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At least 181 records · Page 10

Finalizing the CCSDS Space-Data Link Layer Security Protocol: Setup and Execution of the Interoperability Testing

The protection of data transmitted over the space-link is an issue of growing importance also for civilian space missions. Through the Consultative Committee for Space Data Systems (CCSDS), space agencies have reacted to this need by specifying the Space Data-Link Layer Security (SDLS) protocol which provides confidentiality and integrity services for the CCSDS Telemetry (TM), Telecommand (TC) and Advanced Orbiting Services (AOS) space data-link protocols. This paper describes the approach of the CCSDS SDLS working group to specify and execute the necessary interoperability tests. It first details the individual SDLS implementations that have been produced by ESA, NASA, and CNES and then the overall architecture that allows the interoperability tests between them. The paper reports on the results of the interoperability tests and identifies relevant aspects for the evolution of the test environment.

Fischer, Daniel↗

Diversity Buffers Winegrowing Regions from Climate Change Losses

Agrobiodiversity—the variation within agricultural plants, animals, and practices—is often suggested as a way to mitigate the negative impacts of climate change on crops [S. A. Wood et al., Trends Ecol. Evol. 30, 531–539 (2015)]. Recently, increasing research and attention has focused on exploiting the intraspecific genetic variation within a crop [Hajjar et al., Agric. Ecosyst. Environ. 123, 261–270 (2008)], despite few relevant tests of how this diversity modifies agricultural forecasts. Here, we quantify how intraspecific diversity, via cultivars, changes global projections of growing areas. We focus on a crop that spans diverse climates, has the necessary records, and is clearly impacted by climate change: winegrapes (predominantly Vitis vinifera subspecies vinifera). We draw on long-term French records to extrapolate globally for 11 cultivars (varieties) with high diversity in a key trait for climate change adaptation—phenology. We compared scenarios where growers shift to more climatically suitable cultivars as the climate warms or do not change cultivars. We find that cultivar diversity more than halved projected losses of current winegrowing areas under a 2 °C warming scenario, decreasing areas lost from 56 to 24%. These benefits are more muted at higher warming scenarios, reducing areas lost by a third at 4 °C (85% versus 58%). Our results support the potential of in situ shifting of cultivars to adapt agriculture to climate change—including in major winegrowing regions—as long as efforts to avoid higher warming scenarios are successful.

Morales-Castilla, Ignacio↗

Impact of NASA’s Entry Systems Modeling Project on Planetary Mission Design

Planetary missions continue to grow larger and more complex. Furthermore, the current focus on human exploration of the Moon and Mars, as well as Mars Sample Return(MSR), place increas-ingly stringent requirements on the reliability of the entry, descent, and landing (EDL) system that ensures the safe delivery of payload or crew to their destination. Planetary EDL is an area in which mission designers are critically reliant on modeling and simulation to demonstrate the reliability of the system, as there are no ground facilities that are able to fully test these systems in a flight-relevant environment. NASA’s state-of-the-art modeling and simulation capability must continually evolve to meet the needs of the next generation of planetary EDL. To accomplish this aim, NASA’s Entry Systems Modeling (ESM) Project was formed in 2013and is funded bythe Space Technology Mission Directorate(STMD) and Science Mission Directorate (SMD). ESM is the Agency’s only cross-cutting effort for advancing entry systems modeling and simulation capabilities across a range of technical disciplines and Solar System destinations. ESM is a portfolio project covering a variety of mid-TRL research efforts within four core EDL-related areas of investment: (1) Thermal protection material modeling, (2) Shock layer kinetics and radiation, (3) Aerosciences, and (4) Guidance, navigation, and con-trol. The material modeling group creates detailed material response modelsof thermal protection systems (TPS)from the micro to macro scale, and at the fun-damental and engineering levels. Shock layer kinetics and radiation focuses on radiative heating of space-craft, quantum chemistry and benchmark experiments for validation.Aerosciences is a broad research area that impacts many aspects of entry systems, including parachutes, aerodynamics, and turbulent heating augmentation due to TPS roughness.The guidance, navigation,and control effort under ESM is expanding the capabilities of NASA’s main flight mechanics tool, POST2, for use on high-performance computing architectures and to generalize interoperability with external applications for more detailed end-to-end simula-tion.In addition, several focusedresearch topics have been approvedto augment ESM’s core portfolio. These include efforts for deep post-flight analysis of Mars 2020/MEDLI2 flight data; development ofTPS failure models; improvement of hypersonic wakeflow models; and a recently concluded effort to provide material response models for NuSil-coated PICA heat-shield material. This presentation will discuss each of these investment areas and demonstrate via real mission examples how advances to the state-of-the-art enabled by ESM are directly impacting the missions of today and tomorrow, including InSight, Mars 2020, Mars Sample Return, Orion, and Dragonfly.

