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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 NTRSDate not supplied

Maximizing Earth Science Observations with Data Harmonization: Harmonized Landsat/Sentinel-2

In August 2021, NASA released science quality harmonized Landsat/Sentinel-2 products for both cloud-based access and direct download from the Land Processes Distributed Active Archive Center (LP DAAC). These 30-meter products, HLSS30 (Sentinel-2 component) and HLSL30 (Landsat component) are placed on the same grid and are generated and distributed fully in the cloud. Similarly, ESA is prototyping harmonized Landsat Sentinel-2 products at 10-meter resolution. The data production and science teams from NASA and ESA will present technical details on the data production system, data product status and availability, and the benefit of harmonizing instruments with similar sensing characteristics between the agencies.

Earth Science↗
NASA NTRSDate not supplied

Advancement of Novel Additively Manufactured Alloys for Space Applications

NASA has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts have focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into development and flight applications. While many common aerospace alloys have been and continue to be a focus of ongoing development, the need for custom-alloy developments for high performance applications enabled by AM processes has been realized. The applications being targeted are liquid rocket engines with high heat fluxes, high pressure, and that utilize propellants such as hydrogen, which can degrade the alloy. NASA has recently focused on the development and advancement of novel alloy advancement using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, and JBK-75. These alloys have been evaluated using the laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. The results from these processes have demonstrated that AM can enable rapid development of new alloy systems that can yield higher performances. These alloys have undergone the fundamental metallurgical evaluations, heat treatment study, and microstructure characterization and mechanical testing campaign. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL). This presentation will provide a background and overview of these AM-enabled novel alloys, AM processing development including metallurgical and mechanical property studies. It will also cover the latest advancement in the parallel component development and testing and future developments. The goal of these alloy development is to allow for technology infusion into NASA and commercial spaceflight missions as well as to establish and sustain the needed commercial AM supply chain.

Additive Manufacturing↗
NASA NTRS2021

Tracking aerosols and SO2 clouds from the Raikoke eruption: 3D view from satellite observations

The 21 June 2019 eruption of the Raikoke volcano (Kuril Islands, Russia; 48° N, 153° E) produced significant amounts of volcanic aerosols (sulfate and ash) and sulfur dioxide (SO2) gas that penetrated into the lower stratosphere. The dispersed SO2 and sulfate aerosols in the stratosphere were still detectable by multiple satellite sensors for many months after the eruption. For this study of SO2 and aerosol clouds we use data obtained from two of the Ozone Mapping and Profiler Suite sensors on the Suomi National Polar-orbiting Partnership satellite: total column SO2 from the Nadir Mapper and aerosol extinction profiles from the Limb Profiler as well as other satellite data sets. We evaluated the limb viewing geometry effect (the “arch effect”) in the retrieval of the LP standard aerosol extinction product at 674 nm. It was shown that the amount of SO2 decreases with a characteristic period of 8–18 d and the peak of stratospheric aerosol optical depth recorded at a wavelength of 674 nm lags the initial peak of SO2 mass by 1.5 months. Using satellite observations and a trajectory model, we examined the dynamics of an unusual atmospheric feature that was observed, a stratospheric coherent circular cloud of SO2 and aerosol from 18 July to 22 September 2019.

Eruption of the Raikoke volcano↗
NASA NTRSDate not supplied

Comparative Study of Additively Manufactured Inconel 625 In the As-Built and Heat-Treated Condition

This study was conducted to characterize the microstructure and mechanical properties of Inconel 625 manufactured with laser powder bed fusion (L-PBF), electron beam melting (EBM), wire arc additive manufacturing (WAAM), electron beam directed energy deposition (EB-DED), laser powder directed energy deposition (LP-DED), and laser wire directed energy deposition (LW-DED) in both the as built and heat-treated condition. The heat treatment in this study included stress relieving, hot isostatic pressure (HIP), and solution treatment. The effects of the heat treatment on the grain widths and hardness of the alloy will be observed across the technologies before and after heat-treatment. At the end of this study there will be a comparative analysis of the alloy Inconel 625 across the six technologies.

