through aluminum 3D printing. NASA described the part as lighter than traditional nozzles and capable of increasing payload capacity for deep-space missions. This development marks a notable step in additive manufacturing for aerospace applications.
At the NASA Marshall Space Flight Center in Huntsville, Alabama, collaboration with Elementum 3D in Erie, Colorado yielded A6061-RAM2, an aluminum alloy engineered for successful 3D printing. The alloy demonstrates ample heat resistance to handle the demanding conditions inside rocket engines while maintaining structural integrity under operation.
Aluminum offers a lower density than many alternatives, enabling lighter, yet sturdy, components. Historically, the metal posed challenges for rocket engine parts due to limited resistance to extreme temperatures and a tendency for welds to crack. The RAMFIRE nozzle leverages these properties to deliver a compact, robust solution for spaceflight needs.
The nozzle was produced as a single unit using LP-DED technology, which builds parts layer by layer from metal powder using laser melting. To prevent melting under operating conditions, the design integrates small internal cooling channels that dissipate heat and preserve performance during flight.
Ground tests employed liquid oxygen and hydrogen, and the nozzle endured 22 launch simulations at a pressure near 5.6 megapascals. It operated for nearly ten minutes during these assessments, validating its capability to meet the thermal, structural, and pressure demands of a lunar lander engine. This resilience suggests reliable performance across typical mission profiles that require substantial thrust and dependable cooldown during long-duration burns.
Separately, researchers from Hawaii Pacific University in the United States explored protective strategies for astronauts against lunar dust during future Moon missions. The moon dust issue has persisted for decades, and NASA continues to pursue practical, effective solutions. Dust mitigation remains one of the leading challenges for sustained human presence on the lunar surface, and the agency emphasizes the importance of advancing protective measures for both equipment and personnel.
Meanwhile, Roscosmos announced findings related to the Luna-25 mission crash, highlighting the ongoing efforts of space agencies worldwide to understand and mitigate risks in extraterrestrial operations. The incident underscores the complex, high-stakes nature of deep-space exploration and the continuous pursuit of safer, more reliable technologies for future missions.