Entry Systems Modeling↗

Advances in Stereo Photogrammetry Capabilities for in-Situ Ejecta Measurements in Lunar Plume-Surface Interactions

Plume-surface interaction is a critical topic of interest as human spaceflight programs establish a renewed presence on the Moon and push onwards to Mars. The erosion of regolith and high-speed ejection of soil and rocks which occurs during a powered spacecraft landing on lunar or terrestrial bodies can pose serious risks to the vehicle during landing and to existing ground assets. Ground testing campaigns have provided data sets in relevant environments (e.g., low pressure) in tandem with predictive computational model validation. To-date, limited in-situ flight data exists to inform the study of the key phenomena of plume-surface interaction: plume-flow physics, soil erosion, and ejecta dynamics. In two upcoming lunar missions, erosion of the lunar regolith will be measured in-situ using the stereo photogrammetry technique as part of NASA’s Commercial Lunar Payload Services (CLPS) Program. The Stereo Cameras for Lunar Plume Surface Studies (SCALPSS) will use a multiple-camera system to measure the erosion of the lunar regolith due to the vehicles’ rocket engine plumes during descent and after landing. The application of stereo photogrammetry to accurately measure a realistic eroded shape has been validated in laboratory work ahead of the scheduled flights. In preparation for future CLPS, Artemis, or other lunar science missions, recent advancements have been made to measure the ejecta structure and particle dynamics in addition to the erosion of regolith using a SCALPSS-like photogrammetry system. The thickness and ejection angle of entrained soil and dust produced during plume-induced erosion can be used to determine how far debris will travel, and thus how it may impact nearby infrastructure or the landing vehicle itself. The present work highlights the development of this new flight instrumentation capability and its value to advancements in the plume-surface interaction measurement topic for lunar or planetary landings.

Olivia K. Tyrrell↗

Long-length Scintillating Fibers for Nuclear Waste Repositories (Conference Record)

This paper describes the fabrication, testing, and characterization of long-length, up to 50 m, scintillating fibers for the purpose of radiation monitoring in inaccessible radiological and nuclear waste repositories. The fabrication aspect was focused on ruggedizing the 1-mm diameter fiber and limiting external light interference for fibers. Testing and characterization were performed in a laboratory setting with radiation sources, a photosensor module and a multi-channel analyzer. Light attenuation was studied as a function of distance by analyzing both the spectrum and count rate. Additionally, the scintillating fibers were coupled to optical communication fibers (100 m) to extend the reach of the system. This paper also includes the optical spectrometry results from the sensitivity and response of the signal attenuation. Lastly, the paper covers the field testing of the scintillating fibers in a relevant environment.

47 - OTHER INSTRUMENTATION↗

Acoustic Directivity and Insertion Loss Measurements of Advanced Liners Installed the Inlet of the DGEN Aeropropulsion Research Turbofan

The NASA Glenn Research Center’s DGEN Aeropropulsion Research Turbofan (DART) is based on the Price Induction DGEN380—a small, ~500-lbf thrust class, high-bypass, geared-turbofan engine with a separate flow nozzle. The general characteristics of the DART make it an ideal candidate for utilization as a test bed for engine aeroacoustic research in a relevant performance environment. The DART was used to document the efficacy of acoustic liners installed in the inlet of the DGEN380. An advanced multi-degree-of-freedom liner (MDOF) was designed and tested, along with a traditional single-degree-of- freedom liner (SDOF), and those results compared to a hard-wall baseline inlet. Farfield acoustic data were acquired from an external array, evaluated, and reported here-in terms of overall, broadband, and tonal components of the insertion loss.

