Search NASA⌕ Search

SEARCH · Search NASA

Results for “TEST FIRING”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 181 records · Page 10

Large-Scale Spacecraft Fire Safety Tests

An international collaborative program is underway to address open issues in spacecraft fire safety. Because of limited access to long-term low-gravity conditions and the small volume generally allotted for these experiments, there have been relatively few experiments that directly study spacecraft fire safety under low-gravity conditions. Furthermore, none of these experiments have studied sample sizes and environment conditions typical of those expected in a spacecraft fire. The major constraint has been the size of the sample, with prior experiments limited to samples of the order of 10 cm in length and width or smaller. This lack of experimental data forces spacecraft designers to base their designs and safety precautions on 1-g understanding of flame spread, fire detection, and suppression. However, low-gravity combustion research has demonstrated substantial differences in flame behavior in low-gravity. This, combined with the differences caused by the confined spacecraft environment, necessitates practical scale spacecraft fire safety research to mitigate risks for future space missions. To address this issue, a large-scale spacecraft fire experiment is under development by NASA and an international team of investigators. This poster presents the objectives, status, and concept of this collaborative international project (Saffire). The project plan is to conduct fire safety experiments on three sequential flights of an unmanned ISS re-supply spacecraft (the Orbital Cygnus vehicle) after they have completed their delivery of cargo to the ISS and have begun their return journeys to earth. On two flights (Saffire-1 and Saffire-3), the experiment will consist of a flame spread test involving a meter-scale sample ignited in the pressurized volume of the spacecraft and allowed to burn to completion while measurements are made. On one of the flights (Saffire-2), 9 smaller (5 x 30 cm) samples will be tested to evaluate NASAs material flammability screening tests. The first flight (Saffire-1) is scheduled for July 2015 with the other two following at six-month intervals. A computer modeling effort will complement the experimental effort. Although the experiment will need to meet rigorous safety requirements to ensure the carrier vehicle does not sustain damage, the absence of a crew removes the need for strict containment of combustion products. This will facilitate the first examination of fire behavior on a scale that is relevant to spacecraft fire safety and will provide unique data for fire model validation.

Combustion↗

Space Launch System Base Heating Test: Sub-Scale Rocket Engine/Motor Design, Development and Performance Analysis

The Space Launch System (SLS) base heating test is broken down into two test programs: (1) Pathfinder and (2) Main Test. The Pathfinder Test Program focuses on the design, development, hot-fire test and performance analyses of the 2% sub-scale SLS core-stage and booster element propulsion systems. The core-stage propulsion system is composed of four gaseous oxygen/hydrogen RS-25D model engines and the booster element is composed of two aluminum-based model solid rocket motors (SRMs). The first section of the paper discusses the motivation and test facility specifications for the test program. The second section briefly investigates the internal flow path of the design. The third section briefly shows the performance of the model RS-25D engines and SRMs for the conducted short duration hot-fire tests. Good agreement is observed based on design prediction analysis and test data. This program is a challenging research and development effort that has not been attempted in 40+ years for a NASA vehicle.

Mehta, Manish↗

NASA's SPACE LAUNCH SYSTEM: Development and Progress

NASA is embarked on a new era of space exploration that will lead to new capabilities, new destinations, and new discoveries by both human and robotic explorers. Today, the International Space Station (ISS) and robotic probes are yielding knowledge that will help make this exploration possible. NASA is developing both the Orion crew vehicle and the Space Launch System (SLS) (Figure 1), that will carry out a series of increasingly challenging missions leading to human exploration of Mars. This paper will discuss the development and progress on the SLS. The SLS architecture was designed to be safe, affordable, and sustainable. The current configuration is the result of literally thousands of trade studies involving cost, performance, mission requirements, and other metrics. The initial configuration of SLS, designated Block 1, will launch a minimum of 70 metric tons (mT) (154,324 pounds) into low Earth orbit - significantly greater capability than any current launch vehicle. It is designed to evolve to a capability of 130 mT (286,601 pounds) through the use of upgraded main engines, advanced boosters, and a new upper stage. With more payload mass and volume capability than any existing rocket, SLS offers mission planners larger payloads, faster trip times, simpler design, shorter design cycles, and greater opportunity for mission success. Since the program was officially created in fall 2011, it has made significant progress toward launch readiness in 2018. Every major element of SLS continued to make significant progress in 2015. Engineers fired Qualification Motor 1 (QM-1) in March 2015 to test the 5-segment motor, including new insulation, joint, and propellant grain designs. More than 70 major components of test article and flight hardware for the Core Stage have been manufactured. Seven test firings have been completed with an RS-25 engine under SLS operating conditions. The test article for the Interim Cryogenic Propulsion Stage (ICPS) has also been completed. Major work continues in 2016 as the program continues both flight and development RS-25 engine testing, begins welding test article and flight core stage tanks, completes stage adapter manufacturing, and test fires the second booster qualification motor. This paper will discuss the program's key accomplishments to date and the challenging work ahead for what will be the world's most capable launch vehicle.

