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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.

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At least 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
NASA NTRS1993

VLF wave growth from dispersive bursts of field-aligned electron fluxes

Large-amplitude electrostatic whistler waves near the lower hybrid frequency were observed by an auroral sounding rocket during substorm breakup. The measured wavelengths indicate that the emissions were electrostatic and resonant with electrons that had parallel energies of a few hundred electron volts. We propose that the intense emissions drew their energy from dispersive bursts of low-energy, field-aligned electron fluxes. The dispersive bursts are known to cause a brief, but intense instability that results in large-amplitude Langmuir emissions. The high-frequency emissions can rapidly form a plateau in the one-dimensional electron distribution. We show, however, that these distributions remain unstable to electrostatic whistler waves near the lower hybrid frequency. The amplitude and wavelength of the observed emissions were sufficient to accelerate the hydrogen ions with energies between about 50 eV and about 200 eV.

Ergun, R. E.↗
NASA NTRS2014

A Crewed Mission to Apophis Using a Hybrid Bimodal Nuclear Thermal Electric Propulsion (BNTEP) System

A BNTEP system is a dual propellant, hybrid propulsion concept that utilizes Bimodal Nuclear Thermal Rocket (BNTR) propulsion during high thrust operations, providing 10's of kilo-Newtons of thrust per engine at a high specific impulse (Isp) of 900 s, and an Electric Propulsion (EP) system during low thrust operations at even higher Isp of around 3000 s. Electrical power for the EP system is provided by the BNTR engines in combination with a Brayton Power Conversion (BPC) closed loop system, which can provide electrical power on the order of 100's of kWe. High thrust BNTR operation uses liquid hydrogen (LH2) as reactor coolant propellant expelled out a nozzle, while low thrust EP uses high pressure xenon expelled by an electric grid. By utilizing an optimized combination of low and high thrust propulsion, significant mass savings over a conventional NTR vehicle can be realized. Low thrust mission events, such as midcourse corrections (MCC), tank settling burns, some reaction control system (RCS) burns, and even a small portion at the end of the departure burn can be performed with EP. Crewed and robotic deep space missions to a near Earth asteroid (NEA) are best suited for this hybrid propulsion approach. For these mission scenarios, the Earth return V is typically small enough that EP alone is sufficient. A crewed mission to the NEA Apophis in the year 2028 with an expendable BNTEP transfer vehicle is presented. Assembly operations, launch element masses, and other key characteristics of the vehicle are described. A comparison with a conventional NTR vehicle performing the same mission is also provided. Finally, reusability of the BNTEP transfer vehicle is explored.

Electric Propulsion↗
NASA NTRS1995

The limitation and applicability of Musher-Sturman equation to two dimensional lower hybrid wave collapse

The existence of localized regions of intense lower hybrid waves in the auroral ionosphere recently observed by rocket and satellite experiments can be understood by the study of a non-linear two-timescale coupling process. In this Letter, we demonstrate that the leading non-linear term in the standard Musher-Sturman equation vanishes identically in strict two-dimensions (normal to the magnetic field). Instead, the new two-dimensional equation is characterized by a much weaker non-linear term which arises from the ponderomotive force perpendicular to the magnetic field, particularly that due to the ions. The old and new equations are compared by means of time-evolution calculations of wave fields. The results exhibit a remarkable difference in the evolution of the waves as governed by the two equations. Such dissimilar outcomes motivate our investigation of the limitation of Musher-Sturman equation in quasi-two-dimensions. Only within all these limits can Musher-Sturman equation adequately describe the collapse of lower hybrid waves.

Tam, Sunny W. Y.↗
NASA NTRS1992

Application of composite materials to impact-insensitive munitions

An approach is outlined for developing bullet-impact-insensitive munitions based on composite materials that provide rapid venting of the rocket-motor case. Impact experiments are conducted with test specimens of hybrid laminates of graphite/epoxy and epoxy reinforcing with woven glass fibers. The dynamic strain response and initial impact force are measured with strain gauges, and perforation damage is examined in the plates. The results show that impact damage can be designed by means of parametric variations of the fiber, matrix, and ply orientations. It is suggested that rocket-motor cases can be designed with composite materials to provide rapid venting during the failure mode. The experimental ballistic testing performed provides data that can be used comparatively with analytical data on composite materials.

