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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS2012

Time-Dependent Searches for Point Sources of Neutrinos with the 4O-String and 22-String Configurations of IceCube

This paper presents four searches for flaring sources of neutrinos using the IceCube neutrino telescope. For the first time, a search is performed over the entire parameter space of energy, direction, and time with sensitivity to neutrino flares lasting between 20 micro-s and a year duration from astrophysical sources. Searches that integrate over time are less sensitive to flares because they are affected by a larger background of atmospheric neutrinos and muons that can be reduced by the use of additional timing information. Flaring sources considered here, such as active galactic nuclei, soft gamma-ray repeaters, and gamma-ray bursts, are promising candidate neutrino emitters. Two searches are "untriggered" in the sense that they look for any possible flare in the entire sky and from a predefined catalog of sources from which photon flares have been recorded. The other two searches are triggered by multi-wavelength information on flares from blazars and from a soft gamma-ray repeater. One triggered search uses lightcurves from Fermi-LAT which provides continuous monitoring. A second triggered search uses information where the flux states have been measured only for short periods of time near the flares. The untriggered searches use data taken by 40 strings of IceCube between 2008 April 5 and 2009 May 20. The triggered searches also use data taken by the 22-string configuration of IceCube operating between 2007 May 31 and 2008 April 5. The results from all four searches are compatible with a fluctuation of the background.

Abbasi, R.↗
NASA NTRS2014

Atomic Oxygen Energy in Low Frequency Hyperthermal Plasma Ashers

Experimental and analytical analysis of the atomic oxygen erosion of pyrolytic graphite as well as Monte Carlo computational modeling of the erosion of Kapton H (DuPont, Wilmington, DE) polyimide was performed to determine the hyperthermal energy of low frequency (30 to 35 kHz) plasma ashers operating on air. It was concluded that hyperthermal energies in the range of 0.3 to 0.9 eV are produced in the low frequency air plasmas which results in texturing similar to that in low Earth orbit (LEO). Monte Carlo computational modeling also indicated that such low energy directed ions are fully capable of producing the experimentally observed textured surfaces in low frequency plasmas.

Oxygen atoms↗
NASA NTRS2015

Lunar Cube Transfer Trajectory Options

Numerous Earth-Moon trajectory and lunar orbit options are available for Cubesat missions. Given the limited Cubesat injection infrastructure, transfer trajectories are contingent upon the modification of an initial condition of the injected or deployed orbit. Additionally, these transfers can be restricted by the selection or designs of Cubesat subsystems such as propulsion or communication. Nonetheless, many trajectory options can be considered which have a wide range of transfer durations, fuel requirements, and final destinations. Our investigation of potential trajectories highlights several options including deployment from low Earth orbit (LEO), geostationary transfer orbits (GTO), and higher energy direct lunar transfers and the use of longer duration Earth-Moon dynamical systems. For missions with an intended lunar orbit, much of the design process is spent optimizing a ballistic capture while other science locations such as Sun-Earth libration or heliocentric orbits may simply require a reduced Delta-V imparted at a convenient location along the trajectory.

Libration Orbits↗
NASA NTRS2015

Lunar Cube Transfer Trajectory Options

Numerous Earth-Moon trajectory and lunar orbit options are available for Cubesat missions. Given the limited Cubesat injection infrastructure, transfer trajectories are contingent upon the modification of an initial condition of the injected or deployed orbit. Additionally, these transfers can be restricted by the selection or designs of Cubesat subsystems such as propulsion or communication. Nonetheless, many trajectory options can b e considered which have a wide range of transfer duration, fuel requirements, and final destinations. Our investigation of potential trajectories highlights several options including deployment from low Earth orbit (LEO) geostationary transfer orbits (GTO) and higher energy direct lunar transfer and the use of longer duration Earth-Moon dynamical systems. For missions with an intended lunar orbit, much of the design process is spent optimizing a ballistic capture while other science locations such as Sun-Earth libration or heliocentric orbits may simply require a reduced Delta-V imparted at a convenient location along the trajectory.

Libration Orbits↗
NASA NTRS2016

The Global Precipitation Measurement (GPM) Spacecraft Power System Design and Orbital Performance

The Global Precipitation Measurement (GPM) spacecraft was jointly developed by National Aeronautics and Space Administration (NASA) and Japan Aerospace Exploration Agency (JAXA). It is a Low Earth Orbit (LEO) spacecraft launched on February 27, 2014. The spacecraft is in a circular 400 Km altitude, 65 degrees inclination nadir pointing orbit with a three year basic mission life. The solar array consists of two sun tracking wings with cable wraps. The panels are populated with triple junction cells of nominal 29.5% efficiency. One axis is canted by 52 degrees to provide power to the spacecraft at high beta angles. The power system is a Direct Energy Transfer (DET) system designed to support 1950 Watts orbit average power. The batteries use SONY 18650HC cells and consist of three 8s x 84p batteries operated in parallel as a single battery. The paper describes the power system design details, its performance to date and the lithium ion battery model that was developed for use in the energy balance analysis and is being used to predict the on-orbit health of the battery.

