NASA engineers have successfully developed and tested the first additive-manufactured GRCop combustion chamber through the Relativity Space Terran 1 rocket, which launched in March 2023. Standing at 100 feet tall, this innovative rocket is entirely made of 3D-printed parts, including nine engines crafted from a unique copper alloy called Glenn Research Copper (GRCop). This alloy, developed at NASA’s Glenn Research Center, is designed to withstand extreme temperatures up to 6,000 degrees Fahrenheit and offers significant advantages such as high strength, thermal conductivity, and creep resistance.
The GRCop alloys, particularly GRCop-42, are optimized for multi-mission use, aiming to enhance the longevity of rocket components, capable of enduring up to 500 engine cycles without significant maintenance. Modern additive manufacturing methods, including laser powder bed fusion and directed energy deposition, allow for the creation of complex parts with comparable strengths to forged metals.
These advances in materials and manufacturing processes reflect NASA’s commitment to fueling innovation in commercial space endeavors. By collaborating with Relativity Space, NASA is paving the way for the use of GRCop alloys in future space missions, including potential expeditions to the Moon and Mars, thereby enhancing the capabilities of the aerospace industry.