Neradka, Vincent F.↗
NASA NTRS2002

Innovative Airbreathing Propulsion Concepts for High-speed Applications

The current cost to launch payloads to low earth orbit (LEO) is approximately loo00 U.S. dollars ($) per pound ($22000 per kilogram). This high cost limits our ability to pursue space science and hinders the development of new markets and a productive space enterprise. This enterprise includes NASA's space launch needs and those of industry, universities, the military, and other U.S. government agencies. NASA's Advanced Space Transportation Program (ASTP) proposes a vision of the future where space travel is as routine as in today's commercial air transportation systems. Dramatically lower launch costs will be required to make this vision a reality. In order to provide more affordable access to space, NASA has established new goals in its Aeronautics and Space Transportation plan. These goals target a reduction in the cost of launching payloads to LEO to $lo00 per pound ($2200 per kilogram) by 2007 and to $100'~ per pound by 2025 while increasing safety by orders of magnitude. Several programs within NASA are addressing innovative propulsion systems that offer potential for reducing launch costs. Various air-breathing propulsion systems currently are being investigated under these programs. The NASA Aerospace Propulsion and Power Base Research and Technology Program supports long-term fundamental research and is managed at GLenn Research Center. Currently funded areas relevant to space transportation include hybrid hyperspeed propulsion (HHP) and pulse detonation engine (PDE) research. The HHP Program currently is addressing rocket-based combined cycle and turbine-based combined cycle systems. The PDE research program has the goal of demonstrating the feasibility of PDE-based hybrid-cycle and combined cycle propulsion systems that meet NASA's aviation and access-to-space goals. The ASTP also is part of the Base Research and Technology Program and is managed at the Marshall Space Flight Center. As technologies developed under the Aerospace Propulsion and Power Base Research and Technology Program mature, they are incorporated into ASTP. One example of this is rocket-based combined cycle systems that are being considered as part of ASTP. The NASA Ultra Efficient Engine Technology (UEET) Program has the goal of developing propulsion system component technology that is relevant to a wide range of vehicle missions. In addition to subsonic and supersonic speed regimes, it includes the hypersonic speed regime. More specifically, component technologies for turbine-based combined cycle engines are being developed as part of UEET.