V Luna↗
NASA NTRSDate not supplied

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↗
NASA NTRSDate not supplied

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 GRCop-42, 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↗
NASA NTRS2022

SAGE III/ISS Ozone and NO2 Validation Using Diurnal Scaling Factors

We developed a set of solar zenith angle, latitude- and altitude-dependent scaling factors to account for the diurnal variability in ozone (O3) and nitrogen dioxide (NO2) when comparing Stratospheric Aerosol and Gas Experiment (SAGE) III/ISS observations to observations from other times of day. The scaling factors are calculated as a function of solar zenith angle from the four-dimensional output of a global atmospheric chemistry model simulation of 2017–2020 that shows good agreement with observed vertical profiles. Using a global atmospheric chemistry model allows us to account for both chemically and dynamically driven variability. Both year-specific scale factors and a multi-year monthly climatology are available to decrease the uncertainty in inter-instrument comparisons and allow consistent comparisons between observations from different times of day. We describe the variability in the diurnal scale factors as a function of space and time. The quasi-biennial oscillation (QBO) appears to be a contributing factor to interannual variability in the NO2 scaling factors, leading to differences between years that switch sign with altitude. We show that application of these scaling factors improves the comparison between SAGE III/ISS and OSIRIS NO2 and between SAGE III/ISS and OMPS LP, OSIRIS, and ACE-FTS O3 observations. The comparisons between SAGE III/ISS O3 for sunrise or sunset vs. Microwave Limb Sounder (MLS) daytime or nighttime observations are also more consistent when we apply the diurnal scaling factors. There is good agreement between SAGE III/ISS V5.2 ozone and correlative measurements, with differences within 5 % between 20 and 50 km when corrected for diurnal variability. Similarly, the SAGE III/ISS V5.2 NO2 agreement with correlative measurement is mostly within 10 %. While the scale factors were designed for use with SAGE III/ISS observations, they can easily be applied to other observation intercomparisons as well.

Sarah A. Strode↗
NASA NTRS2022

Systematic Detection of Anomalous Ionospheric Perturbations Above LEOs From GNSS POD Data Including Possible Tsunami Signatures

In this article, we show the capability of a global navigation satellite system (GNSS) precise orbit determination (POD) low Earth orbit (LEO) data to detect anomalous ionospheric disturbances in the spectral range of the signals associated with earthquakes and tsunamis, applied to two of these events in Papua New Guinea (PNG) and the Solomon Islands during 2016. This is achieved thanks to the new PIES approach (POD-GNSS LEO Detrended Ionospheric Electron Content Significant Deviations). The significance of such ionospheric signals above the swarm LEOs is confirmed with different types of independent data: in situ electron density measurements provided by the Langmuir Probe (LP) onboard swarm LEOs, DORIS, and ground-based GNSS colocated measurements, as it is described in this article. In this way, we conclude the possible detection of the tsunami-related ionospheric gravity wave in PNG 2016 event, consistent with the most-recent theory, which shows that a tsunami (which is localized in space and time) excites a spectrum of gravity waves, some of which have faster horizontal phase speeds than the tsunami. We believe that this work shows as well the feasibility of a future potential monitoring system of ionospheric disturbances, to be made possible by hundreds of CubeSats with POD GNSS receivers among other appropriate sensors, and supported for real-time or near real-time confirmation and characterization by thousands of worldwide existing ground GNSS receivers.

Global Navigation Satellite System↗
NASA NTRSDate not supplied

Maturation of Additive Manufactured Aerospace Alloys and Development of Mechanical and Thermophysical Properties for Space 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 have focused on the understanding of AM processes through design optimization, component fabrication, material characterization, testing, standards development, and infusion into propulsion development for flight applications. NASA and partners have matured commonly used aerospace alloys from various alloy families (Nickel, Steel, Iron, Aluminum, and Titanium) and AM processes. An extensive effort has been ongoing between NASA, industry partners, and academia to complete detailed AM process and heat treatment characterization, in addition to generating temperature-dependent mechanical and thermophysical properties. This presentation highlights the characterization and property results using laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes among various alloys. In addition to commonly used alloys, 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 launch vehicles, liquid rocket engines, advanced propulsion systems, advanced power systems, and in-space propulsion with high heat fluxes, high pressure, and that utilize propellants such as hydrogen, which can degrade alloys. This presentation will also discuss some of the ongoing novel alloy development and maturation using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, and C-103. The results from these processes have demonstrated that AM can enable rapid development and new AM optimized alloys can yield higher performance. These alloys have undergone modeling, fundamental metallurgical evaluations, heat treatment studies, and microstructure characterization and mechanical testing campaigns. This, combined with direct application-specific component fabrication and hot-fire testing, can enable the increase of the Technology Readiness Level (TRL) through high duty-cycle testing. This presentation provides a background and overview of these various common and AM-enabled alloys and processing developments including the initial effort related to metallurgical, mechanical, and thermophysical property studies. It also covers the latest advancement in the parallel component development, hot-fire testing, and future developments for these alloys.

