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NASA NTRSDate not supplied

NASA's Compact High-Efficiency Rotating Detonation Rocket Engine for Mars Interplanetary Missions

NASA has successfully test fired a novel and compact liquid propulsion system known as a Rotating Detonation Rocket Engine. This is a specially designed ring-shaped thrust chamber that leverages additive manufacturing techniques and novel alloys such as GRCop-42 and GRX-810. The extreme combustion event, known as a detonation, reduces the combustion chamber length requirements down to a few inches while equivalent constant pressure rocket thrust chambers are on the order of feet. This is primarily due to rapid completion of combustion by the high-pressure detonation, an order of magnitude faster than deflagration combustion. In addition, the ring shape allows for rapid expansion of the combustion products. Depending on the thrust class and design supersonic area ratio, the full RDRE can be anywhere from 10% to 50% shorter than a traditional liquid rocket assuming the same exit diameter but is dependent on a number of design assumptions. This may enable substantial mass savings, cost savings, and broader design trade space for various mission architectures. Finally, the engine system has potential for higher Isp at identical average chamber pressure, which is currently being assessed by NASA. Experimental data obtained from testing in 2022 identified the feasibility of the novel propulsion system while multiple test series scheduled throughout 2023 and 2024 target closing the remaining critical technical gaps preventing widespread use of the technology amongst industry.

Thomas Teasley↗

NASA NTRSDate not supplied

Toward Fully 3D-Printed Two Degree of Freedom Acoustic Liners

An acoustic liner optimization tool is developed for designing two degree of freedom (2DOF) liners with high absorption over a wide range of frequencies and sound pressure levels (SPLs). Two additively manufactured 2DOF liners (one constant and one variable chamber depth) are designed and printed with an embedded perforate layer as the septum. A normal incidence impedance tube study is performed to directly compare impedance and absorption spectra to a more traditionally manufactured 2DOF liner with embedded mesh caps in phenolic honeycomb. Comparisons of test data to predictions are shown as well as SPL sensitivities for each acoustic liner. Broadband absorption is achieved with the 3D printed 2DOF liner containing constant chamber depths, although due to current limitations in printed embedded perforate hole size, not as broad as the traditional mesh cap liner. However, results also show that the 3D printed variable chamber depth sample is more comparable to the mesh cap liner absorption, demonstrating the viability of printed embedded perforates in novel concepts.

acoustic liner 2DOF two degree of freedom 3D print↗

NASA NTRS1990

Systems engineering and integration: Cost estimation and benefits analysis

Space Transportation Avionics hardware and software cost has traditionally been estimated in Phase A and B using cost techniques which predict cost as a function of various cost predictive variables such as weight, lines of code, functions to be performed, quantities of test hardware, quantities of flight hardware, design and development heritage, complexity, etc. The output of such analyses has been life cycle costs, economic benefits and related data. The major objectives of Cost Estimation and Benefits analysis are twofold: (1) to play a role in the evaluation of potential new space transportation avionics technologies, and (2) to benefit from emerging technological innovations. Both aspects of cost estimation and technology are discussed here. The role of cost analysis in the evaluation of potential technologies should be one of offering additional quantitative and qualitative information to aid decision-making. The cost analyses process needs to be fully integrated into the design process in such a way that cost trades, optimizations and sensitivities are understood. Current hardware cost models tend to primarily use weights, functional specifications, quantities, design heritage and complexity as metrics to predict cost. Software models mostly use functionality, volume of code, heritage and complexity as cost descriptive variables. Basic research needs to be initiated to develop metrics more responsive to the trades which are required for future launch vehicle avionics systems. These would include cost estimating capabilities that are sensitive to technological innovations such as improved materials and fabrication processes, computer aided design and manufacturing, self checkout and many others. In addition to basic cost estimating improvements, the process must be sensitive to the fact that no cost estimate can be quoted without also quoting a confidence associated with the estimate. In order to achieve this, better cost risk evaluation techniques are needed as well as improved usage of risk data by decision-makers. More and better ways to display and communicate cost and cost risk to management are required.

Dean, ED↗

NASA NTRS1987

Dynamic analysis and design of the SIRTF primary mirror mount

The criteria and considerations for the design of the support system for the Space Infrared Telescope Facility (SIRTF) primary mirror are presented. A flexural-gimbal-baseplate design for the 0.5 m primary mirror was developed. Preliminary studies have indicated that this design may be further improved by replacing the flexures by a post-gimbal system wherein the gimbal design accomodates both the cryogenic cool down effects, the dynamic launch loads, and manufacturing tolerance effects. Additionally, a prestressed baseplate concept had evolved and was presented for the full scale 1.0 m mirror. However, preliminary design studies indicate that this concept will not be required, and the post-gimbal-baseplate design similar to the 0.5 m alternate support system will meet the cryogenic cool down, dynamic launch load criteria, and manufacturing tolerance effects.

