Additively manufactured combustion chambers, manifold structures and hybrid additive processes related thereto

A hybrid additive manufacturing method for forming a thermal combustion chamber comprising:

• powder bed fusion forming an integral regeneratively-cooled liner body of a first material, having an inner wall defining an open-ended combustion chamber volume, an outer wall having at least one set of inlets and at least one set of outlets disposed at different heights along a length thereof, and a plurality of cooling channels formed between the inner and outer walls and in fluid communication with the at least one set of inlets and at least one set of outlets;
• wire arc additive manufacturing, directed energy deposition, or cold spray additive manufacturing forming at least one structural cladding region of a second material, integral with and extending around a perimeter of the liner body over at least a portion of the outer wall adjacent to or overlapping the at least one set of inlets and at least one set of outlets;
• wire arc additive manufacturing or directed energy deposition forming at least one separate fluid manifold formed of a third material and disposed in association with and in fluid communication with each of the at least one set of inlets and the at least one set of outlets, each of the separate fluid manifolds being integral with the at least one structural cladding region and comprising:
• first and second base structures, wherein each of the first and second base structures comprises a plurality of tapered stepped layers such that each of the first and second base structures narrow from a first end proximal to the structural cladding to a second end distal to the structural cladding, wherein the first and second base structures are integral with the at least one structural cladding region and extend around the perimeter of the liner body on opposing sides of the at least one set of inlets or at least one set of outlets, and
• an upper wall integral with the second ends of and spanning between the first and second base structures such that the first and second base structures and the upper wall form a fluid manifold enclosure extending around the perimeter of the liner body over the associated at least one set of inlets and at least one set of outlets,
• wherein the fluid manifold enclosure of each fluid manifold defines a fluid manifold outer wall and inner fluid conduit and are configured such that the inner fluid conduit has a generally cylindrical fluid manifold cross-section;
• wire arc additive manufacturing or directed energy deposition forming at least one fluid access port integrally disposed in each of the fluid manifold outer walls and having connection elements disposed thereon such that each of the at least one fluid access port allows for external fluid communication to one of the fluid manifolds;
• and
• wherein the at least one separate fluid manifold, at least one fluid access port, at least one set of inlets, at least one set of outlets, and cooling channels of the liner body define a single fluid flow path therebetween having a termination at an upper end of the thermal combustion chamber.