Method of making a rocket thrust chamber

A method of fabricating a thrust chamber comprising:

• forming a one piece hollow refractory metal thrust chamber having a barrel portion forming a combustion chamber, a first conical portion connecting the barrel portion to a venturi throat section, and a second conical portion extending downstream from the venturi throat portion and forming an expansion nozzle;
• positioning a first hollow metal cylindrical liner section, having a first end and a scarfed second end, in said barrel portion;
• positioning a second hollow metal liner section having a scarfed first end and a scarfed second end, the first end of said second hollow metal liner section being larger than the second end of said second hollow metal liner section, in said first conical portion, wherein said larger first end abuts and overlaps said second end of the first liner section;
• positioning a third hollow metal liner section having a scarfed first end and a second end, the scarfed first end being smaller than the second end, in said second conical portion, wherein said scarfed first end of said third hollow metal liner section abuts and overlaps said second end of the second liner section;
• inserting a split hollow mandrel within said liner sections;
• forcing elements of said split hollow mandrel together to push said liner sections against a chamber wall;
• sealing an end of said hollow mandrel to an end of said thrust chamber, wherein said hollow mandrel and said thrust chamber each have two ends;
• and
• expanding said hollow mandrel to push the liner sections against the chamber walls at sufficient pressure and heat to bond said liner sections to said chamber walls.