Noise Reduction↗

An Overview of High Temperature Seal Development and Testing Capabilities at the NASA Glenn Research Center

The NASA Glenn Research Center (GRC), partnering with the University of Toledo, has a long history of developing and testing seal technologies for high-temperature applications. The GRC Seals Team has conducted research and development on high-temperature seal technologies for applications including advanced propulsion systems, thermal protection systems (airframe and control surface thermal seals), high-temperature preloading technologies, and other extreme-environment seal applications. The team has supported several high-profile projects over the past 30 years and has partnered with numerous organizations, including other government entities, academic institutions, and private organizations. Some of these projects have included the National Aerospace Space Plane (NASP), Space Shuttle Space Transport System (STS), the Multi-Purpose Crew Vehicle (MPCV), and the Dream Chaser Space Transportation System, as well as several high-speed vehicle programs for other government organizations. As part of the support for these programs, NASA GRC has developed unique seal-specific test facilities that permit evaluations and screening exercises in relevant environments. The team has also embarked on developing high-temperature preloaders to help maintain seal functionality in extreme environments. This paper highlights several propulsion-related projects that the NASA GRC Seals Team has supported over the past several years and will provide an overview of existing testing capabilities

National Aerospace Plane↗

Results of an Advanced Development Zero Boil-Off Cryogenic Propellant Storage Test

A zero boil-off (ZBO) cryogenic propellant storage concept was recently tested in a thermally relevant low-earth orbit environment, an important development in the effort to apply this concept to flight projects. Previous efforts documented the benefits of ZBO for launch vehicle upper stages in a low-earth orbit (LEO). Central to that analysis is a ZBO Cryogenic Analysis Tool that estimates the performance of each component and the ZBO system. This test is essential to the validation of that tool, and was the first flight representative configuration tested in a thermally representative environment. The test article was comprised of a spherical 1.4 m diameter insulated propellant tank, with a submerged mixer, a cryogenic heat pipe, flight design cryocooler, and a radiator. All were enclosed in a thermal shroud and inserted into and tested in a vacuum chamber that simulated an LEO thermal environment. Thermal and pressure control tests were performed at sub-critical LN2 temperatures and approximately 2 atmospheres pressure. The cold side of the ZBO system performed well. In particular, the heat pipe performed better than expected, which suggests that the cryocooler could be located further from the tank than anticipated, i.e. on a spacecraft bus, while maintaining the desired efficiency. Also, the mixer added less heat than expected. The tank heating rate through the insulation was higher than expected; also the temperatures on the cryocooler hot side were higher than planned. This precluded the cryocooler from eliminating the boil-off. The results show the cryocooler was successful at removing 6.8 W of heat at approximately 75 K and 150 W of input power, with a heat rejection temperature of 311 K. The data generated on the ZBO components is essential for the upgrade of the ZBO Cryogenic Analysis Tool to more accurately apply the concept to future missions.

Plachta, David↗

Constitutive Model Development for Aging Polymer Encapsulants (ASC P&EM FY2021 L2 Milestone 7836)

This SAND report fulfills the completion requirements for the ASC Physics and Engineering Modeling Level 2 Milestone 7836 during Fiscal Year 2021. The Sandia Simplified potential energy clock (SPEC) non-linear viscoelastic constitutive model was developed to predict a whole host of polymer glass physical behaviors in order to provide a tool to assess the effects of stress on these materials over their lifecycle. Polymer glasses are used extensively in applications such as electronics packaging, where encapsulants and adhesives can be critical to device performance. In this work, the focus is on assessing the performance of the model in predicting material evolution associated with long-term physical aging, an area that the model has not been fully vetted in. These predictions are key to utilizing models to help demonstrate electronics packaging component reliability over decades long service lives, a task that is very costly and time consuming to execute experimentally. The initiating hypothesis for the work was that a model calibration process can be defined that enables confidence in physical aging predictions under ND relevant environments and timescales without sacrificing other predictive capabilities. To test the hypothesis, an extensive suite of calibration and aging data was assembled from a combination of prior work and collaborating projects (Aging and Lifetimes as well as the DoD Joint Munitions Program) for two mission relevant epoxy encapsulants, 828DGEBA/DEA and 828DGEBA/T403. Multiple model calibration processes were developed and evaluated against the entire set of data for each material. A qualitative assessment of each calibration's ability to predict the wide range of aging responses was key to ranking the calibrations against each other. During this evaluation, predictions that were identified as non-physical, i.e., demonstrated something that was qualitatively different than known material behavior, were heavily weighted against the calibration performance. Thus, unphysical predictions for one aspect of aging response could generate a lower overall rating for a calibration process even if that process generated better quantitative predictions for another aspect of aging response. This insurance that all predictions are qualitatively correct is important to the overall aim of utilizing the model to predict residual stress evolution, which will depend on the interplay amongst the different material aging responses. The DSC-focused calibration procedure generated the best all-around aging predictions for both materials, demonstrating material models that can qualitatively predict the whole host of different physical aging responses that have been measured. This step forward in predictive capability comes from an unanticipated source, utilization of calorimetry measurements to specify model parameters. The DSC-focused calibration technique performed better than compression-focused techniques that more heavily weigh measurements more closely related to the structural responses to be predicted. Indeed, the DSC-focused calibration procedure was only possible due to recent incorporation of the enthalpy and heat capacity features into SPEC that was newly verified during this L2 milestone. Fundamentally similar aspects of the two material model calibrations as well as parametric studies to assess sensitives of the aging predictions are discussed within the report. A perspective on the next steps to the overall goal of residual stress evolution predictions under stockpile conditions closes the report.