Power System Design and Orbital Performance↗
NASA NTRS2016

Global Precipitation Measurement (GPM) Spacecraft Lithium Ion Battery Micro-Cycling Investigation

The Global Precipitation Measurement (GPM) spacecraft was jointly developed by NASA and JAXA. It is a Low Earth Orbit (LEO) spacecraft launched on February 27, 2014. The power system is a Direct Energy Transfer (DET) system designed to support 1950 watts orbit average power. The batteries use SONY 18650HC cells and consist of three 8s by 84p batteries operated in parallel as a single battery. During instrument integration with the spacecraft, large current transients were observed in the battery. Investigation into the matter traced the cause to the Dual-Frequency Precipitation Radar (DPR) phased array radar which generates cyclical high rate current transients on the spacecraft power bus. The power system electronics interaction with these transients resulted in the current transients in the battery. An accelerated test program was developed to bound the effect, and to assess the impact to the mission.

Lithium Ion Battery Performance↗
NASA NTRS2017

Verification of a Finite Element Model for Pyrolyzing Ablative Materials

Ablating thermal protection system (TPS) materials have been used in many reentering spacecraft and in other applications such as rocket nozzle linings, fire protection materials, and as countermeasures for directed energy weapons. The introduction of the finite element model to the analysis of ablation has arguably resulted in improved computational capabilities due the flexibility and extended applicability of the method, especially to complex geometries. Commercial finite element codes often provide enhanced capability compared to custom, specially written programs based on versatility, usability, pre- and post-processing, grid generation, total life-cycle costs, and speed.

ablating materials↗
NASA NTRS2018

Hybrid Additive Manufacturing Deposition and Selective Laser Melting Techniques Applied to Copper-Alloy Liquid Rocket Engine Combustion Chambers

Virgin Orbit and the NASA Marshall Space Flight Center have partnered to fabricate a small, multi-metallic, regeneratively cooled thrust chamber by leveraging the strengths of two different types of additive manufacturing: Direct Metal Laser Sintering (DMLS) for the copper alloy liner and blown powder Directed Energy Deposition (DED) for the Inconel structural jacket. The DED is being developed using Virgin Orbit's DMG Mori Seiki hybrid additive/subtractive machining center to further enable unique processing and further cost savings. The materials chosen are preferred for high performance thrust chamber applications, representing a significant advancement from the compromises typically made in the production of metal 3D printed thrust chambers for rocket engines. The 1.2K-lbf thrust article is a 16" tall, 3" diameter design modified for this effort to be regeneratively cooled with water and hot fired using a RP-1/LOX pintle-style development injector from Virgin Orbit's NewtonFour upper stage engine. The thrust chamber was tested at Virgin Orbit's Necker test site in Mojave, California. Results from this test campaign are reported in addition to information characterizing the liner, jacket, and bimetallic diffusion layer materials. This paper will also highlight some of the future bimetallic thrust chamber developments that MSFC and Virgin Orbit will complete under a recently awarded NASA contract.

Zagorski, Kevin↗
NASA NTRS2018

Additive Manufacturing of Liquid Rocket Engine Combustion Devices: A Summary of Process Developments and Hot-Fire Testing Results

Additive Manufacturing (AM) of metals is a processing technology that has significantly matured over the last decade. For liquid propellant rocket engines, the advantages of AM for replacing conventional manufacturing of complicated and expensive metallic components and assemblies are very attractive. AM can significantly reduce hardware cost, shorten fabrication schedules, increase reliability by reducing the number of joints, and improve hardware performance by allowing fabrication of designs not feasible by conventional means. The NASA Marshall Space Flight Center (MSFC) has been involved with various forms of metallic additive manufacturing for use in liquid rocket engine component design, development, and testing since 2010. The AM technique most often used at the NASA MSFC has been powder-bed fusion or selective laser melting (SLM), although other techniques including laser directed energy deposition (DED), arc-based deposition, and laser-wire cladding techniques have also been used to develop several components. The purpose of this paper is to discuss the various internal programs at the NASA MSFC using AM to develop combustion devices hardware. To date at the NASA MSFC, combustion devices component hardware ranging in size from 100 lbf to 35,000 lbf have been designed and manufactured using SLM and deposition-based AM processes, and many of these pieces have been hot-fire tested. Combustion devices component hardware have included thrust chamber injectors, injector components such as faceplates, regeneratively-cooled combustion chambers, regeneratively-cooled nozzles, gas generator and preburner hardware, and augmented spark igniters. Ongoing and future developments for combustion devices have also included design of components sized for boost-class engines. Several design and hot-fire test iterations have been completed on these subscale and larger scale components, and a summary of these results will be presented as well.