Whitlow, Woodrow, Jr.↗
NASA NTRS2011

NASA Tech Briefs, January 2011

The topics include: 1) Distributed Aerodynamic Sensing and Processing Toolbox; 2) Collaborative Supervised Learning for Sensor Networks; 3) Hazard Detection Software for Lunar Landing; 4) Onboard Nonlinear Engine Sensor and Component Fault Diagnosis and Isolation Scheme; 5) Network-Capable Application Process and Wireless Intelligent Sensors for ISHM; 6) Interface Supports Multiple Broadcast Transceivers for Flight Applications; 7) FPGA Sequencer for Radar Altimeter Applications; 8) Miniature Sapphire Acoustic Resonator - MSAR; 9) Process-Hardened, Multi-Analyte Sensor for Characterizing Rocket Plume Constituents; 10) SAD5 Stereo Correlation Line-Striping in an FPGA; 11) Hybrid Composite Cryogenic Tank Structure; 12) Nanoscale Deformable Optics; 13) Reliability-Based Design Optimization of a Composite Airframe Component; 14) Zinc Oxide Nanowire Interphase for Enhanced Lightweight Polymer Fiber Composites; 15) Plasma Igniter for Reliable Ignition of Combustion in Rocket Engines; 16) Wire Test Grip Fixture; 17) A Sub-Hertz, Low-Frequency Vibration Isolation Platform; 18) Carbon Nanofibers Synthesized on Selective Substrates for Nonvolatile Memory and 3D Electronics; 19) Nanoparticle/Polymer Nanocomposite Bond Coat or Coating; 20) High-Resolution Wind Measurements for Offshore Wind Energy Development; 21) Spring Tire; 22) Marsviewer 2008; 23) Mission Services Evolution Center Message Bus; 24) Major Constituents Analysis for the Vehicle Cabin Atmosphere Monitor; 25) Astronaut Health Participant Summary Application; 26) Adaption of the AMDIS Method to Flight Status on the VCAM Instrument; 27) Natural Language Interface for Safety Certification of Safety-Critical Software; 28) Cryogenic Caging for Science Instrumentation; 29) Wide-Range Neutron Detector for Space Nuclear Applications; 30) In Situ Guided Wave Structural Health Monitoring System; 31) Multiplexed Energy Coupler for Rotating Equipment; 32) Attitude Estimation in Fractionated Spacecraft Cluster Systems; 33) Full Piezoelectric Multilayer-Stacked Hybrid Actuation/Transduction Systems; 34) Active Flow Effectors for Noise and Separation Control; 35) Method and System for Temporal Filtering in Video Compression Systems; 36) Apparatus for Measuring Total Emissivity of Small, Low-Emissivity Samples; 37) Multiple-Zone Diffractive Optic Element for Laser Ranging Applications; 38) Simplified Architecture for Precise Aiming of a Deep-Space Communication Laser Transceiver; 39) Two-Photon-Absorption Scheme for Optical Beam Tracking; 40) High-Sensitivity, Broad-Range Vacuum Gauge Using Nanotubes for Micromachined Cavities; 41) Wide-Field Optic for Autonomous Acquisition of Laser Link; 42) Extracting Zero-Gravity Surface Figure of a Mirror; 43) Modeling Electromagnetic Scattering From Complex Inhomogeneous Objects; 44) Visual Object Recognition and Tracking of Tools; 45) Method for Implementing Optical Phase Adjustment; 46) Visual SLAM Using Variance Grid Maps; 47) Rapid Calculation of Spacecraft Trajectories Using Efficient Taylor Series Integration; 48) Efficient Kriging Algorithms; 49) Predicting Spacecraft Trajectories by the WeavEncke Method; 50) An Augmentation of G-Guidance Algorithms; 51) Comparison of Aircraft Icing Growth Assessment Software; 52) Silicon-Germanium Voltage-Controlled Oscillator at 105 GHz; 53) Estimation of Coriolis Force and Torque Acting on Ares-1; 54) Null Lens Assembly for X-Ray Mirror Segments; and 55) High-Precision Pulse Generator.

Source record↗
NASA NTRS2004

Wavelength-Agile Optical Sensor for Exhaust Plume and Cryogenic Fluid Interrogation

Two optical sensors developed in UW-Madison labs were evaluated for their potential to characterize rocket engine exhaust plumes and liquid oxygen (LOX) fluid properties. The plume sensor is based on wavelength-agile absorption spectroscopy A device called a chirped white pulse emitter (CWPE) is used to generate the wavelength agile light, scanning, for example, 1340 - 1560 nm every microsecond. Properties of the gases in the rocket plume (for example temperature and water mole fraction) can be monitored using these wavelength scans. We have performed preliminary tests in static gas cells, a laboratory GOX/GH2 thrust chamber, and a solid-fuel hybrid thrust chamber, and these initial tests demonstrate the potential of the CWPE for monitoring rocket plumes. The LOX sensor uses an alternative to wavelength agile sensing: two independent, fixed-wavelength lasers are combined into a single fiber. One laser is absorbed by LOX and the other not: by monitoring the differential transmission the LOX concentration in cryogenic feed lines can be inferred. The sensor was successful in interrogating static LOX pools in laboratory tests. Even in ice- and bubble-laden cryogenic fluids, LOX concentrations were measured to better than 1% with a 3 microsec time constant.