36 MATERIALS SCIENCE↗

Ampaire ARPA-e Electric Flight Testbed

A hybrid-electric aircraft flying testbed was developed in this program with the intent to serve as a dedicated, enduring testbed to test and evaluate ARPA-e CIRCUITS Program and other electrified aviation technologies in relevant flight environments. This testbed enabled rapid development cycles of novel and innovative technologies in the electrified aviation space, maturing them from a research lab environment to flying in an aircraft. By providing research groups with the means to test their transformative technologies in a real-world, aircraft environment, the path to validating the safety and reliability of their technologies for future commercial opportunities was greatly accelerated. Three core technologies were integrated and tested: an inverter/motor drive built by the University of Arkansas, a solid-state circuit breaker (iBreaker) built by the Illinois Institute of Technology, and a Flying Capacitor Multi-level (FCML) DC/DC converter built by the University of California, Berkeley. In each of these cases, the requirements established for safety of flight resulted in a holistic approach to the designs, evoking a deeper understanding of the potential failure modes and mitigations necessary to build a robust and flightworthy system. Further, the integration into a hybrid-electric aircraft de-risked the potential electrical and mechanical issues that cannot easily be experienced or replicated in a lab environment. The experiments were also required to undergo representative temperature, shock, and vibration testing as the FAA prescribes for this category of aircraft, facilitating familiarity with the relevant design and test guidelines necessary to commercialize the technologies. This testbed unlocks the massive potential of core power electronics technologies necessary for a safe, robust, and efficient electric aviation future. With quick iterative design, test, and flight cycles, these core technologies are on a quicker path to technology readiness level maturity and commercialization, enabling a more sustainable future for the aviation industry.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Toward Standardized Microscale Tensile Testing for Two‐Photon Polymerization‐Fabricated Materials in Liquid

Two-photon polymerization (TPP) enables the fabrication of intricate 3D microstructures with submicron precision, offering significant potential in biomedical applications like tissue engineering. In such applications, to print materials and structures with defined mechanics, it is crucial to understand how TPP printing parameters impact the material properties in a physiologically relevant liquid environment. Herein, an experimental approach utilizing microscale tensile testing (μTT) for the systematic measurement of TPP-fabricated microfibers submerged in liquid as a function of printing parameters is introduced. Using a diurethane dimethacrylate-based resin, the influence of printing parameters on microfiber geometry is first explored, demonstrating cross-sectional areas ranging from 1 to 36 μm 2 . Tensile testing reveals Young's moduli between 0.5 and 1.5 GPa and yield strengths from 10 to 60 MPa. The experimental data show an excellent fit with the Ogden hyperelastic polymer model, which enables a detailed analysis of how variations in writing speed, laser power, and printing path influence the mechanical properties of TPP microfibers. The μTT method is also showcased for evaluating multiple commercial resins and for performing cyclic loading experiments. Collectively, this study builds a foundation toward a standardized microscale tensile testing framework to characterize the mechanical properties of TPP printed structures.

