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NASA NTRSDate not supplied

NASA's Composite Overwrap Lessons Learned on 40k Thrust Chamber Assemblies

Filament wound carbon fiber/polymer composite overwraps combined with additively manufactured (AM) copper alloy combustion chambers are a critical part of NASA’s Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project. The composite overwrap is a high strength-to-weight material and allows for significant weight reduction of the high-pressure thrust chamber assembly, reduction of overall cost, and reduced fabrication time while offering structural robustness. Integrated AM/composite overwrap chamber assemblies using 2,000 lbf (2k) and 7,000 lbf (7k) thrust were successfully hot fire tested at NASA Marshall Space Flight Center (MSFC). These assemblies allowed the team to learn lessons related to the design, analysis, and manufacturing of these integrated assemblies. A final goal of the RAMPT project is to design and test a 40,000 lbf (40k) thrust chamber assembly. The40k chamber presented the team several new challenges including an integral inlet port in the main body of the composite overwrap. Through multiple iterations of manufacturing techniques, varied materials, and Non-Destructive Evaluations (NDE), many lessons were learned to obtain a final design solution that would not only allow for the interrupted port inlet but also allow for sufficient material margins for the most critically stressed part of the chamber. This paper will cover the manufacturing techniques exploring fabric designs to help subsidize the coverage in the areas left bare by the inlet port during the filament winding process and custom tooling needed for the final full chamber processing. The original material choice of bismaleimide (BMI) 5250-4 from the 7k chamber performed well for the extreme environment of hot fire testing but proved to be difficult with the increased scale and interrupted port design of the 40kchamber. Discussion in this paper will cover these changes, including evaluation of the design, comparison to the prior 2k and 7k designs, and show the final hardware that will be tested. One primary goal of this work and RAMPT project is to provide this development process and data to industry for infusion into future engine designs.

Filament Wound↗
NASA NTRS1991

The influence of Ag+Mg additions on the nucleation of strengthening precipitates in a non-cold-worked Al-Cu-Li alloy

Aluminum-copper-lithium alloys generally require cold work to attain their highest strengths in artificially aged tempers. These alloys are usually strengthened by a combination of the metastable delta prime (Al3Li) and theta prime (Al2Cu) phases and the equilibrium T sub 1 (Al2CuLi) phase, and where the T sub 1 phase is a more potent strengthener than the delta prime. Various investigators have shown that the high strengths obtained after artificial aging associated with cold work result from the heterogeneous precipitation of T sub 1 on matrix dislocations. The objective here is to elucidate the mechanism by which the Ag+Mg additions stimulate the precipitation of T sub 1 type precipitates without cold work. To accomplish this, the microstructure of an Al-6.3Cu-1.3Li-0.14Zr model alloy was evaluated in a T6 type temper with and without the Ag+Mg addition.

Source record↗
NASA NTRS1973

Role of plastic deformation in wear of copper and copper - 10-percent-aluminum alloy in cryogenic fuels

High-purity copper specimens and a copper-aluminum (10%) alloy specimen were subjected to sliding against Type 440 C in cryogenic fuel environments. It was found that virtually all wear occurred by the plastic deformation of a recrystallized layer extending to about 10 micrometers below the wear scar surface of the copper or copper alloy. The wear debris was in the form of a layered structure adhering to the exit region of the wear scar. Measurements on the high purity copper specimens indicated that the wear rate was proportional to the applied load and to the sliding velocity squared. A physical model of the wear process is proposed to account for these observations.

Bill, R. C.↗
NASA NTRS1992

Reaction layer formation at the graphite/copper-chromium alloy interface

Sessile drop tests were used to obtain information about copper chromium alloys that suitably wet graphite. Characterization of graphite/copper-chromium alloy interfaces subjected to elevated temperatures were conducted using scanning electron micrography, energy dispersive spectroscopy, auger electron spectroscopy, and x ray diffraction analyses. These analyses indicate that during sessile drop tests conducted at 1130 C for one hour, copper alloys containing greater than 0.98 percent chromium form continuous reaction layers of approximately 10 micron thickness. The reaction layers adhere to the graphite surface. The copper wets the reaction layer to form a contact angle of 60 degrees or less. X ray diffraction results indicate that the reaction layer is chromium carbide. The kinetics of reaction layer formation were modelled in terms of bulk diffusion mechanisms. Reaction layer thickness is controlled initially by the diffusion of Cr out of Cu alloy and later by the diffusion of C through chromium carbide.

Devincent, Sandra M.↗
NASA NTRS1993

Reaction layer formation at the graphite/copper-chromium alloy interface

Sessile drop tests were used to obtain information about copper chromium alloys that suitably wet graphite. Characterization of graphite/copper-chromium alloy interfaces subjected to elevated temperatures were conducted using scanning electron micrography, energy dispersive spectroscopy, Auger electron spectroscopy, and X-ray diffraction analyses. These analyses indicate that during sessile drop tests conducted at 1130 C for one hour, copper alloys containing greater than 0.98 percent chromium form continuous reaction layers of approximately 10 micron thickness. The reaction layers adhere to the graphite surface. The copper wets the reaction layer to form a contact angle of 60 degrees or less. X-ray diffraction results indicate that the reaction layer is chromium carbide. The kinetics of reaction layer formation were modelled in terms of bulk diffusion mechanisms. Reaction layer thickness is controlled initially by the diffusion of Cr out of Cu alloy and later by the diffusion of C through chromium carbide.