Richard, Ralph M.↗

NASA NTRS2018

NASA Additive Manufacturing Initiatives for Deep Space Human Exploration

Additive Manufacturing (AM) is being infused into aerospace industries at an accelerated pace. Reasons for this rapid adoption include: (1) Innovation Capability e.g. design features such as topology optimization, integrated fluid passages, and mesh structures; (2) Rapid Development and Optimization - ability to quickly iterate the design, development, and test cycle; (3) Affordability - reductions in part counts, cost, and schedule. NASA's Marshall Space Flight Center (MSFC) has taken a leadership role in application of AM technologies for deep space human exploration, leading the Agency's In Space Manufacturing (ISM) initiative and the application of AM for a broad variety of space propulsion systems. MSFC has championed the development of ISM capabilities since our first reduced-gravity aircraft experiment flew in 1999. Partnering with Made In Space, MSFC placed the first 3D Printer on ISS in 2014 and the second generation printer, the Additive Manufacturing Facility, in 2016. The next ISS technology demonstration will be the Refabricator, a recycler/basic printer scheduled to launch in late Fall 2018. Ground-based development is progressing in common use materials, metals 3D printing, printed electronics, and the new cornerstone of ISM, the FabLab. The latest developments in each area will be described. An overview of NASA's In Space Robotic Manufacturing and Assembly (IRMA) ground-based risk reduction projects will also be presented. MSFC has aggressively incorporated AM capabilities for design and development of space propulsion components. The capabilities have been rapidly matured and extensively exercised to produce and hot-fire test the Additive Manufacturing Demonstrator Engine, an in-space class prototype engine. This experience base has been extended to support Aerojet Rocketdyne in the application of AM to the RS-25, the Space Launch System Core Stage engine, and to small propulsion systems and thrusters for small satellites and cubesats. The latest developments will be described. In responding to a request from NASA's Commercial Crew Program for a consistent methodology for evaluation of AM processes and parts, MSFC began development of a draft standard for AM space flight hardware in late 2014. The draft was broadly disseminated for comments in mid-2015, and subsequently revised into two documents, a standard and a specification for AM space flight hardware, which were formally released by MSFC in October 2017. An overview of the key elements of these documents will be presented.

Clinton, Raymond↗

NASA NTRS2016

3D Printing in Zero G Technology Demonstration Mission: Summary of On-Orbit Operations, Material Testing, and Future Work

Human space exploration to date has been limited to low Earth orbit and the moon. The International Space Station (ISS), an orbiting laboratory 200 miles above the earth, provides a unique and incredible opportunity for researchers to prove out the technologies that will enable humans to safely live and work in space for longer periods of time and venture farther into the solar system. The ability to manufacture parts in-space rather than launch them from earth represents a fundamental shift in the current risk and logistics paradigm for human spaceflight. In particularly, additive manufacturing (or 3D printing) techniques can potentially be deployed in the space environment to enhance crew safety (by providing an on-demand part replacement capability) and decrease launch mass by reducing the number of spare components that must be launched for missions where cargo resupply is not a near-term option. In September 2014, NASA launched the 3D Printing in Zero G technology demonstration mission to the ISS to explore the potential of additive manufacturing for in-space applications and demonstrate the capability to manufacture parts and tools on-orbit. The printer for this mission was designed and operated by the company Made In Space under a NASA SBIR (Small Business Innovation Research) phase III contract. The overarching objectives of the 3D print mission were to use ISS as a testbed to further maturation of enhancing technologies needed for long duration human exploration missions, introduce new materials and methods to fabricate structure in space, enable cost-effective manufacturing for structures and mechanisms made in low-unit production, and enable physical components to be manufactured in space on long duration missions if necessary. The 3D print unit for fused deposition modeling (FDM) of acrylonitrile butadiene styrene (ABS) was integrated into the ISS Microgravity Science Glovebox (MSG) in November 2014 and phase I printing operations took place from November through December of that year. Phase I flight operations yielded 14 unique parts (21 total specimens) that could be directly compared against ground-based prints of identical geometry manufactured using the printer prior to its launch to ISS. The 3DP unit functioned safely and produced specimens necessary to advance the understanding of the critical design and operational parameters for the FDM process as affected by the microgravity environment. From the standpoint of operations, 3DP demonstrated the ability to remove parts from the build-tray on-orbit, teleoperate the printer from the ground, perform critical maintenance functions within defined human factors limits, produce a functional tool that could be evaluated for form/fit/function, and uplink a new part file from the ground and produce it on the printer. The flight parts arrived at NASA Marshall Space Flight Center in Huntsville, Alabama in April 2015, where they underwent months of testing in the materials and processes laboratory. Ground and flight prints completed the following phases of testing: photographic/visual inspection, mass and density evaluation, structured light scanning, XRay and CT, mechanical testing, optical microscopy, scanning electron microscopy, and chemical analysis. This presentation will discuss the results of this testing as well as phase II operations for the printer, which took place in June and July of 2016. Lessons learned from the tech demo and their impacts on the design and development of the second generation 3D printer for ISS, the Additive Manufacturing Facility (AMF) by Made In Space will also be presented. In addition, progress in other elements of NASA's In Space Manufacturing (ISM) initiative such as the on-demand ISM utilization catalog, in-space Recycler ISS Technology Demonstration development, launch packaging recycling, in-space printable electronics, development of higher strength polymeric materials for 3D printing and Additive Construction by Mobile Emplacement (ACME) will also be addressed.