Sanders, Scott T.↗
NASA NTRS2010

Physics-Based Methods of Failure Analysis and Diagnostics in Human Space Flight

The Integrated Health Management (IHM) for the future aerospace systems requires to interface models of multiple subsystems in an efficient and accurate information environment at the earlier stages of system design. The complexity of modern aeronautic and aircraft systems (including e.g. the power distribution, flight control, solid and liquid motors) dictates employment of hybrid models and high-level reasoners for analysing mixed continuous and discrete information flow involving multiple modes of operation in uncertain environments, unknown state variables, heterogeneous software and hardware components. To provide the information link between key design/performance parameters and high-level reasoners we rely on development of multi-physics performance models, distributed sensors networks, and fault diagnostic and prognostic (FD&P) technologies in close collaboration with system designers. The main challenges of our research are related to the in-flight assessment of the structural stability, engine performance, and trajectory control. The main goal is to develop an intelligent IHM that not only enhances components and system reliability, but also provides a post-flight feedback helping to optimize design of the next generation of aerospace systems. Our efforts are concentrated on several directions of the research. One of the key components of our strategy is an innovative approach to the diagnostics/prognostics based on the real time dynamical inference (DI) technologies extended to encompass hybrid systems with hidden state trajectories. The major investments are into the multiphysics performance modelling that provides an access of the FD&P technologies to the main performance parameters of e.g. solid and liquid rocket motors and composite materials of the nozzle and case. Some of the recent results of our research are discussed in this chapter. We begin by introducing the problem of dynamical inference of stochastic nonlinear models and reviewing earlier results. Next, we present our analytical approach to the solution of this problem based on the path integral formulation. The resulting algorithm does not require an extensive global search for the model parameters, provides optimal compensation for the effects of dynamical noise, and is robust for a broad range of dynamical models. In the following Section the strengths of the algorithm are illustrated illustrated by inferring the parameters of the stochastic Lorenz system and comparing the results with those of earlier research. Next, we discuss a number of recent results in application to the development of the IHM for aerospace system. Firstly, we apply dynamical inference approach to a solution of classical three tank problems with mixed unknown continuous and binary parameters. The problem is considered in the context of ground support system for filling fuel tanks of liquid rocket motors. It is shown that the DI algorithm is well suited for successful solution of a hybrid version of this benchmark problem even in the presence of additional periodic and stochastic perturbation of unknown strength. Secondly, we illustrate our approach by its application to an analysis of the nozzle fault in a solid rocket motor (SRM). The internal ballistics of the SRM is modelled as a set of one-dimensional partial differential equations coupled to the dynamics of the propellant regression. In this example we are specifically focussed on the inference of discrete and continuous parameters of the nozzle blocking fault and on the possibility of an application of the DI algorithm to reducing the probability of "misses" of an on-board FD&P for SRM. In the next section re-contact problem caused by first stage/upper stage separation failure is discussed. The reaction forces imposed on the nozzle of the upper stage during the re-contact and their connection to the nozzle damage and to the thrust vector control (TVC) signal are obtained. It is shown that transient impact induced torquean be modelled as a response of an effective damped oscillator. A possible application of the DI algorithm to the inference of damage parameters and predicting fault dynamics ahead of time using the actuator signal is discussed. Finally, we formulate Bayesian inferential framework for development of the IHM system for in-flight structural health monitoring (SHM) of composite materials. We consider the signal generated by piezoelectric actuator mounted on composite structure generating elastic waves in it. The signal received by the sensor is than compared with the baseline signal. The possibility of damage inference is discussed in the context of development of the SHM.