Gradl, Paul↗
NASA NTRS2018

Low Power Radioisotope Conversion Technology and Performance Summary

This work presents a summary of low-power radioisotope-based power sources. This includes systems that use direct energy conversion from radioactive decay such as betavoltaics and systems that convert heat generated by the isotope decay. These types of power systems have terrestrial and space-based applications. Their main application is to provide low levels of power in remote environments where long life and reliability are the main objectives. This work looked at the potential performance of these types of systems and the range of output power they can achieve. Also considered was the amount of power that could be achieved from these different conversion technologies, while remaining under the critical limit acceptable for space flight without the need for special handling and controls. This is of interest for space missions where low power levels can be used for operating sensors or other devices, but the expense associated with the incorporation of radioactive material above this critical level would be cost prohibitive.

Colozza, Anthony J.↗
NASA NTRS2016

A Roadmap to Interstellar Flight

In the nearly 60 years of spaceflight we have accomplished wonderful feats of exploration that have shown the incredible spirit of the human drive to explore and understand our universe. Yet in those 60 years we have barely left our solar system with the Voyager 1 spacecraft launched in 1977 finally leaving the solar system after 37 years of flight at a speed of 17 km/s or less than 0.006% the speed of light. As remarkable as this is we will never reach even the nearest stars with our current propulsion technology in even 10 millennium. We have to radically rethink our strategy or give up our dreams of reaching the stars, or wait for technology that does not currently exist. While we all dream of human spaceflight to the stars in a way romanticized in books and movies, it is not within our power to do so, nor it is clear that this is the path we should choose. We posit a technological path forward, that while not simple, it is within our technological reach. We propose a roadmap to a program that will lead to sending relativistic probes to the nearest stars and will open up a vast array of possibilities of flight both within our solar system and far beyond. Spacecraft from gram level complete spacecraft on a wafer ("wafersats") that reach more than _ c and reach the nearest star in 20 years to spacecraft with masses more than 105 kg (100 tons) that can reach speeds of greater than 1000 km/s. These systems can be propelled to speeds currently unimaginable with existing propulsion technologies. To do so requires a fundamental change in our thinking of both propulsion and in many cases what a spacecraft is. In addition to larger spacecraft, some capable of transporting humans, we consider functional spacecraft on a wafer, including integrated optical communications, imaging systems, photon thrusters, power and sensors combined with directed energy propulsion. The costs can be amortized over a very large number of missions beyond relativistic spacecraft as such planetary defense, beamed energy for distant spacecraft, sending power back to Earth, stand-off composition analysis of solar system targets, long range laser communications, SETI searches and even terra forming. The human factor of exploring the nearest stars and exo-planets would be a profound voyage for humanity, one whose non-scientific implications would be enormous. It is time to begin this inevitable journey far beyond our home.

Interstellar Flight↗
NASA NTRS2019

Progress in Additively Manufactured Copper-Alloy GRCop-84, GRCop-42, and Bimetallic Combustion Chambers for Liquid Rocket Engines

Additive Manufacturing (AM) has significantly evolved over the last decade for use in the aerospace industry, particularly for liquid rocket engines. AM offers a considerable departure from traditional manufacturing to rapidly fabricate components with complex internal features. High performance liquid rocket engine combustion chambers that operate in a high heat flux environment are fabricated using a copper-alloy liner with a series of integral coolant channels. Copper-alloys provide the necessary conductivity and material strength for adequate design margins offering high performance without the need for film coolant. Copper-alloys present unique challenges to properly melt the powder in laser-based AM processes due to their high reflectivity and conductivity. Starting in 2014, NASA’s Marshall Space Flight Center (MSFC) and Glenn Research Center (GRC) have developed a process for AM of GRCop (Copper- Chrome-Niobium) alloys using Selective Laser Melting (SLM). GRCop, originally developed at GRC, is a high conductivity, high-strength, dispersion strengthened copper-alloy for use in high-temperature, high heat flux applications. NASA has completed significant material characterization and testing, along with hot-fire testing, to demonstrate that GRCop-42 and GRCop-84 alloys are suitable for use in combustion chambers. Additional development and testing has been completed on AM bimetallic chambers using GRCop-84 liners and superalloy jackets, fabricated using two Directed Energy Deposition (DED) processes: Electron Beam Freeform Fabrication (EBF³) and Blown Powder DED. NASA completed hot-fire testing on various AM chambers using GRCop-84, GRCop-42, and bimetallic chambers in Liquid Oxygen (LOX)/Hydrogen, LOX/Methane, and LOX/Kerosene propellants.

