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Metal Additive Manufacturing for

Propulsion Applications

Paul R. Gradl,  Omar R. Mireles, 

Christopher S. Protz and  Chance P. Garcia

ISBN (print): 978-1-62410-626-2

eISBN: 978-1-62410-627-9

Publication Date: July 11, 2022

Select ⮟

DESCRIPTION

Additive manufacturing (AM) processes are proving

to be a disruptive technology and are grabbing the
attention of the propulsion industry. AM-related
advancements in new industries, supply chains,
design opportunities, and novel materials are
increasing at a rapid pace. The goal of this text is to
provide an overview of the practical concept-to-
utilization lifecycle in AM for propulsion applications.

As with any new process, it's tempting to get caught

up in the excitement of AM and its application and to
give little forethought to the potential economic and
technical challenges. This text is intended to help AM
adopters to be intentional as they apply these
technologies, and to understand the basis for the
lifecycle of AM components. It is a practical guide
based on lessons learned and experiences with both
successes and in failures in AM. The organization of
this text seeks to guide an engineer through the
intertwined basics, regarding design and
implementation, as they begin their journey into AM.
The book is also relevant for veteran AM users as a
reference. While AM is still in the development phase
and continues to evolve, the fundamental lessons
learned remain of great value even as forthcoming
technology emerges. While many metal AM
processes are referenced, the book focuses on those
with more industry maturity, including powder bed
fusion and directed energy deposition.

Paul R. Gradl is a principal engineer and subject

matter expert at NASA Marshall Space Flight Center.
He leads several projects across NASA for additive
manufacturing of liquid rocket engine components
supporting various development and flight programs
since 2004. He is an Associate Fellow of AIAA,
recipient of “Engineer of the Year” by AIAA in 2022,
serves as an industry advisor in additive, and was
named one of “The Most Influential Personalities of
Additive Manufacturing in 2020.” He holds a master's
in engineering, MBA, and is a PhD candidate at Delft
University of Technology.

Omar R. Mireles is a research engineer at NASA

Marshall. He serves as principal investigator for
several additive manufacturing research and
development projects and infusion of additive
components into propulsion, power, cryogenic fluid
management, and nuclear systems. He holds a PhD in
Nuclear Engineering with emphasis in Materials
Science and Engineering with work experience since
2002 at several NASA centers, Oak Ridge National
Laboratory, and the U.S. Air Force.

Christopher S. Protz is the advanced manufacturing

technology lead at NASA Marshall where he
coordinates the evaluation, development, and
integration of terrestrial and in-space manufacturing
technologies/capabilities for NASA and partner
programs. He has been with MSFC since 2004 and
has deep experience in design, analysis,
manufacturing and testing of liquid rocket engine
components, spacecraft, and vehicle systems. He
holds a bachelor's, master's, and PhD from the
Massachusetts Institute of Technology in Aerospace
Systems.

Chance P. Garcia is a lead engineer in propulsion

systems engineering at NASA Marshall. He has
experience with propulsion systems development for
design, analysis, manufacturing and testing of additive
components. He holds a bachelor's, master's, and PhD
from the University of Texas El Paso. He is a graduate
of the International Space University: Space Studies
Program and an advisor and session chair for various
STEM activities and conferences.


Front Matter

pp. i–xxii

https://doi.org/10.2514/5.9781624106279.0000.00
00

 


Introduction to and Applications of
Additive Manufacturing for Propulsion

Paul R. Gradl, Christopher S. Protz, Chance P. Garcia,

Omar R. Mireles and Martin Leary

pp. 1–48

https://doi.org/10.2514/5.9781624106279.0001.00
48

 


Metal Additive Manufacturing Processes
and Selection

Paul R. Gradl, Christopher S. Protz, Megan Le Corre,

Omar R. Mireles, Frank Medina, … See all authors ⮞

pp. 49–186

https://doi.org/10.2514/5.9781624106279.0049.01
86

 


Selection and Overview of Additive
Manufactured Metals and Metal Alloys

Paul R. Gradl, Omar R. Mireles, Colton Katsarelis,

Christopher S. Protz, … See all authors ⮞

pp. 187–236

https://doi.org/10.2514/5.9781624106279.0187.02
36

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
Microstructure and Properties of
Additively Manufactured Metal Alloys

Judy Schneider, Nima Shamsaei, Shuai Shao,

Reza Ghiaasiaan, Shengmin Guo, … See all authors ⮞

pp. 237–306

https://doi.org/10.2514/5.9781624106279.0237.03
06

 


Post-Processing of Metal Additively
Manufactured Components

Omar R. Mireles, Paul R. Gradl, Erin Lanigan,

Will Evans and Anton du Plessis

pp. 307–404

https://doi.org/10.2514/5.9781624106279.0307.04
04

 


Feedstock for Metal Additive
Manufacturing

Christopher Kantzos

pp. 405–438

https://doi.org/10.2514/5.9781624106279.0405.04
38

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
Functional Design for Metal Additive
Manufacturing

Chance P. Garcia, Shawn W. Skinner,

Omar R. Mireles, Paul R. Gradl, … See all authors ⮞

pp. 439–526

https://doi.org/10.2514/5.9781624106279.0439.05
26

 


Component Performance and Application
Characteristics

Thomas Teasley, Paul R. Gradl, Darren C. Tinker,

Omar R. Mireles and Agustin Diaz

pp. 527–592

https://doi.org/10.2514/5.9781624106279.0527.05
92

 


Certification of Metal Additive
Manufacturing: A NASA Perspective

Brian West and Doug Wells

pp. 593–644

https://doi.org/10.2514/5.9781624106279.0593.06
44

 


Emerging Additive Manufacturing
Technology for Propulsion

Omar R. Mireles, Erin Lanigan, Paul R. Gradl,

Kevin Wheeler, … See all authors ⮞

pp. 645–716

https://doi.org/10.2514/5.9781624106279.0645.07
16

 


Mechanical Properties of Select AM
Alloys

pp. 717–774

https://doi.org/10.2514/5.9781624106279.0717.07
74

 


Thermophysical Properties of Select AM
Alloys

Congyuan Zeng, Shengmin Guo, Paul R. Gradl and

Travis Belcher

pp. 775–824

https://doi.org/10.2514/5.9781624106279.0775.08
24

 


Standards Applicable to Metal AM

pp. 825–832

https://doi.org/10.2514/5.9781624106279.0825.08
32

 


Index

pp. 833–850

https://doi.org/10.2514/5.9781624106279.0833.08
50

 


Supporting Materials

pp. 851–852

https://doi.org/10.2514/5.9781624106279.0851.08
52

 

THIS BOOK

Copyright © 2022 by the American Institute of

Aeronautics and Astronautics, Inc.

https://doi.org/10.2514/4.106279

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