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<p>This study introduces a novel design for a 3D-printed nozzle neck with integrated deformation-absorbing cavities, aimed at mitigating drive torque caused by thermal deformation and mechanical interference in solid propellant motors. Fabricated using metal 3D printing technology with a tungsten-copper alloy, the nozzle neck was verified using 3D CT scanning to ensure precise realization of the internal cavities according to the design. This approach addresses the limitations of traditional machining by enabling complex internal structures while preserving external geometry. Experimental results demonstrated a 37.2% reduction in drive torque at a 400&#xa0;μm interference distance compared to a baseline WCu nozzle neck. Finite element analysis (FEA) further confirmed that the internal cavities effectively dissipate mechanical stress and deformation, significantly decreasing frictional forces and drive torque. The findings suggest that deformation-absorbing cavity structures, enabled by advanced 3D printing, can enhance component durability under mechanical interference, offering significant improvements for high-performance aerospace applications.</p>

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Reduction of Drive Torque and Friction under Mechanical Interference through Deformation-Absorbing Nozzle Neck Structures Using Metal 3D Printing

  • 期刊论文

  • 发表日期：

    2025年10月2日

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  • Yeon-Gwan Lee,
  • Min-Su Jang

摘要

This study introduces a novel design for a 3D-printed nozzle neck with integrated deformation-absorbing cavities, aimed at mitigating drive torque caused by thermal deformation and mechanical interference in solid propellant motors. Fabricated using metal 3D printing technology with a tungsten-copper alloy, the nozzle neck was verified using 3D CT scanning to ensure precise realization of the internal cavities according to the design. This approach addresses the limitations of traditional machining by enabling complex internal structures while preserving external geometry. Experimental results demonstrated a 37.2% reduction in drive torque at a 400 μm interference distance compared to a baseline WCu nozzle neck. Finite element analysis (FEA) further confirmed that the internal cavities effectively dissipate mechanical stress and deformation, significantly decreasing frictional forces and drive torque. The findings suggest that deformation-absorbing cavity structures, enabled by advanced 3D printing, can enhance component durability under mechanical interference, offering significant improvements for high-performance aerospace applications.