Gradl, Paul R.↗
NASA NTRS2019

A Roadmap to Interstellar Flight

In the nearly 60 years of spaceflight we have accomplished wonderful feats of exploration that have shown the incredible spirit of the human drive to explore and understand our universe. Yet in those 60 years we have barely left our solar system with the Voyager 1 spacecraft launched in 1977 finally leaving the solar system after 37 years of flight at a speed of 17 km/s or less than 0.006% the speed of light. As remarkable as this, to reach even the nearest stars with our current propulsion technology will take 100 millennium. We have to radically rethink our strategy or give up our dreams of reaching the stars, or wait for technology that does not currently exist. While we all dream of human spaceflight to the stars in a way romanticized in books and movies, it is not within our power to do so, nor it is clear that this is the path we should choose. We posit a path forward, that while not simple, it is within our technological reach. We propose a roadmap to a program that will lead to sending relativistic probes to the nearest stars and will open up a vast array of possibilities of flight both within our solar system and far beyond. Spacecraft from gram level complete spacecraft on a wafer (“wafersats”) that reach more than ¼ c and reach the nearest star in 20 years to spacecraft with masses more than 105 kg (100 tons) that can reach speeds of greater than 1000 km/s. These systems can be propelled to speeds currently unimaginable with existing propulsion technologies. To do so requires a fundamental change in our thinking of both propulsion and in many cases what a spacecraft is. In addition to larger spacecraft, some capable of transporting humans, we consider functional spacecraft on a wafer, including integrated optical communications, imaging systems, photon thrusters, power and sensors combined with directed energy propulsion. The costs can be amortized over a very large number of missions beyond relativistic spacecraft as such planetary defense, beamed energy for distant spacecraft, sending power back to Earth, stand-off composition analysis of solar system targets, long range laser communications, SETI searches and even terra forming. The human factor of exploring the nearest stars and exo-planets would be a profound voyage for humanity, one whose non-scientific implications would be enormous. It is time to begin this inevitable journey far beyond our home.

Lubin, Philip↗
NASA NTRS2019

Additive Manufacturing of NASA HR-1 Material for Liquid Rocket Engine Component Applications

NASA HR-1 is a high-strength Fe-Ni superalloy designed to resist high pressure, hydrogen environment embrittlement, oxidation, and corrosion. NASA HR-1 was originally developed at NASA in the 1990’s and derived from JBK-75 to increase strength and ductility in high-pressure hydrogen environments. The NASA HR-1 chemistry was formulated to meet requirements for liquid rocket engine applications, specifically components used in a high-pressure hydrogen environment. Recent developments using additive manufacturing (AM) have made this material an attractive option for channel-cooled nozzles under the Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) program and other liquid rocket engine component applications. The RAMPT program has baselined to fully evolve and characterize NASA HR-1 material. NASA HR-1 meets materials requirements for liquid rocket engine components, including good hydrogen resistance, high conductivity, good low cycle fatigue performance, and high elongation and strength for channel-cooled nozzles in high heat flux environments. Initial development and characterization has been completed using blown powder Directed Energy Deposition (DED) and Laser Powder Bed Fusion (L-PBF) additive manufacturing techniques to develop material test samples and nozzle hardware. NASA HR-1 powder has been sourced and characterized from several powder suppliers, and a series of development and hardware samples completed fabrication using DED and L-PBF. Characterization of the material has included heat treatment development, metallography, chemistry evaluations, mechanical testing, measurement of thermophysical properties, and fabrication of relevant nozzle hardware to demonstrate feasibility. This paper presents results from the process and early materials development and provide future development work including hardware fabrication.