Honeycutt, John↗

Thermal Analysis of the MC-1 Chamber/Nozzle

This paper will describe the thermal analysis techniques used to predict temperatures in the film-cooled ablative rocket nozzle used on the MC-1 60K rocket engine. A model was developed that predicts char and pyrolysis depths, liner thermal gradients, and temperatures of the bondline between the overwrap and liner. Correlation of the model was accomplished by thermal analog tests performed at Southern Research, and specially instrumented hot fire tests at the Marshall Space Flight Center. Infrared thermography was instrumental in defining nozzle hot wall surface temperatures. In-depth and outboard thermocouple data was used to correlate the kinetic decomposition routine used to predict char and pyrolysis depths. These depths were anchored with measured char and pyrolysis depths from cross-sectioned hot-fire nozzles. For the X-34 flight analysis, the model includes the ablative Thermal Protection System (TPS) material that protects the overwrap from the recirculating plume. Results from model correlation, hot-fire testing, and flight predictions will be discussed.

Davis, Darrell W.↗

Thermal Analysis of the Fastrac Chamber/Nozzle

This paper will describe the thermal analysis techniques used to predict temperatures in the film-cooled ablative rocket nozzle used on the Fastrac 60K rocket engine. A model was developed that predicts char and pyrolysis depths, liner thermal gradients, and temperatures of the bondline between the overwrap and liner. Correlation of the model was accomplished by thermal analog tests performed at Southern Research, and specially instrumented hot fire tests at the Marshall Space Flight Center. Infrared thermography was instrumental in defining nozzle hot wall surface temperatures. In-depth and outboard thermocouple data was used to correlate the kinetic decomposition routine used to predict char and pyrolysis depths. These depths were anchored with measured char and pyrolysis depths from cross-sectioned hot-fire nozzles. For the X-34 flight analysis, the model includes the ablative Thermal Protection System (TPS) material that protects the overwrap from the recirculating plume. Results from model correlation, hot-fire testing, and flight predictions will be discussed.

Davis, Darrell↗

NASA's Space Launch System: Development and Progress

NASA is embarked on a new era of space exploration that will lead to new capabilities, new destinations, and new discoveries by both human and robotic explorers. Today, the International Space Station (ISS), supported by NASA's commercial partners, and robotic probes, are yielding knowledge that will help make this exploration possible. NASA is developing both the Orion crew vehicle and the Space Launch System (SLS) that will carry out a series of increasingly challenging missions that will eventually lead to human exploration of Mars. This paper will discuss the development and progress on the SLS. The SLS architecture was designed to be safe, affordable, and sustainable. The current configuration is the result of literally thousands of trade studies involving cost, performance, mission requirements, and other metrics. The initial configuration of SLS, designated Block 1, will launch a minimum of 70 metric tons (t) into low Earth orbit - significantly greater capability than any current launch vehicle. It is designed to evolve to a capability of 130 t through the use of upgraded main engines, advanced boosters, and a new upper stage. With more payload mass and volume capability than any rocket in history, SLS offers mission planners larger payloads, faster trip times, simpler design, shorter design cycles, and greater opportunity for mission success. Since the program was officially created in fall 2011, it has made significant progress toward first launch readiness of the Block 1 vehicle in 2018. Every major element of SLS continued to make significant progress in 2015. The Boosters element fired Qualification Motor 1 (QM-1) in March 2015, to test the 5-segment motor, including new insulation, joint, and propellant grain designs. The Stages element marked the completion of more than 70 major components of test article and flight core stage tanks. The Liquid Engines element conducted seven test firings of an RS-25 engine under SLS conditions. The Spacecraft/Payload Integration and Evolution element marked completion of the upper stage test article. Major work continues in 2016 as the program continues both flight and development RS-25 engine testing, begins welding test article and flight core stage tanks, completes stage adapter manufacturing, and test fires the second booster qualification motor. This paper will discuss the program's key accomplishments to date and the challenging work ahead for what will be the world's most capable launch vehicle.

