Method of fabricating a rocket engine combustion chamber

A process for forming a combustion chamber for a liquid rocket engine, comprising

• a. providing a hollow metal jacket having an inner surface on which a liner is to be formed,
• b. projecting a stream of a heated carrier gas at a velocity of Mach 2 to Mach 3 to impinge the gas stream on the inner surface of the jacket, said gas stream being heated to the temperature of 5,000 to 20,000 degrees K, said projecting being done under a vacuum of 40 to 200 torr.
• c. injecting into the gas stream an alloy in particle form having a particle size of 5 to 45 microns, said particles being in the gas stream for a sufficient length of time to heat said particles to a temperature sufficient to soften the particles sufficiently that said particles will flatten and adhere to previously deposited particles but will not spatter upon impact with the jacket,
• d. moving the gas stream inside the hollow jacket to form a first layer having a uniform thickness of 0.6 to 1.5 cm,
• e. cutting slots in said layer to form cooling channels,
• f. filling the slots with a filling material,
• g. repeating steps b and c to form a second layer adhered to the first layer and covering the filled slots to a depth of 0.05 to 0.15 cm, and
• h. removing the filling material from the slots to leave open cooling channels.