Smelyanskiy, Vadim N.↗
NASA NTRSDate not supplied

NASA’s Space Launch System: Progress Toward Launch

The Space Launch System (SLS), NASA’s cornerstone launch capability for a new generation of deep space exploration, has begun assembly at Kennedy Space Center (KSC) in preparation for launch in 2021. SLS will provide an unparalleled launch capability for human and robotic deep space exploration missions. Its proven propulsion system, upgrade path to more powerful vehicles, and high-volume payload fairings make it the foundation for ambitious and demanding as part of the Artemis program. Artemis is NASA’s 21st-century plan to put boots on the Moon and to perform sustainable, long-term science in deep space, with eyes toward sending explorers to Mars. The initial SLS vehicle to fly, Block 1 in the crew configuration – with the new Orion spacecraft – is scheduled to lift off from revitalized launch facilities at KSC in 2021 for an uncrewed test flight known as Artemis I. Manufacturing is complete on the vehicle and all elements have been delivered to the Exploration Ground Systems (EGS) Program, except the core stage. The program’s all-new development, the core stage is currently in the midst of a “Green Run” test campaign at Stennis Space Center (SSC). Eight progressively more challenging tests in the Green Run series will culminate in a hot-fire of four flight-proven liquid hydrogen/liquid oxygen (LH2/LOX) RS25 engines. Following the Green Run hotfiring, the core stage will ship to KSC. Already at KSC, aft sections of the fivesegment solid rocket boosters are being assembled. Previously delivered elements, including the upper stage, are undergoing final checkouts in preparation for stacking. An exciting 2021 will include such milestones as stacking SLS and Orion in KSC’s Vehicle Assembly Building (VAB), modal testing, roll out to Launch Pad 39B, Wet Dress Rehearsal (WDR), and launch. Teams across the country are preparing for launch by finalizing procedures, defining launch constraints and flight rules, training console operators, performing simulations, and more. With the SLS Block 1 vehicle for Artemis I nearing integration and launch, the second Block 1 vehicle in the crew configuration, which will carry astronauts on an Artemis II hybrid lunar flyby mission, has several elements manufactured. In fact, the solid rocket motor segments and RS-25 engines are complete. Those program elements are processing hardware for the third flight and working toward manufacturing the second SLS variant to fly, Block 1B, which will onramp a powerful new upper stage, the Exploration Upper Stage (EUS).

John Honeycutt↗
NASA NTRS2015

Additive Manufacturing of Aerospace Propulsion Components

The presentation will provide an overview of ongoing activities on additive manufacturing of aerospace propulsion components, which included rocket propulsion and gas turbine engines. Future opportunities on additive manufacturing of hybrid electric propulsion components will be discussed.

Additive Manufacturing↗
NASA NTRS2016

A Hybrid Mars Ascent Vehicle Design and FY 2016 Technology Development

Hybrid propulsion is currently favored for a Mars Ascent Vehicle (MAV) concept from a thermal performance and Gross Lift Off Mass standpoint. However, it is at a relatively low level of maturity compared to conventional propulsion options. Technology development efforts are currently underway to bring hybrid propulsion to a technology readiness level that would enable its infusion into potential Mars Sample Return. A new propellant combination is being considered for this design that has excellent low temperature behavior. Preliminary results of two ground test campaigns are currently underway to characterize this propellant combination. Hotfire testing is being carried out in parallel at Parabilis Space Technologies and Space Propulsion Group. In addition to the new propellant combination, several other technologies are being pursued for a potential hybrid MAV: hypergolic ignition and Liquid Injection Thrust Vector Control. Both of these technologies have been applied in other rocket applications, e.g. liquid propulsion commonly uses hypergolic propellants and missiles, such as the Minuteman II, have used LITVC in the past. Hypergolic ignition, when oxidizer and fuel combust upon contact, is highly desirable for multiple starts required by the MAV concept. Therefore, testing at Penn State and Purdue is being completed in this area. An updated hybrid propulsion system design for a Mars Ascent Vehicle concept based on JPL’s current understanding of potential Mars Sample Return requirements will be presented, leveraging the advances in technology development as well as updated understanding of how requirements may evolve.

Karp, Ashley C.↗
NASA NTRS1984

Preliminary analysis of space mission applications for electromagnetic launchers

The technical and economic feasibility of using electromagnetically launched EML payloads propelled from the Earth's surface to LEO, GEO, lunar orbit, or to interplanetary space was assessed. Analyses of the designs of rail accelerators and coaxial magnetic accelerators show that each is capable of launching to space payloads of 800 KG or more. A hybrid launcher in which EML is used for the first 2 KM/sec followed by chemical rocket stages was also tested. A cost estimates study shows that one to two EML launches per day are needed to break even, compared to a four-stage rocket. Development models are discussed for: (1) Earth orbital missions; (2) lunar base supply mission; (3) solar system escape mission; (4) Earth escape missions; (5) suborbital missions; (6) electromagnetic boost missions; and (7) space-based missions. Safety factors, environmental impacts, and EML systems analysis are discussed. Alternate systems examined include electrothermal thrustors, an EML rocket gun; an EML theta gun, and Soviet electromagnetic accelerators.

