Atmospheric Rheo-Spraying (ARS) using the HVOF process enables injection-molded structures and thick-film coatings from steels and from high-temperature Ni-based alloys with layer thicknesses down to the centimeter. The ARS process control is based on the thermal spraying of particles in the solid state at a maximum average speed of more than 600 m/s. The coating consolidation to porosity values below 1% occurs through the particle impact with high kinetic energy. Because of the low particle oxidation, the mechanical properties of the heat-treated injection-molded structures are comparable to those of forged alloys. In this paper, ARS injection molding is successfully implemented in combination with an innovative manufacturing technique in rocket engine technology to produce a model composite combustion chamber with a thermally sprayed internal pressure jacket. Paper includes a German-language abstract.

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