Additive Manufacturing↗
NASA NTRSDate not supplied

Characterizing Wildfires in Western US.: A Cloud-based Case Study for Interdisciplinary Research using NASA Resources

This presentation will demonstrate a case study of interdisciplinary research done in the Amazon Web Services (AWS) cloud platform, in addition to in the local machine. We conduct data analysis next to data by leveraging various cloud-based data in NASA Earthdata Cloud, which are distributed by different missions/NASA Distributed Active Archive Centers (DAACs), and cloud computing resources at NASA. For instance, we directly access multiple datasets stored in the AWS Simple Storage Service (S3) buckets using a Python Jupyter notebook through a JupyterHub interface hosted in AWS (without having to download data), and conduct data analysis next to data in the cloud. We will also show how to share the research results following Open Source policy. This case study characterizes the change in wildfire events in the western United States during the past 20 years. In particular, we focus on the wildfires in California in 2021, one of the most severe wildfire years occurring in the most recent 20 years in California. We will analyze the possible causes of wildfires, such as drought conditions and climate variability, and examine the impacts of wildfires on air quality and atmospheric composition, and on land cover. We will examine the data distributed by the NASA Goddard Earth Sciences Data and Information Services Center (GES DISC), including aerosols and meteorological data from the NASA Modern-Era Retrospective analysis for Research and Applications version 2 (MERRA-2), precipitation from the Global Precipitation Measurement (GPM) and Global Precipitation Climate Project (GPCP), and aerosol index from Ozone Monitoring Instrument (OMI). We also utilize the data distributed by the Physical Oceanography (PO) DAAC, such as Sea Surface Temperature (SST) data from the Group for High Resolution Sea Surface Temperature (GHRSST), and the data distributed by Land Processes (LP) DAAC, such as Normalized Difference Vegetation Index (NDVI).

Xiaohua Pan↗
NASA NTRSDate not supplied

Coupled Aerosol-Chemistry Simulations of the January 2022 Eruptions of Hunga Tonga-Hunga Ha’apai in the NASA GEOS Earth System Model

The January 2022 eruptions of the underwater Hunga Tonga-Hunga Ha’apai volcano injected more than 100 Tg of water vapor and approximately 0.5 Tg of sulfur dioxide into the stratosphere. Injected materials reached as high as ~55 km in altitude, while the main plume from the eruption travelled west over Australia and the Indian Ocean between about 20 – 30 km altitude. We investigate the transport and the impact of the erupted materials in coupled aerosol-chemistry simulations performed with the NASA Goddard Earth Observing System (GEOS) Earth system model. A sulfur mechanism introduced into the Global Modeling Initiative (GMI) stratospheric-tropospheric chemistry package allows for an interactive simulation of the water vapor-chemistry impacts, and the large water vapor perturbation results in rapid conversion of sulfur dioxide to sulfate aerosol in our aerosol mechanism. We report on the results of a multi-year ensemble of simulations performed with this system that include a control ensemble (no eruption), a water vapor-only injection ensemble, and a water vapor and sulfur dioxide injection ensemble. Simulations of the near-field aerosol and chemistry transport are compared to available measurements from OMPS-LP, OMPS-NM, CALIOP, MLS, and other sensors. The extended impact of the volcanic materials on the stratospheric composition and chemistry over the next several years is further investigated in forecast simulations.

Peter Colarco↗
NASA NTRSDate not supplied

Development of Directed Energy Deposited NASA HR-1 to Optimize Properties for Liquid Rocket Engine Applications

Metal additive manufacturing (AM) processes have been demonstrated to be effective at reducing costs and lead times associated with fabrication of complex propulsion component designs. Laser powder directed energy deposition (LP-DED) and laser powder bed fusion (L-PBF) are metal AM technologies that have effectively been used to produce a variety of parts for space applications. These technologies have enabled new designs and materials for these applications. The National Aeronautics and Space Administration (NASA) has identified the need to develop and advance new materials in unique space applications such as high-pressure hydrogen environments. One such metal alloy being developed for these applications is NASA HR-1. A high-strength Fe-Ni based superalloy, NASA HR-1 was designed to resist high pressure hydrogen environment embrittlement, oxidation, and corrosion. AM technologies have enabled the manufacturing of NASA HR-1 to be a feasible material for components in hydrogen environments. Development efforts for NASA HR-1 have completed build and heat treatment optimization, material characterization, thermophysical property testing, and mechanical testing in air and hydrogen environments to mature the understanding of the material. This poster will summarize the development of NASA HR-1 for AM including composition and heat treatment optimization, microstructure characterization, and results of mechanical testing in air and high pressure hydrogen.