Prater, Tracie↗

NASA NTRS2020

Additive Manufactured Ultra-Fine Lattice Structures for Propulsion Catalysts

Traditional mono-propulsion catalysts consist of coated ceramic or graphite foams that possess anisotropic mechanical and fluid properties limiting design, cost, availability, and operational use. Ultra-fine lattice structures are repeating unit cells with ligament thickness as small as 100 μm produced via Additive manufacture (AM). These lattice structures have the potential to replace coated foams used in a mono-propellant system catalysts. AM ultrafine lattice structures are designed to mimic the operational intent of coated foams but with improved design flexibility, compressive strength, and flow behavior printed from into a single part directly from the preferred platinum metal alloy. The investigation objective was to conduct feasibility studies of AM ultra-fine lattice structures capable of replacing coated foams with superior functionality. NASA MSFC identified desired lattice characteristics and created designs while EOS developed optimized laser powder bed fusion AM parameters to manufacture Ti6Al4V and tungsten specimens. Optimized designs, computational tools, AM parameters, and post-process methods were developed. Specimens underwent x-ray microfocus CT, metallographic inspection, compression testing, and flow testing. Results demonstrate that AM ultra-fine lattices improved geometric and performance repeatability with the potential for significantly increased availability while decreasing cost and lead time.

Omar R Mireles↗

NASA NTRSDate not supplied

Additive Manufactured Ultra-Fine Lattice Structures for Propulsion Catalysts

Traditional mono-propulsion catalysts consist of coated ceramic or graphite foams that possess anisotropic mechanical and fluid properties limiting design, cost, availability, and operational use. Ultra-fine lattice structures are repeating unit cells with ligament thickness as small as 100 μm produced via Additive manufacture (AM). These lattice structures have the potential to replace coated foams used in a mono-propellant system catalysts. AM ultra-fine lattice structures are designed to mimic the operational intent of coated foams but with improved design flexibility, compressive strength, and flow behavior printed from into a single part directly from the preferred platinum metal alloy. The investigation objective was to conduct feasibility studies of AM ultra-fine lattice structures capable of replacing coated foams with superior functionality. NASA MSFC identified desired lattice characteristics and created designs while EOS developed optimized laser powder bed fusion AM parameters to manufacture Ti6Al4V and tungsten specimens. Optimized designs, computational tools, AM parameters, and post-process methods were developed. Specimens underwent x-ray micro-focus CT, metallographic inspection, compression testing, and flow testing. Results demonstrate that AM ultra-fine lattices improved geometric and performance repeatability with the potential for significantly increased availability while decreasing cost and lead time.

Omar R Mireles↗

NASA NTRS2016

Mechanical Design and Development of TES Bolometer Detector Arrays for the Advanced ACTPol Experiment

The next generation Advanced ACTPol (AdvACT) experiment is currently underway and will consist of four Transition Edge Sensor (TES) bolometer arrays, with three operating together, totaling 5800 detectors on the sky. Building on experience gained with the ACTPol detector arrays, AdvACT will utilize various new technologies, including 150 mm detector wafers equipped with multichroic pixels, allowing for a more densely packed focal plane. Each set of detectors includes a feedhorn array of stacked silicon wafers which form a spline pro le leading to each pixel. This is then followed by a waveguide interface plate, detector wafer, back short cavity plate, and backshort cap. Each array is housed in a custom designed structure manufactured from high purity copper and then gold plated. In addition to the detector array assembly, the array package also encloses cryogenic readout electronics. We present the full mechanical design of the AdvACT high frequency (HF) detector array package along with a detailed look at the detector array stack assemblies. This experiment will also make use of extensive hardware and software previously developed for ACT, which will be modi ed to incorporate the new AdvACT instruments. Therefore, we discuss the integration of all AdvACT arrays with pre-existing ACTPol infrastructure.