Miller, L. A.↗
NASA NTRS1986

Observations of plasma waves within regions of perpendicular ion acceleration

The acceleration of ionospheric ions transverse to the geomagnetic field by factors of 1000 is believed to be caused by plasma waves. The authors made simultaneous measurements of electric fields and energetic ions within regions of perpendicular ion acceleration from the sounding rocket MARIE. Perpendicular ion acceleration was correlated with plasma waves near and above the lower hybrid frequency. Ions were detected up to energies of 300 eV and the broadband lower hybrid waves reached an amplitude of 10-30 mV/m (RMS) over the frequency band 4-16 kHz. Although electric field amplitudes near the O(+) cyclotron frequency reached a maximum value of 10 mV/m (RMS), there was no spectral evidence of electrostatic ion cyclotron waves associated with ion acceleration. There was spectral evidence of H(+) Bernstein modes near the lower hybrid frequency.

Kintner, P. M.↗
NASA NTRS2012

Low-Cost Phased Array Antenna for Sounding Rockets, Missiles, and Expendable Launch Vehicles

A low-cost beamformer phased array antenna has been developed for expendable launch vehicles, rockets, and missiles. It utilizes a conformal array antenna of ring or individual radiators (design varies depending on application) that is designed to be fed by the recently developed hybrid electrical/mechanical (vendor-supplied) phased array beamformer. The combination of these new array antennas and the hybrid beamformer results in a conformal phased array antenna that has significantly higher gain than traditional omni antennas, and costs an order of magnitude or more less than traditional phased array designs. Existing omnidirectional antennas for sounding rockets, missiles, and expendable launch vehicles (ELVs) do not have sufficient gain to support the required communication data rates via the space network. Missiles and smaller ELVs are often stabilized in flight by a fast (i.e. 4 Hz) roll rate. This fast roll rate, combined with vehicle attitude changes, greatly increases the complexity of the high-gain antenna beam-tracking problem. Phased arrays for larger ELVs with roll control are prohibitively expensive. Prior techniques involved a traditional fully electronic phased array solution, combined with highly complex and very fast inertial measurement unit phased array beamformers. The functional operation of this phased array is substantially different from traditional phased arrays in that it uses a hybrid electrical/mechanical beamformer that creates the relative time delays for steering the antenna beam via a small physical movement of variable delay lines. This movement is controlled via an innovative antenna control unit that accesses an internal measurement unit for vehicle attitude information, computes a beam-pointing angle to the target, then points the beam via a stepper motor controller. The stepper motor on the beamformer controls the beamformer variable delay lines that apply the appropriate time delays to the individual array elements to properly steer the beam. The array of phased ring radiators is unique in that it provides improved gain for a small rocket or missile that uses spin stabilization for stability. The antenna pattern created is symmetric about the roll axis (like an omnidirectional wraparound), and is thus capable of providing continuous coverage that is compatible with very fast spinning rockets. For larger ELVs with roll control, a linear array of elements can be used for the 1D scanned beamformer and phased array, or a 2D scanned beamformer can be used with an NxN element array.

Mullinix, Daniel↗
NASA NTRS2003

Techniques for the Installation of Internal Fiber Optic Instrumentation on an 11-Inch Hybrid Motor Test Bed

The recent developments in Fabry-Perot fiber optic instruments have resulted in accurate transducers with some of the physical characteristics required for use in obtaining internal data from solid rocket motors. These characteristics include small size, non-electrical excitation, and immunity to electro-magnetic interference. These transducers have not been previously utilized in this environment due to the high temperatures typically encountered. A series of tests were conducted using a 1 1-Inch Hybrid test bed to develop installation techniques that will allow the fiber optic instruments to survive and obtain data for a short period of time following the motor ignition. The installation methods developed during this test series have the potential to allow data to be acquired in the motor chamber, propellant bore, and nozzle during the ignition transient. These measurements would prove to be very useful in the characterization of current motor designs and provide insight into the requirements for further refinements. The process of developing these protective methods and the installation techniques used to apply them is summarized.