Devincent, Sandra M.↗
NASA NTRS1972

Influence of alloying elements on friction and wear of copper

The friction and wear characteristics were determined for copper binary alloys containing 10 atomic percent aluminum, silicon, indium, and tin. A ternary alloy containing 10 atomic percent aluminum and 5 atomic percent silicon was also examined. The effectiveness of each of the alloying elements aluminum and silicon were very effective in reducing friction. Silicon, however, also reduced wear appreciably. With lubrication, silicon, indium, and tin were all effective alloying elements in reducing friction and wear from values obtained for copper. Silicon was the most effective single element in reducing friction and wear in dry sliding and with lubrication.

Buckley, D. H.↗
NASA NTRS1992

The transition from columnar to equiaxed dendritic growth in proeutectic, low-volume fraction copper, Pb-Cu alloys

Lead, 17.1, 11.2, and 5 volume fraction copper (14, 9, and 4 wt pct Cu) alloys have been directionally solidified at constant growth velocities ranging from 1 to 100 microns/s. Serially increasing the growth velocity within this range results in a graded microstructural transition from fully columnar, albeit segregated, copper dendrites in a lead matrix to one consisting only of equiaxed grains. The imposed velocity necessary to effect fully equiaxed growth is found to drop rapidly as the volume fraction of copper is decreased. Factors which complicate the controlled, directional solidification of these alloys are discussed and the experimental results are interpreted in view of, and seen to be in qualitative agreement with, Hunt's theory on the transition from columnar to equiaxed growth of dendrites.

Kim, Shinwoo↗
NASA NTRS1973

Flight/ground sample comparison relating to flight experiment M552, exothermic brazing

Comparisons were made between Skylab and ground-based specimens of nickel and stainless steel which were vacuum brazed using silver-copper-lithium alloy with various joint configurations. It was established that the absence of gravity greatly extends the scope of brazing since capillary flow can proceed without gravity interference. There was also evidence of enhanced transport, primarily in that liquid silver copper alloy dissolves nickel to a much greater extent in the zero gravity environment.

Heine, R. W.↗
NASA NTRS2001

Lightweight Chambers for Thrust Assemblies

The Marshall Space Flight Center (MSFC) of the National Aeronautics and Space Administration (NASA) has successfully applied new materials and fabrication techniques to create actively cooled thrust chambers that operate 200-400 degrees hotter and weigh 50% lighter than conventional designs. In some vehicles, thrust assemblies account for as much as 20% of the engine weight. So, reducing the weight of these components and increasing their operating range will benefit many engines and vehicle designs, including Reusable Launch Vehicle (RLV) concepts. Obviously, copper and steel alloys have been used successfully for many years in the chamber components of thrust assemblies. Yet, by replacing the steel alloys with Polymer Matrix Composite (PMC) and/or Metal Matrix Composite (MMC) materials, design weights can be drastically reduced. In addition, replacing the traditional copper alloys with a Ceramic Matrix Composite (CMC) or an advanced copper alloy (Cu-8Cr-4Nb, also known as GRCop-84) significantly increases allowable operating temperatures. Several small MMC and PMC demonstration chambers have recently been fabricated with promising results. Each of these designs included GRCop-84 for the cooled chamber liner. These units successfully verified that designs over 50% lighter are feasible. New fabrication processes, including advanced casting technology and a low cost vacuum plasma spray (VPS) process, were also demonstrated with these units. Hot-fire testing at MSFC is currently being conducted on the chambers to verify increased operating temperatures available with the GRCop-84 liner. Unique CMC chamber liners were also successfully fabricated and prepared for hot-fire testing. Yet, early results indicate these CMC liners need significantly more development in order to use them in required chamber designs. Based on the successful efforts with the MMC and PMC concepts, two full size "lightweight" chambers are currently being designed and fabricated for hot-fire testing at MSFC in 2001. These "full size" chambers will be similar in size to those used on the X33 engine (RS2200). One will be fabricated with a MMC structural jacket, while the other uses a PMC jacket. Each will be designed for thrust levels of 15,000 pounds in an oxygen/hydrogen environment with liquid hydrogen coolant. Both chambers will use GRCop-84 for its channel wall liner. Each unit is expected to be at least 60% lighter than a conventional design with traditional materials. Hot-fire testing on the full size units in late 2001 will directly compare performance results between a conventional chamber design and these "lightweight" alternatives. The technology developed and demonstrated by this effort will not only benefit next generation RLV programs, but it can be applied to other existing and future engine programs, as well. Efforts were sponsored by the Advanced Space Transportation Program for RLV Focused Technologies. The task team was led by MSFC with additional members from NASA-Glenn Research Center and the Rocketdyne Division of The Boeing Company. Specific materials development and fabrication processes were provided by Aerojet, Lockheed Martin Astronautics, Composite Optics, Inc., Hyper-Therm, Ceramic Composites, Inc., MSE Technology Applications, and Plasma Processes, Inc.

Elam, Sandra K.↗
NASA NTRS1981

Laser-initiated combustion studies of selected aluminum, copper, iron, and nickel alloys

The results of combustion studies at atmospheric pressure on ten metal alloys are presented. The alloys studied were aluminum alloys 1100, 2219, 6061, and tensile-50; 304, 347 and 21-6-9 stainless steel; inconel 600; beryllium copper and a bronze. It was found that once ignition was achieved all alloys would generally burn to completion. The overall combustion process appears to obey a first order rate process. Preliminary conclusions are presented along with recommendations for future work.

Bransford, J. W.↗