Advanced ACTPol (AdvACT)↗

NASA NTRSDate not supplied

Additive Manufacture of Ultra-Fine Lattice Structures of Green Propulsion Catalysts

Omar Mireles↗

NASA NTRSDate not supplied

SIBatt-3D: In-Space/On-Surface 3D Printing of Sodium Ion Batteries from ISRU Materials

Constructed more than 20 years ago, the International Space Station’s primary power system originally used nickel-hydrogen batteries with a lifetime of 6.5 years, until NASA began the process of replacing them in 2016 with lithium-ion batteries with a lifetime of 10 years. The demanding and costly process was accomplished after four flights of the Japanese H-II Transfer Vehicle cargo spacecraft (with a cost of about $10,000 per pound of payload), and 13 different astronauts conducting 14 spacewalks. Besides utilization in the ISS, rechargeable batteries are present in many space applications: they are installed in exploration robots, life support systems and in portable communication devices, to mention some. In this context, this project is focused on the in-space manufacturing of shape-conformable batteries using in-situ resources, and aims to address the NASA’s gaps related to the development of next generation of energy storage devices (TX03), as well as in-space manufacturing and in-situ resource utilization (TX07). The proposed work also tackles the HEOMD’s objectives targeting the in-space additive manufacturing (AM) from Lunar/Martian materials (regolith as AM feedstock) to reinvigorate America’s Human Space Exploration Program (SPD-1). This project is in direct alignment with the STMD’s objectives to demonstrate in-space autonomous manufacturing and assembly of complete systems by 2030, and to enable humans to live and explore in space and on planetary surfaces by 2040 thanks to in-space habitation, infrastructure development and in-situ resource utilization (ST1 and ST5). Manufacturing of shape conformable batteries directly in-space and using in-situ resources would also contribute to reducing the payload weight and volume (TX12) for future missions, thus reducing risk for long term Mars missions where rapid resupply is logistically infeasible. Nowadays, commercial batteries consist of stacked two-dimensional (2D) sheets, which are only manufactured in restricted geometries (cylindrical and coin cell). Evolving from conventional 2D, complex 3D battery architectures have been proven to increase the electrochemical active surface area and ion diffusion path, leading to improved areal energy density and power performance. This tendency was illustrated in our recent in-depth modeling studies by simulating a classical Ragone plot exhibiting the energy-power relationship. Our team demonstrated through modeling that a complex gyroidal 3D printed battery architecture exhibits significantly improved power performances (>150% at the current density of 6C; full discharge in 10 minutes) in comparison to a traditional 3D printed planar geometry. Motivated by these results and as the fabrication of intricate 3D battery design is only possible experimentally thanks to the geometric freedom offered by additive manufacturing (AM), our team has already initiated leveraging thermoplastic material extrusion at the laboratory scale. While 3D printing of batteries is relatively recent (2013), it has witnessed a growing interest during the last recent years, as next-generation shape-conformable 3D batteries can be co-designed with the system. Consequently, dead-volume and mass brought from Earth are minimized, in addition to improved battery performance, in alignment with the aforementioned NASA’s objectives. Further, while this project is specifically dedicated to batteries, it lends itself towards the maturation of in-space manufacturing via 3D printing using in-situ resources, stated in HEOMD and STMD goals.

In-Space Manufacturing↗

NASA NTRS1994

Project Genesis: Mars in situ propellant technology demonstrator mission

Project Genesis is a low cost, near-term, unmanned Mars mission, whose primary purpose is to demonstrate in situ resource utilization (ISRU) technology. The essence of the mission is to use indigenously produced fuel and oxidizer to propel a ballistic hopper. The Mars Landing Vehicle/Hopper (MLVH) has an Earth launch mass of 625 kg and is launched aboard a Delta 117925 launch vehicle into a conjunction class transfer orbit to Mars. Upon reaching its target, the vehicle performs an aerocapture maneuver and enters an elliptical orbit about Mars. Equipped with a ground penetrating radar, the MLVH searches for subsurface water ice deposits while in orbit for several weeks. A deorbit burn is then performed to bring the MLVH into the Martian atmosphere for landing. Following aerobraking and parachute deployment, the vehicle retrofires to a soft landing on Mars. Once on the surface, the MLVH begins to acquire scientific data and to manufacture methane and oxygen via the Sabatier process. This results in a fuel-rich O2/CH4 mass ratio of 2, which yields a sufficiently high specific impulse (335 sec) that no additional oxygen need be manufactured, thus greatly simplifying the design of the propellant production plant. During a period of 153 days the MLVH produces and stores enough fuel and oxidizer to make a 30 km ballistic hop to a different site of scientific interest. At this new location the MLVH resumes collecting surface and atmospheric data with the onboard instrumentation. Thus, the MLVH is able to provide a wealth of scientific data which would otherwise require two separate missions or separate vehicles, while proving a new and valuable technology that will facilitate future unmanned and manned exploration of Mars. Total mission cost, including the Delta launch vehicle, is estimated to be $200 million.