mechanical characterization↗

Compact and Integrated Liquid Bismuth Propellant Feed System

Operation of Hall thrusters with bismuth propellant has been shown to be a promising path toward high-power, high-performance, long-lifetime electric propulsion for spaceflight missions [1]. There has been considerable effort in the past three years aimed at resuscitating this promising technology and validating earlier experimental results indicating the advantages of a bismuth-fed Hall thruster. A critical element of the present effort is the precise metering of propellant to the thruster, since performance cannot be accurately assessed without an accurate accounting of mass flow rate. Earlier work used a pre./post-test propellant weighing scheme that did not provide any real-time measurement of mass flow rate while the thruster was firing, and makes subsequent performance calculations difficult. The motivation of the present work is to develop a precision liquid bismuth Propellant Management System (PMS) that provides hot, molten bismuth to the thruster while simultaneously monitoring in real-time the propellant mass flow rate. The system is a derivative of our previous propellant feed system [2], but the present system represents a more compact design. In addition, all control electronics are integrated into a single unit and designed to reside on a thrust stand and operate in the relevant vacuum environment where the thruster is operating, significantly increasing the present technology readiness level of liquid metal propellant feed systems. The design of various critical components in a bismuth PMS are described. These include the bismuth reservoir and pressurization system, 'hotspot' flow sensor, power system and integrated control system. Particular emphasis is given to selection of the electronics employed in this system and the methods that were used to isolate the power and control systems from the high-temperature portions of the feed system and thruster. Open loop calibration test results from the 'hotspot' flow sensor are reported, and results of integrated thruster/PMS tests demonstrate operation of the feed system in the relevant environment.

Polzin, Kurt A.↗

GN&C Sequencing for Orion Rendezvous, Proximity Operations, and Docking

As part of the Artemis program to return humans to the lunar surface, the National Aeronautics and Space Administration is planning to use the Orion Multi- Purpose Crew Vehicle to transport crew to a small orbital platform called Gate- way in cislunar space. To facilitate this activity, Orion is required to perform Rendezvous, Proximity Operations, and Docking (RPOD) with both the Gate- way and the launch vehicle upper stage. The Orion spacecraft uses sequencing in the form of Phases, Segments, Activities, and Modes (PSAM) to configure Guidance, Navigation, & Control (GN&C) software during each portion of the mission. Significant updates to Orion PSAM definitions are required for RPOD. This paper describes the process of defining these new sequencing elements, implementing them in prototype flight software, and testing them in an integrated simulation environment. First, requirements are specified to determine the nominal and off-nominal sequencing behavior necessary to complete the mission. These requirements also specify which software functions should be fully autonomous and which functions require manual interactions from crew or ground operators. Next, the RPOD concept of operations is defined with detailed events listed in a mission timeline. Third, a state machine diagram is developed to show all PSAM states, including all possible transitions between them. After this, the PSAM states and transitions are entered into a sequencing software emulator and parameter values and modes are defined for GN&C software elements. Finally, the PSAM architecture is tested within an integrated simulation environment by connecting it with prototypes of relevant GN&C flight software elements and with detailed vehicle models. After the sequencing design has been finalized and tested, it is implemented in flight software.

Schulte, Peter Z.↗

Assessments of Physiology and Cognition in Hybrid-Reality Environments (APACHE)