Honeycutt, John↗

Spacecraft Fire Safety

Fire detection, fire standards and testing, fire extinguishment, inerting and atmospheres, fire-related medical science, aircraft fire safety, Space Station safety concerns, microgravity combustion, spacecraft material flammability testing, and metal combustion are among the topics considered.

Margle, Janice M.↗

The 260: The Largest Solid Rocket Motor Ever Tested

Aerojet in the mid 1960s, under contract to NASA, built and static hot fire tested the largest solid rocket motor (SRM) in history for the purpose of demonstrating the feasibility of utilizing large SRMs for space exploration. This program successfully fabricated two high strength steel chambers, loaded each with approximately 1,68 million pounds of propellant, and static test fired these giants with their nozzles up from an underground silo located adjacent to the Florida everglades. Maximum thrust and total impulse in excess of 5,000,000 lbf and 3,470,000,000 lbf-sec were achieved. Flames from the second firing, conducted at night, were seen over eighty miles away. For comparative purposes: the thrust developed was nearly 100 times that of a Minuteman III second stage and the 260 in.-dia cross-section was over 3 times that of the Space Shuttle SRM.

Crimmins, P.↗

In-Space Engine (ISE-100) Development - Design Verification Test

In the past decade, NASA has formulated science mission concepts with an anticipation of landing spacecraft on the lunar surface, meteoroids, and other planets. Advancing thruster technology for spacecraft propulsion systems has been considered for maximizing science payload. Starting in 2010, development of In-Space Engine (designated as ISE-100) has been carried out. ISE-100 thruster is designed based on heritage Missile Defense Agency (MDA) technology aimed for a lightweight and efficient system in terms volume and packaging. It runs with a hypergolic bi-propellant system: MON-25 (nitrogen tetroxide, N2O4, with 25% of nitric oxide, NO) and MMH (monomethylhydrazine, CH6N2) for NASA spacecraft applications. The utilization of this propellant system will provide a propulsion system capable of operating at wide range of temperatures, from 50 C (122 F) down to -30 C (-22 F) to drastically reduce heater power. The thruster is designed to deliver 100 lb(sub f) of thrust with the capability of a pulse mode operation for a wide range of mission duty cycles (MDCs). Two thrusters were fabricated. As part of the engine development, this test campaign is dedicated for the design verification of the thruster. This presentation will report the efforts of the design verification hot-fire test program of the ISE-100 thruster in collaboration between NASA Marshall Space Flight Center (MSFC) and Aerojet Rocketdyne (AR) test teams. The hot-fire tests were conducted at Advance Mobile Propulsion Test (AMPT) facility in Durango, Colorado, from May 13 to June 10, 2016. This presentation will also provide a summary of key points from the test results.

Trinh, Huu P.↗

Coil-On-Plug Ignition for Oxygen/Methane Liquid Rocket Engines in Thermal-Vacuum Environments

A coil-on-plug ignition system has been developed and tested for Liquid Oxygen (LOX)/liquid methane (LCH4) rocket engines operating in thermal vacuum conditions. The igniters were developed and tested as part of the Integrated Cryogenic Propulsion Test Article (ICPTA), previously tested as part of the Project Morpheus test vehicle. The ICPTA uses an integrated, pressure-fed, cryogenic LOX/LCH4 propulsion system including a reaction control system (RCS) and a main engine. The ICPTA was tested at NASA Glenn Research Center's Plum Brook Station in the Spacecraft Propulsion Research Facility (B-2) under vacuum and thermal vacuum conditions. A coil-on-plug ignition system has been developed to successfully demonstrate ignition reliability at these conditions while preventing corona discharge issues. The ICPTA uses spark plug ignition for both the main engine igniter and the RCS. The coil-on-plug configuration eliminates the conventional high-voltage spark plug cable by combining the coil and the spark plug into a single component. Prior to ICPTA testing at Plum Brook, component-level reaction control engine (RCE) and main engine igniter testing was conducted at NASA Johnson Space Center (JSC), which demonstrated successful hot-fire ignition using the coil-on-plug from sea-level ambient conditions down to 10(exp -2) torr. Integrated vehicle hot-fire testing at JSC demonstrated electrical and command/data system performance. Lastly, hot-fire testing at Plum Brook demonstrated successful ignitions at simulated altitude conditions at 30 torr and cold thermal-vacuum conditions at 6 torr. The test campaign successfully proved that coil-on-plug technology will enable integrated LOX/LCH4 propulsion systems in future spacecraft.

