Produced by: Tarun Mishra
ISRO marks a significant milestone by conducting successful hot testing of a liquid rocket engine manufactured through Additive Manufacturing (AM) technology.
The hot testing took place on May 9, 2024, lasting for an impressive duration of 665 seconds.
The engine in question is the PS4 engine of the PSLV upper stage, known for its thrust of 7.33 kN in vacuum conditions and its utilization in the Reaction Control System (RCS) of the first stage (PS1) of PSLV.
LPSC redesigned the engine to adhere to the Design for Additive Manufacturing (DfAM) concept, resulting in notable advantages. The Laser Powder Bed Fusion technique reduced the number of parts from 14 to a single-piece, eliminating 19 weld joints and significantly saving on raw material usage.
The manufacturing of the engine was conducted by M/s WIPRO 3D, an Indian industry, utilizing the Laser Powder Bed Fusion technique. The hot testing was carried out at the ISRO Propulsion Complex, Mahendragiri.
Prior to the long-duration hot test, detailed flow and thermal modelling, structural simulation, and cold flow characterization of the prototype hardware were undertaken to ensure confidence in the engine's performance.
Four developmental hot tests of the integrated engine were conducted, culminating in a full qualification duration test of 665 seconds. All performance parameters were observed to be as expected, validating the engine's functionality.
With the successful completion of the hot tests, ISRO plans to induct this Additive Manufactured PS4 engine into its regular PSLV program, marking a significant advancement in space technology.