NASA is planning to return to the Moon in the mid-2020s as a stepping stone to Mars missions in the 2030s. Spacewalks, or extravehicular activities (EVAs), performed on the Moon and Mars will differ in a variety of ways from those that have been performed in decades past. NASA has identified multiple risks to human health and performance associated with a crewed mission to Mars, especially those associated with exploration EVAs which are expected to be a primary mission activity. Crew may be expected to conduct up to 24 hours of EVA per person per week, where the likelihood of injury and/or mental mistakes are increased compared to ground-based training or current microgravity EVAs and the consequences of which can be catastrophic. Current test environments for exploration EVA research and technology development are large, costly facilities that are limited in their availability or capabilities. Spacesuit testing in a reduced gravity environment such as NASA’s Neutral Buoyancy Laboratory, while a good representation of the crew’s physical workload during exploration EVAs, typically has small datasets and is difficult to integrate physiological sensors or other types of crew performance measures. Meanwhile, scientific field-based testing such as NASA’s Desert Research and Technology Studies offers an operationally relevant environment for exploration EVAs, particularly for cognitive workload, but is also limited by small datasets, lack of a pressurized spacesuit, and obtrusive measures. The limitations of current analogs for exploration EVAs identify a need for a new test environment that can approximate both the physical and cognitive demands associated with exploration EVAs to enable rapid, controlled, and repeatable evaluations of human health and performance risks of exploration missions. In response, the Human Physiology, Performance, Protection, and Operations Laboratory (H-3PO) at NASA Johnson Space Center has developed a hybrid reality exploration EVA analog named the Assessments of Physiology And Cognition in Hybrid-reality Environments (APACHE) to address these limitations using a combination of virtual, physical, and hybrid reality techniques. The APACHE facility resides at NASA Johnson Space Center and serves as a large “sandbox” for EVA research and simulation. At its center is a roughly 15x20ft space surrounded by a 14” tall sandbox partially filled with lunar regolith simulant to emulate the physical feeling of walking on a planetary surface and to allow for simulated geology operations. Nearby, a curved passive treadmill (Skillmill Connect, Technogym, Fairfield, NJ) and an omnidirectional treadmill (Infinadeck, Infinadeck, Rocklin, CA) are included to enable exploration of these large virtual environments while also imposing the physical demands, representative timelines, and cognitive burdens required to navigate and traverse these distances during exploration EVA. A 6DOF motion platform is used to simulate rover operations and supports various human performance evaluations and associated risks. Lastly, APACHE can support two extravehicular (EV) crewmembers working in tandem. A computer workstation is located nearby and also supports an intravehicular (IV) crewmember as part of a full mission simulation. The IV crewmember has direct video and audio communication with the EV crew in VR to provide operational and procedural support. The software used in APACHE was created by the JSC Engineering Directorate, in partnership with Buendea, powered by a custom Unreal Engine 5 (UE5.3, Epic Games) project. APACHE currently utilizes the HTC Vive Pro Eye in a wireless configuration for VR simulations. There are two virtual environments that subjects can explore within APACHE, a Lunar and Martian surface. The virtual Lunar surface was created from LIDAR data of the Lunar South Pole to create roughly 16 sq km of explorable terrain. The virtual Martian surface contains roughly 400 sq km of explorable terrain derived from Mars Reconnaissance Orbiter LIDAR data of the Jezero Crater. The immersion and related cognitive burdens of conducting a planetary EVA is simulated through a series of EVA-relevant tasks performed in the VR environment, using these high-fidelity visual representations. Additionally, APACHE includes biosensor driven informatics, such as real-time heart rate monitoring and/or derived values from model simulations, for active monitoring by the EV crew and added cognitive demand. A “Wizard of Oz” control panel enables test operators to activate contingency events such as simulated spacesuit malfunctions, loss of communications, and/or limited visibility. Embedded performance measures such as accuracy, completeness, and execution time have been developed for various exploration tasks to objectively quantify crew performance during an EVA and compare impacts to performance when different environmental stressors, both physical and cognitive, are added to or removed from the simulation. Additionally, validated cognitive and operational performance measures such as the Digit Symbol Substitution Task have been recreated and embedded in VR for direct and relatively unobtrusive measurement of motor perception. The APACHE environment currently supports multiple research studies at NASA. Examples include the CHAPEA project, a series of simulated year-long missions on Mars by a 4-person crew; and the CO2 Contingency Walk Back Study, an investigation of elevated CO2 exposure on crew performance during a contingency EVA scenario. APACHE also provides a test environment to support the development of the Crew State and Risk Model, which is a collection of individualized, mathematical models of crew physical and cognitive state; and the Personalized EVA Informatics and Decision Support system, an operational tool for flight controllers, and eventually a self-reliant Martian crew, to make biomedically-informed decisions in real-time to optimize the EVA planning and execution with respect to crew health and performance. Some technical challenges associated with developing the APACHE environment, as well as current limitations, include VR limitless natural walking with a hybrid spacesuit simulator, optimizing performance for wireless PC VR streaming while maintaining a high degree of visual fidelity, and the integration of various physiological (metabolic masks) and psychometric (eye tracking) sensors with the VR headset.