Katsarelis, Colton↗
NASA NTRS2021

A Study of Particle Size Metrics Using Non-Spherical Feedstock for Metal Additive Manufacturing

The goal of this work was to determine which standard particle size metric derived from optical analysis most closely approximates the sieved weight percent of irregularly shaped powder intended to be used for directed energy deposition. In this investigation, equivalent circle diameter, maximum diameter, minimum diameter, and perimeter are used as metrics to “virtually sieve” the particles in samples of irregularly shaped powder into the following particle size bins: <45 µm, 45 µm - 150 µm, and >150 µm. The percentage in the 45 µm - 150 µm bin is then compared to the weight percent of the powder mechanically sieved into this size range. The absolute difference between the virtually sieved percentage and the mechanically sieved percentage was assessed for 81 samples of mechanically-generated stainless steel 316L powder all produced under different processing conditions in an oscillation ball mill. This difference was found to be on average, the least with the minimum diameter assessed as an area percentage, followed by the equivalent diameter assessed as an area percentage, and then the maximum diameter assessed as a percentage of the total number of particles ranked third. These findings may be used by powder production process engineers and quality assurance personnel to assist in process control as more diverse additive manufacturing feedstocks become utilized.

Marcus Jackson↗
NASA NTRSDate not supplied

Hot-Fire Testing Results of Additively Manufactured NASA HR-1 towards Large Scale Implementation of Channel Wall Nozzles

Additive manufacturing (AM) has provided new design and manufacturing opportunities to reduce cost and schedules, consolidate parts, and optimize performance. One technique being evaluated is Laser Powder Directed Energy Deposition (LP-DED), which provides a significant increase in scale compared to Laser Powder Bed Fusion (L-PBF). NASA along with industry partners have been developing the LP-DED process to demonstrate internal channel geometry and development components for use in liquid rocket engine channel cooled nozzles. One material that has been the focus of this development is NASA HR-1, an Iron-Nickel based superalloy optimized for use in high pressure hydrogen environments. Material properties and process characterization has been completed on the high density thin-wall material in addition to advancements of the supply chain. NASA has also completed fabrication of several subscale and full scale channel wall nozzles in LP-DED NASA HR-1 and completed hot-fire testing. This includes refinement of the process to produce thin-walls and various channel geometries to meet the requirements for channel wall nozzle applications. This paper will provide an overview of the LP-DED process development, material characterization and properties, component manufacturing, and hot-fire testing. Hot-fire testing was completed for a lander-class 7K-lbf thrust chamber using Liquid Oxygen (LOX)/Methane. The design overview and results from hot-fire testing will be presented in addition to hardware development for future testing on 2K-lbf and 35k-lbf thrust chambers and large-scale manufacturing technology demonstrators.

Paul Gradl↗
NASA NTRSDate not supplied

Investigation into Interfacial Mixing Behavior of Blown Powder Deposited Inconel 625-Copper Alloy Bimetallic for Improvement of Bimetallic Joint Strength

Use of laser blown powder, directed energy deposition (DED) provides a method for fabrication of bimetallic functional materials for high heat flux applications. However, this relatively new process currently has a low technology readiness level (TRL). Key to increasing the TRL is a better understanding of the factors that control mixing of the bi-metallic materials at the interface. The resulting interfaces in specimens obtained from three vendors were characterized using optical and electron microscopy with electron dispersion spectroscopy in addition to mechanical testing. Based on the range of process parameters and resulting interfaces, a model is being developed to predict interfacial mixing for development of specifications for improved and repeatable microstructures.

Additive Manufacturing↗
NASA NTRSDate not supplied

Additive Manufacturing (AM) for Propulsion Component and System Applications

NASA MSFC is developing several areas of additive manufacturing (AM) for propulsion component and system applications. These developments include new AM process and material development, large-scale AM pathfinder component fabrication and hot-fire testing, AM-centric design methodology, modeling and simulation, post-processing advancements, and new design applications of AM in aerospace. Some specific areas NASA has focused is the development and commercial infusion of AM supply chain for materials such as copper-alloy GRCop (Cu-Cr-Nb), Hydrogen-resistant alloys (NASA HR-1, JBK-75), refractory-based alloys (C-103, W, Mo, new formulations), and bimetallic and multi-metallic AM processes. Additional efforts have been focused on large scale AM demonstrating complex thin-wall structures up to 60” diameter using directed energy deposition. Material characterization, properties and component hot-fire testing has been completed using many of these newly developed AM alloys/processes. NASA has also focused on improvements to post-processing including powder removal, surface enhancements, and support removal to further realize cost and schedule benefits to the overall supply chain. These developments are part of the NASA Rapid Analysis and Manufacturing Propulsion Technology (RAMPT), Low Cost Upper Stage Propulsion (LCUSP) and Long Life Additive Manufacturing (LLAMA) projects, in addition to internal IRAD, and external collaborations.

Additive Manufacturing↗