Patent ID: 8661992

Claim:
A method for fabricating an outer shroud for a solid fuel nozzle tip, the method comprising: selecting a preform cut from flat stock for each of a top shell portion and a bottom shell portion; shaping each preform to form the top shell portion and the bottom shell portion; bending each preform to form outlet sidewalls and rounded corners for each shell portion; the top shell portion having: a substantially horizontal backward area, a forward area connected to the backward area that angles downward as it extends away from the backward area, the forward area having a left and right side, a right outlet sidewall extending upward from the right side of the forward area, a left outlet sidewall extending upward from the left side of the forward area, a rounded corner connecting the right side of the forward area with the right outlet sidewall, a rounded corner connecting the left side of the forward area with the left outlet sidewall, wherein the backward area, the forward area, right outlet sidewall, the left outlet sidewall and the rounded corners are all formed by a single piece of flat stock; the bottom shell portion having, a substantially horizontal backward area, a forward area connected to the backward area that angles upward as it extends away from the backward area, the forward area having a left and right side, a right outlet sidewall extending upward from the right side of the forward area, a left outlet sidewall extending upward from the left side of the forward area, a rounded corner connecting the right side of the forward area with the right outlet sidewall; a rounded corner connecting the left side of the forward area with the left outlet sidewall; wherein the backward area, the forward area, right outlet sidewall, the left outlet sidewall and the rounded corners are all formed by bending a single piece of flat stock; coupling the top shell portion and the bottom shell portion, and fabricating separately from the top shell portion and bottom shell portion a left inlet sidewall and a right inlet sidewall, and coupling the inlet sidewalls to each of the top and bottom shell portions.