In the area of rocket engines, regeneratively cooled rocket engines currently undergo long manufacturing time frames. This deters the speed of the development process resulting in a longer time to get to the market with a proven new design. There is a need to create methods that can manufacture regeneratively cooled rocket engines faster with a quick time to the market. This disclosure relates to faster methods for manufacturing regeneratively cooled rocket thrust chamber nozzles that use rocket propellant fluids to cool the chamber walls of the nozzle itself before being injected and burned. Furthermore, the new methods lead to enhanced designs that could enable reusable rocket engines by limiting overall fatigue with novel materials.

A gear from a sintering powder has a first track and a second track, wherein the first track is a first cylindrical gear toothing with first teeth and with a first diameter and the second track is a second cylindrical gear toothing with second teeth and with a second, in comparison to the first diameter of the first track larger, diameter, and wherein depressions are configured on the first teeth of the first track in a transition region adjoining the second track.

A method produces a connecting rod from a sintered material, which rod has at least one bore having a center axis, and has a first connecting rod eye in a connecting rod head, and a second connecting rod eye in a connecting rod foot, wherein the connecting rod head is connected with the connecting rod foot with a connecting rod shaft, wherein the bore is configured in the connecting rod shaft, wherein furthermore, the connecting rod is produced from a metallic powder, in accordance with a sintering process, for which purpose the powder is pressed into the corresponding mold to form a green compact, the bore is introduced into the green compact, and the green compact is afterward sintered. The bore is introduced into the green compact as a first and second partial bore, proceeding from the connecting rod foot and from the connecting rod head.

A method produces a connecting rod from a sintered material, which rod has at least one bore having a center axis, and has a first connecting rod eye in a connecting rod head, and a second connecting rod eye in a connecting rod foot, wherein the connecting rod head is connected with the connecting rod foot with a connecting rod shaft, wherein the bore is configured in the connecting rod shaft, wherein furthermore, the connecting rod is produced from a metallic powder, in accordance with a sintering process, for which purpose the powder is pressed into the corresponding mold to form a green compact, the bore is introduced into the green compact, and the green compact is afterward sintered. The bore is introduced into the green compact as a first and second partial bore, proceeding from the connecting rod foot and from the connecting rod head.

Raw material powder containing metal powder as a main component is molded to form a metal powder molded body (3), and the metal powder molded body (3) is sintered to form a metal substrate (3). Further, a lubricating member (4) is made of an aggregate of graphite particles (13), and at least a part of a bearing surface (11) is formed of the lubricating member (4). The lubricating member (4) is fitted into the metal powder molded body (3). After that, the metal powder molded body (3) is sintered, and at this time, the lubricating member (4) is fixed onto the metal substrate (3) with a contraction force (F) generated in the metal powder molded body (3).

A rod includes a first rod section occupying a predetermined region in a longitudinal direction, and a second rod section occupying a region different from the first rod section in the longitudinal direction. The first rod section has composition including A% by mass of cobalt, 0 to 1% by mass of chromium, 0 to 0.5% by mass of vanadium, and remainder of tungsten carbide and unavoidable impurities. The second rod section has composition including B% by mass of cobalt, 0 to 1% by mass of chromium, 0 to 0.5% by mass of vanadium, and remainder of tungsten carbide and unavoidable impurities. Contents of cobalt in the first rod section and the second rod section satisfy a relationship of 1% by massB<A20% by mass. The second rod section has a length of 10 to 1000% with respect to the first rod section in the longitudinal direction.

A metal wire containing tungsten is provided. A tungsten content of the metal wire is at least 90 wt %. A tensile strength of the metal wire is at least 4000 MPa. An elastic modulus of the metal wire is at least 350 GPa and at most 450 GPa. A diameter of the metal wire is at most 60 m. An average crystal grain size of the metal wire in a cross-section orthogonal to an axis of the metal wire is at most 0.20 m.

A metal wire containing tungsten is provided. A tungsten content of the metal wire is at least 90 wt %. A tensile strength of the metal wire is at least 4000 MPa. An elastic modulus of the metal wire is at least 350 GPa and at most 450 GPa. A diameter of the metal wire is at most 60 m. An average crystal grain size of the metal wire in a cross-section orthogonal to an axis of the metal wire is at most 0.20 m.

A method for manufacturing a sintered component includes a compaction step of press-compacting a starting powder containing a metal powder to form a compact; a drilling step of forming a hole in the compact with a drill to form a thin portion where the thickness between an inner circumferential surface of the hole and an outer surface of the compact is smaller than the diameter of the hole; and a sintering step of sintering the compact after the drilling step. The drilling step is performed while the outer surface of the compact is pressed in a region extending over the entire length of the hole in an axial direction. The width of the region where the outer surface of the compact is pressed is from 1/3 times to twice the diameter of the hole.

A method for manufacturing a sintered component includes a compaction step of press-compacting a starting powder containing a metal powder to form a compact; a drilling step of forming a hole in the compact with a drill to form a thin portion where the thickness between an inner circumferential surface of the hole and an outer surface of the compact is smaller than the diameter of the hole; and a sintering step of sintering the compact after the drilling step. The drilling step is performed while the outer surface of the compact is pressed in a region extending over the entire length of the hole in an axial direction. The width of the region where the outer surface of the compact is pressed is from 1/3 times to twice the diameter of the hole.