Melcher, John C.↗

Design, Instrumentation, and Data Analysis for the SLS Core Stage Green Run Test Series

The Space Launch System (SLS) Core Stage (CS) Thrust Vector Control (TVC) system is comprised of eight mechanical feedback Shuttle heritage Type III TVC actuators and four RS-25 engines, each attached to a Shuttle heritage gimbal block/bearing. The actuators are powered by a Shuttle-derived hydraulic Core Auxiliary Power Unit (CAPU), and integrated with an all-new Core Stage thrust structure. The actuators are interfaced to the SLS Vehicle Management (VM) software via an all-new TVC Actuator Control (TAC) avionics subsystem. Despite the significant test and flight experience of the Shuttle hardware, the SLS Green Run ambient and hot fire test activities revealed a number of new findings associated with the dynamic response of the TVC integrated system. Test responses suggested that the TVC system did not meet its performance specifications and its step and frequency responses exhibited unexpected departures from prior lab tests and modeled behavior. This paper is the fifth installment in a seven-paper series surveying the design, engineering, test validation, and flight performance of the Core Stage Thrust Vector Control system. In this paper, the design of the TVC analyses conducted during the Core Stage Green Run test series are discussed in detail. Throughout the course of the test activities, the SLS flight control team worked diligently with the Core Stage contractor to revise test command profiles and ensure sufficient instrumentation was available to collect data. Post-test analysis combined the Green Run modal, ambient, and hot fire test data, MSFC 2- axis Core Stage TVC Inertial Load Simulator (ILS) data, Hardware-In-the-Loop (HWIL) Systems Integration Lab (SIL) results, and actuator Acceptance Testing Procedure (ATP) responses. These data were used to characterize the response, validate critical math models of the TVC subsystem, and isolate the probable cause of the unexpected responses. Through comprehensive analysis of the available test data sources, the integrated team identified the dominant contributors to the observed response and developed test-correlated rationale for vehicle flight control system performance, ultimately leading to a confident posture for the Artemis I mission.

John H. Wall↗

Robust Low Cost Liquid Rocket Combustion Chamber by Advanced Vacuum Plasma Process

Next-generation, regeneratively cooled rocket engines require materials that can meet high temperatures while resisting the corrosive oxidation-reduction reaction of combustion known as blanching, the main cause of engine failure. A project was initiated at NASA-Marshal Space Flight Center (MSFC) to combine three existing technologies to build and demonstrate an advanced liquid rocket engine combustion chamber that would provide a 100 mission life. Technology developed in microgravity research to build cartridges for space furnaces was utilized to vacuum plasma spray (VPS) a functional gradient coating on the hot wall of the combustion liner as one continuous operation, eliminating any bondline between the coating and the liner. The coating was NiCrAlY, developed previously as durable protective coatings on space shuttle high pressure fuel turbopump (HPFTP) turbine blades. A thermal model showed that 0.03 in. NiCrAlY applied to the hot wall of the combustion liner would reduce the hot wall temperature 200 F, a 20% reduction, for longer life. Cu-8Cr-4Nb alloy, which was developed by NASA-Glenn Research Center (GRC), and which possesses excellent high temperature strength, creep resistance, and low cycle fatigue behavior combined with exceptional thermal stability, was utilized as the liner material in place of NARloy-Z. The Cu-8Cr-4Nb material exhibits better mechanical properties at 650 C (1200 F) than NARloy-Z does at 538 C (1000 F). VPS formed Cu-8Cr-4Nb combustion chamber liners with a protective NiCrAlY functional gradient coating have been hot fire tested, successfully demonstrating a durable coating for the first time. Hot fire tests along with tensile and low cycle fatigue properties of the VPS formed combustion chamber liners and witness panel specimens are discussed.

Holmes, Richard↗

Test results from a simple, low-cost, pressure-fed liquid hydrogen/liquid oxygen rocket combustor