Human Performance↗

Optimization of Rocket Engine Components using Multi-Metallic Additive Manufacturing

Additive manufacturing (AM) is advancing many applications of component design for liquid rocket engines. AM has been demonstrated in various rocket component applications using a variety of monolithic metal alloys, many of which are traditional alloys for extreme environments. NASA and industry partners have focused in recent years to advance processing to create bimetallic and multicomponent AM processes and materials. The role of multi-metallic AM offers advantages since it can further optimize weight, optimize reliability and performance by increasing the strength to weight ratio of a component, and can optimize materials for various engineering requirements. NASA’s Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project has designed and manufactured a series of additively manufactured (AM) coupled combustion chambers, nozzles, and other engine components to advance new AM processes and materials with the goal of reducing cost and schedule for engine manufacturing. These designs incorporated multimetallic AM, which further enabled carbon-fiber composite overwrap to reduce overall thrust chamber assembly (TCA) mass. Various AM processes were demonstrated on these components using a copper-based alloy/superalloy bimetallic solution. The AM processes being explored individually and in combination for bimetallic applications include Laser Powder Bed Fusion (L-PBF), Laser Powder Directed Energy Deposition (LP-DED), and cold spray. The combination of bimetallic material combinations explored in this research include GRCop-based alloys and superalloys, Inconel 625 or NASA HR-1. One unique development that will be presented is the combustion chamber and nozzle as a single component by using freeform integrated DED to build the nozzle directly onto the aft end of the chamber. The various aspects of the additive manufacturing processes and challenges, materials characterization and mechanical testing, and hot-fire testing of bimetallic components in a relevant rocket engine environment will be discussed.

Additive Manufacturing↗

Design and Test Plans for a Non-Nuclear Fission Power System Technology Demonstration Unit

A joint National Aeronautics and Space Administration (NASA) and Department of Energy (DOE) team is developing concepts and technologies for affordable nuclear Fission Power Systems (FPSs) to support future exploration missions. A key deliverable is the Technology Demonstration Unit (TDU). The TDU will assemble the major elements of a notional FPS with a non-nuclear reactor simulator (Rx Sim) and demonstrate system-level performance in thermal vacuum. The Rx Sim includes an electrical resistance heat source and a liquid metal heat transport loop that simulates the reactor thermal interface and expected dynamic response. A power conversion unit (PCU) generates electric power utilizing the liquid metal heat source and rejects waste heat to a heat rejection system (HRS). The HRS includes a pumped water heat removal loop coupled to radiator panels suspended in the thermal-vacuum facility. The basic test plan is to subject the system to realistic operating conditions and gather data to evaluate performance sensitivity, control stability, and response characteristics. Upon completion of the testing, the technology is expected to satisfy the requirements for Technology Readiness Level 6 (System Demonstration in an Operational and Relevant Environment) based on the use of high-fidelity hardware and prototypic software tested under realistic conditions and correlated with analytical predictions.

Mason, Lee↗

Preliminary Investigation of Surface Treatments to Enhance the Wear Resistance of 60-Nitinol

The use of protective surface treatments on 60-Nitinol (60wt%Ni-40wt%Ti) was studied. Various nitriding techniques as well as a (Ti, Al)N coating were evaluated visually, microscopically, and by hardness and scratch testing. The chemical composition of the surface treatments was investigated by x-ray techniques. The results indicate that very hard (greater than 1,000 HK) and adherent surface layers can be produced on 60-Nitinol. Further work is needed to determine the tribological properties of these surface treatments in relevant operating environments.

Nitinol↗

NASA PS304 Lubricant Tested in World's First Commercial Oil-Free Gas Turbine

In a marriage of research and commercial technology, a 30-kW Oil-Free Capstone microturbine electrical generator unit has been installed and is serving as a test bed for long-term life-cycle testing of NASA-developed PS304 shaft coatings. The coatings are used to reduce friction and wear of the turbine engine s foil air bearings during startup and shut down when sliding occurs, prior to the formation of a lubricating air film. This testing supports NASA Glenn Research Center s effort to develop Oil-Free gas turbine aircraft propulsion systems, which will employ advanced foil air bearings and NASA s PS304 high temperature solid lubricant to replace the ball bearings and lubricating oil found in conventional engines. Glenn s Oil-Free Turbomachinery team s current project is the demonstration of an Oil-Free business jet engine. In anticipation of future flight certification of Oil-Free aircraft engines, long-term endurance and durability tests are being conducted in a relevant gas turbine environment using the Capstone microturbine engine. By operating the engine now, valuable performance data for PS304 shaft coatings and for industry s foil air bearings are being accumulated.

Weaver, Harold F.↗