Acosta, Francisco Garcia↗

NASA NTRS2014

Additive Manufacturing and 3D Printing in NASA: An Overview of Current Projects and Future Initiatives for Space Exploration

NASA, including each Mission Directorate, is investing in, experimenting with, and/or utilizing AM across a broad spectrum of applications and projects; Centers have created and are continuing to create partnerships with industry, other Government Agencies, other Centers, and Universities; In-house additive manufacturing capability enables rapid iteration of the entire design, development and testing process, increasing innovation and reducing risk and cost to projects; For deep space exploration, AM offers significant reduction to logistics costs and risk by providing ability to create on demand; There are challenges: Overwhelming message from recent JANNAF AM for Propulsion Applications TIM was "certification."; NASA will continue to work with our partners to address this and other challenges to advance the state of the art in AM and incorporate these capabilities into an array of applications from aerospace to science missions to deep space exploration.

Clinton, R. G., Jr.↗

NASA NTRSDate not supplied

Backshell Thermal Protection Materials for Additive Manufacturing

NASA invests in additive manufacturing (AM) to enable new mission architectures and design methods, including autonomous fabrication. AM is suited for backshell thermal protection materials that require many complex closeouts that lead to integration challenges. Current work will review printable backshell thermal protection material formulation, development, and characterization, such as Arc-jet testing results.

Tane Boghozian↗

NASA NTRS2012

Sizing and Lifecycle Cost Analysis of an Ares V Composite Interstage

The Interstage Element of the Ares V launch vehicle was sized using a commercially available structural sizing software tool. Two different concepts were considered, a metallic design and a composite design. Both concepts were sized using similar levels of analysis fidelity and included the influence of design details on each concept. Additionally, the impact of the different manufacturing techniques and failure mechanisms for composite and metallic construction were considered. Significant details were included in analysis models of each concept, including penetrations for human access, joint connections, as well as secondary loading effects. The designs and results of the analysis were used to determine lifecycle cost estimates for the two Interstage designs. Lifecycle cost estimates were based on industry provided cost data for similar launch vehicle components. The results indicated that significant mass as well as cost savings are attainable for the chosen composite concept as compared with a metallic option.

Mann, Troy↗

NASA NTRS1974

Nickel-cadmium cells

A high energy density nickel cadmium cell of aerospace quality was designed. The approach used was to utilize manufacturing techniques which produce highly uniform and controlled starting materials in addition to improvements in the overall design. Parameters controlling the production of plaque and both positive and negative plate were studied. Quantities of these materials were produced and prototype cells were assembled to test the proposed design.

Rubin, E. J.↗

NASA NTRS2019

Additive Manufacturing of Multi-Material Systems for Aerospace Applications

Additive manufacturing methods for producing single materials are rapidly improving. The resulting material properties and microstructures are becoming more comparable to those of conventionally fabricated materials. However, the need for multi-functional and complex structures and components requires additional innovations in manufacturing such as multi-material and hybrid additive manufacturing approaches. Additive manufacturing machines with multiple print capabilities and combinations of AM, machining, and conventional processing methods will further open up design spaces and possibilities. In this presentation, several examples of the needs and methods for multi-material fabrication will be discussed with a focus on aerospace applications. Direct printing of silver coils in conjunction with fused deposition modeling, machined parts, and, binder jetting is being developed for innovative stator designs. Binder jetting of silicon-based materials with powder bed additions is being developed for heat exchanger applications. Additive manufacturing of bi-material systems is being pursued to fabricate lightweight, integrated, multifunctional structures.

multi-materials↗

NASA NTRSDate not supplied

Advanced and Additive Manufacturing Technologies for Liquid Rocket Engine Components

Overview of advanced manufacturing and additive manufacturing development at NASA for liquid rocket engines. Presentation includes various material, process, design, and hot-fire testing developments demonstrating the use of advanced components for liquid rocket engines on launch vehicles and in-space systems.

Additive Manufacturing↗