A simple, low-cost rocket engine was designed, fabricated, and successfully hot fire tested over a wide range of interface conditions and operating parameters. The engine used low enthalpy hydrogen (45 to 70 R, 200 to 390 psia) and oxygen (139 to 163 R, 210 to 480 psia) propellants pressure-fed directly from facility cryogenic tanks. The engine demonstrated excellent performance, with 97% average combustion efficiency, and absence of combustion instabilities. Engine design chamber pressure was 300 psia, yielding about 16,500 pounds thrust at sea level with a 3:1 expansion ration test nozzle. The engine used a fixed-element injector based on TRW's unique coaxial pintle design, but was operated at 60%, 80%, and 100% thrust levels by throttling facility propellant valves. The engine was tested at propellant mixture ratios (O/F) from 5.8 to 8.4; design O/F was 6.6. To document combustion stability, in five tests RDX explosive pulse guns were detonated in radial and tangential directions across the combustion chamber during steady-state operation. The largest disturbance consisted of simultaneous detonation of a 20-grain radial gun and a 40-grain tangential gun. In no case was an instability, either feed system mode or chamber acoustic mode, excited. High-frequency piezoelectric pressure transducers documented stable recovery from disturbance overpressures within 40 milliseconds of peak pressure. A total of 67 firing tests, accumulating 149 seconds of firing time above 10% P(sub c), were performed. Since parametric testing required run durations of only 2 to 3 seconds, a heat sink combustion chamber was employed for most runs. To evaluate the feasibility of a low-cost ablative system for a flight engine design, one 20-second continuous firing was conducted with a silicone rubber chamber/throat/nozzle liner cast in one piece directly into the engine. The ablative engine operated at the equivalent of 309 seconds sea level specific impulse, when adjusted to a 98% efficient 6:1 expansion ration nozzle, and 430 seconds vacuum specific impulse, when adjusted to a 98% efficient 50:1 expansion ratio nozzle. This engine and test series represent an initial subscale demonstration of a new booster-class engine that eliminates the cost and complexity associated with regenerative cooling and typical engine cycles. This paper presents a description of the engine design and discussion and summary data plots of the performance measured during the parametric testing.

Dressler, G. A.↗

LOX/Hydrocarbon Combustion Instability Investigation

The LOX/Hydrocarbon Combustion Instability Investigation Program was structured to determine if the use of light hydrocarbon combustion fuels with liquid oxygen (LOX) produces combustion performance and stability behavior similar to the LOX/hydrogen propellant combination. In particular methane was investigated to determine if that fuel can be rated for combustion instability using the same techniques as previously used for LOX/hydrogen. These techniques included fuel temperature ramping and stability bomb tests. The hot fire program probed the combustion behavior of methane from ambient to subambient temperatures. Very interesting results were obtained from this program that have potential importance to future LOX/methane development programs. A very thorough and carefully reasoned documentation of the experimental data obtained is contained. The hot fire test logic and the associated tests are discussed. Subscale performance and stability rating testing was accomplished using 40,000 lb. thrust class hardware. Stability rating tests used both bombs and fuel temperature ramping techniques. The test program was successful in generating data for the evaluation of the methane stability characteristics relative to hydrogen and to anchor stability models. Data correlations, performance analysis, stability analyses, and key stability margin enhancement parameters are discussed.

Jensen, R. J.↗

Launching to the Moon, Mars, and Beyond

America is returning to the Moon in preparation for the first human footprint on Mars, guided by the U.S. Vision for Space Exploration. This presentation will discuss NASA's mission today, the reasons for returning to the Moon and going to Mars, and how NASA will accomplish that mission. The primary goals of the Vision for Space Exploration are to finish the International Space Station, retire the Space Shuttle, and build the new spacecraft needed to return people to the Moon and go to Mars. Unlike the Apollo program of the 1960s, this phase of exploration will be a journey, not a race. In 1966, the NASA's budget was 4 percent of federal spending. Today, with 6/10 of 1 percent of the budget, NASA must incrementally develop the vehicles, infrastructure, technology, and organization to accomplish this goal. Fortunately, our knowledge and experience are greater than they were 40 years ago. NASA's goal is a return to the Moon by 2020. The Moon is the first step to America's exploration of Mars. Many questions about the Moon's history and how its history is linked to that of Earth remain even after the brief Apollo explorations of the 1960s and 1970s. This new venture will carry more explorers to more diverse landing sites with more capable tools and equipment. The Moon also will serve as a training ground in several respects before embarking on the longer, more perilous trip to Mars. The journeys to the Moon and Mars will require a variety of vehicles, including the Ares I Crew Launch Vehicle, the Ares V Cargo Launch Vehicle, the Orion Crew Exploration Vehicle, and the Lunar Surface Access Module. The architecture for the lunar missions will use one launch to ferry the crew into orbit on the Ares I and a second launch to orbit the lunar lander and the Earth Departure Stage to send the lander and crew vehicle to the Moon. In order to reach the Moon and Mars within a lifetime and within budget, NASA is building on proven hardware and decades of experience derived from the Apollo Saturn, Space Shuttle, and contemporary commercial launch vehicle programs. Less than one year after the Exploration Launch Projects Office was formed at NASA's Marshall Space Flight Center, engineers are testing engine components, firing test rocket motors, refining vehicle designs in wind tunnel tests, and building hardware for the first flight test of Ares I, scheduled for spring 2009. The Vision for Exploration will require this nation to develop tools, machines, materials, and processes never before invented, technologies and capabilities that can be turned over to the private sector to benefit nearly all aspects of life on Earth. This new pioneering venture, as did the Apollo Program before it, will contribute to America's economic leadership, national security, and technological global competitiveness and serve as an inspiration for all its citizens.