Cornelius, Michael↗
NASA NTRS2019

Additive Manufacturing and Hot-Fire Testing of Bimetallic GRCop-84 and C-18150 Channel-Cooled Combustion Chambers Using Powder Bed Fusion and Inconel 625 Hybrid Directed Energy Deposition

Additive manufacturing (AM) is an advanced fabrication technique that is demonstrating tremendous potential to reduce fabrication lead times and costs for liquid rocket engine components. The additive manufacturing technology lends itself to fabricate components with complex features such as internal coolant channels in combustion chambers that would otherwise require complex manufacturing operations. A requirement for high performance engines is to use high conductivity, high strength materials such as copper-alloys for combustion chamber liners to provide adequate wall temperatures and meet subsequent structural margins. A further requirement of this configuration is to minimize weight by defining and fabricating material in discrete locations as required. NASA and Industry partner, Virgin Orbit, have been working to advance these technologies through development of bimetallic additive manufacturing techniques under a public-private partnership through NASA’s Announcement of Collaborative Opportunity (ACO). This partnership is advancing a bimetallic hybrid additively manufactured combustion chamber that integrates Powder Bed Fusion (PBF), specifically Selective Laser Melting (SLM), and Directed Energy Deposition (DED) blown powder techniques to optimize the chamber materials and subsequent assembly. The SLM process is being developed for the combustion chamber liner to use copper-alloys GRCop-84 (Copper-Chrome-Niobium) or C-18150 (Copper-Chrome-Zirconium). The hybrid DED blown powder technology is used to apply an integrated structural jacket and manifolds using an Inconel 625 superalloy on the outer surface of the SLM copper liner. The hybrid DED technology being used on this program is a DMG Mori Seiki AM machining center which integrates the DED blown powder with an integral subtractive (traditional) machining to minimize overall setups. A series of chambers were fabricated using these techniques with GRCop-84/Inconel 625 and C-18150/Inconel and hot-fire tested at NASA Marshall Space Flight Center (MSFC) in LOX/Kerosene (RP-1). This paper describes the process development to integrate these AM technologies into an integrated bimetallic assembly, the design of the chamber, results from hot-fire testing, and further development.

Gradl, Paul R.↗
NASA NTRS2019

Additive Manufacturing and Hot-fire Testing of Bimetallic GRCop-84 and C-18150 Channel-Cooled Combustion Chambers using Powder Bed Fusion and Inconel 625 Hybrid Directed Energy Deposition

Additive manufacturing (AM) is an advanced fabrication technique that is demonstrating tremendous potential to reduce fabrication lead times and costs for liquid rocket engine components. The additive manufacturing technology lends itself to fabricate components with complex features such as internal coolant channels in combustion chambers that would otherwise require complex manufacturing operations. A requirement for high performance engines is to use high conductivity, high strength materials such as copper-alloys for combustion chamber liners to provide adequate wall temperatures and meet subsequent structural margins. A further requirement of this configuration is to minimize weight by defining and fabricating material in discrete locations as required. NASA and Industry partner, Virgin Orbit, have been working to advance these technologies through development of bimetallic additive manufacturing techniques under a public-private partnership through NASA’s Announcement of Collaborative Opportunity (ACO). This partnership is advancing a bimetallic hybrid additively manufactured combustion chamber that integrates Powder Bed Fusion (PBF), specifically Selective Laser Melting (SLM), and Directed Energy Deposition (DED) blown powder techniques to optimize the chamber materials and subsequent assembly. The SLM process is being developed for the combustion chamber liner to use copper-alloys GRCop-84 (Copper-Chrome-Niobium) or C-18150 (Copper-Chrome-Zirconium). The hybrid DED blown powder technology is used to apply an integrated structural jacket and manifolds using an Inconel 625 superalloy on the outer surface of the SLM copper liner. The hybrid DED technology being used on this program is a DMG Mori Seiki AM machining center which integrates the DED blown powder with an integral subtractive (traditional) machining to minimize overall setups. A series of chambers were fabricated using these techniques with GRCop-84/Inconel 625 and C-18150/Inconel and hot-fire tested at NASA Marshall Space Flight Center (MSFC) in LOX/Kerosene (RP-1). This paper describes the process development to integrate these AM technologies into an integrated bimetallic assembly, the design of the chamber, results from hot-fire testing, and further development.

Gradl, Paul↗