Sumrall, John P.↗

Portable light source unit for simulating fires having an adjustable aperture

A portable, hand held light source unit is employed to check operation of fire detectors, such as hydrogen fire detectors. The unit emits radiation in a narrow band of wavelengths which are generated by the type of fire to be tested, but not by other light sources such as the sun or incandescent lamps. The unit can test fire detectors at different distances, and of different sensitivities. The intensity of the radiation emitted by the unit is adjustable for this purpose by means of a rotatable disk having a plurality of different sized apertures for selective placement between the light source and an output lens. The disk can also be rotated to a calibration position which causes a microprocessor circuit in the unit to initiate a calibration procedure. During this procedure, the lamp intensity is measured by a photodetector contained within the unit, and the microprocessor adjusts the lamp current to insure that its intensity remains within a preset range of values. A green and a red LED are mounted on the unit which indicate to an operator whether the calibration is successful, as well as the condition of the unit's battery power supply.

Youngquist, Robert C.↗

Engine Gimbal Requirements for Ground Testing of J-2X

Based on the Apollo-era J-2 that powered the second and third stages of the Saturn V, the current J-2X is the liquid hydrogen and oxygen high-altitude rocket engine in development for both the Ares I Upper Stage and Ares V Earth Departure Stage. During my summer 2009 internship, J-2X was at a stage in its design maturity where verification testing needed to be considered for the benefit of adequate test facility preparation. My task was to focus on gimbal requirements and gimbal related hot-fire test plans. Facility capabilities were also of interest, specifically for hot-fire testing slated to occur at test stands A-1, A-2, and A-3 at Stennis Space Center(SSC) in Bay St. Louis, Mississippi. Gimbal requirements and stage interface conditions were investigated by applying a top-to-bottom systems engineering approach, which involved system level requirements, engine level requirements from both government and engine contractor perspectives, component level requirements, and the J-2X to Upper Stage and Earth Departure Stage interface control documents. Previous hydrogen and oxygen liquid rocket engine gimbal verification methods were researched for a glimpse at lessons learned. Discussion among the J-2X community affected by gimballing was organized to obtain input relative to proper verification of their respective component. Implementing suggestions such as gimbal pattern, angulated dwell time, altitude testing options, power level, and feed line orientation, I was able to match tests to test stands in the A Complex at SSC. Potential test capability gaps and risks were identified and pursued. The culmination of all these efforts was to coordinate with SSC to define additional facility requirements for both the A-3 altitude test stand that is currently under construction and the A-1 sea level test stand which is being renovated

Kovalcik, Julia↗

Advancement of Extreme Environment Additively Manufactured Alloys for Next Generation Space Propulsion Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into propulsion development and flight applications. NASA matured commonly used aerospace alloys from various alloy families (Nickel, Copper, Stainless and Steel, Aluminum, and Titanium-based) through detailed AM process and heat treatment characterization, in addition to mechanical and thermophysical testing. While these alloys are actively used in many propulsion applications, there is a need for ongoing AM optimized alloys using integrated computational materials engineering (ICME) and process development for high performance applications. The applications targeted are liquid rocket engines; advanced propulsion systems; and in-space propulsion with high heat fluxes, high pressure, and/or that use propellants that can degrade alloys (e.g., hydrogen). This paper highlights the characterization and physical properties of the more common AM alloys using laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Additionally, this paper discusses some of the ongoing novel alloy development and maturation using AM for use in these harsh environments, such as GRCop42, GRCop-84, NASA HR-1, GRX-810, and C-103. The results from these processes demonstrated that AM could enable rapid development and ongoing efforts for optimized alloys using ICME, yielding higher performances. These alloys have undergone modeling, fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing campaigns. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL) through high duty-cycle testing. A background and overview of these novel AM-enabled alloys and AM processing developments including metallurgical and mechanical property studies is presented here. The latest advancement in the parallel component development and hot-fire testing and future developments for these alloys is also discussed.

Additive Manufacturing↗