NASA HR-1↗
NASA NTRSDate not supplied

NASA’s Human Landing System: A Sustaining Presence on the Moon

For more than a decade, efforts have been ongoing at NASA’s Marshall Space Flight Center (MSFC) in Huntsville, Alabama, to land humans and cargo on planetary bodies like the Moon and Mars and today this work continues under the Center’s Lander Programs (LP) office. In August of 2019, NASA stood up the Human Landing System (HLS) program to be responsible for spacecrafts that will land astronauts on the Moon under Artemis. Work is well underway with the historic Artemis III mission to land the first Americans on the lunar surface in more than 50 years through the Appendix H Option A [1] contract with SpaceX. In November, NASA awarded SpaceX an Option B modification to its existing HLS Appendix H contract, which will further develop its Starship HLS to meet NASA’s sustaining lander requirements for lunar missions beyond Artemis III. In September of 2022, NASA issued an HLS Sustaining Lunar Development solicitation under the NextSTEP-2 Appendix P Broad Agency Announcement [2] asking a second provider, in addition to SpaceX, to develop and demonstrate a lander that meets the program’s extended set of requirements for missions beyond Artemis III. Under the umbrella of Sustaining Lunar Development [3], these requirements will meet NASA’s needs for recurring, long-term access to the lunar surface. Proposals were received from industry late last year and NASA is planning to award an Appendix P contract in the summer of 2023. This paper will provide an update of the Lander Program office’s progress and will discuss how the program is bridging from the initial demonstration phase of development for the Human Landing System program to the Sustaining Lunar Development phase. The paper will include publicly available information on SpaceX’s Starship HLS design as well as near-term and future milestones for HLS and the Artemis program.

Lisa Watson-Morgan↗
NASA NTRS2023

Additive Manufacturing Process Development DOE for NASA HR-1 using Laser Blown Powder Directed Energy Deposition

NASA HR-1 is a Fe-Ni-Cr alloy that is used for high pressure hydrogen applications such as rocket engines, energy, and oil and gas. This investigation was focused on conducting a design of experiment program aimed at mapping the parameter process window for NASA HR-1 using the laser blown powder directed energy deposition (LP-DED) process. A two phased design of experiments (DOE), the first phase of the experiment was focused on optimizing single bead tracks while the second phase of the experiment was focused on optimizing bead overlap hatching in a multi pass bead build up. During the first phase of the deposition parameters, namely laser power, travel speed, and powder feed rate were varied. A down selection from the single bead parameter set was made and hatching experiments were conducted that focused on the overlap distance. In this paper the approach for conducting the DOE and results are discussed. The results focused on measurement of bead geometry, the as-built microstructural evolution, and porosity within the samples. The team at MSFC saw a variety of results across the process map created during the first phase of experimentation and were able to down select a parameter that created an optimal bead shape with a minimal amount of build porosity. It was determined that laser power and robot travel speed were the most sensitive parameters. The results from this investigation will inform future laser powder directed energy deposition parameter developments.

Parker Shake↗
NASA NTRSDate not supplied

Development and Optimization of Additively Manufactured NASA HR-1 for Space Applications

Metal additive manufacturing (AM) processes have been demonstrated to be effective at reducing costs and lead times associated with fabrication of complex propulsion component designs. Laser powder directed energy deposition (LP-DED) and laser powder bed fusion (L-PBF) are metal AM technologies that have effectively been used to produce a variety of parts for space applications. These technologies have enabled new designs and materials for these applications. The National Aeronautics and Space Administration (NASA) has identified the need to develop and advance new materials in unique space applications such as high-pressure hydrogen environments. One such metal alloy being developed for these applications is NASA HR-1. A high-strength Fe-Ni based superalloy, NASA HR-1 was designed to resist high pressure hydrogen environment embrittlement, oxidation, and corrosion. AM technologies have enabled the manufacturing of NASA HR-1 to be a feasible material for components in hydrogen environments. Development efforts for NASA HR-1 have completed build and heat treatment optimization, material characterization, thermophysical property testing, and mechanical testing in air and hydrogen environments to mature the understanding of the material. This presentation will summarize the development of NASA HR-1 for AM including composition and heat treatment optimization, microstructure characterization, and results of mechanical testing in air and high pressure hydrogen.

Additive Manufacturing↗
NASA NTRS2024

Extreme Temperature Additively Manufactured GRX-810 Alloy Development and Hot-fire Testing for Liquid Rocket Engines

Additive manufacturing (AM) has revolutionized component design for liquid rocket engines by offering rapid manufacturing capabilities. This has led to significant opportunities for development and flight programs in the propulsion industry, resulting in cost and schedule savings, as well as performance improvements through new designs and alloy development. A noteworthy example is the GRX-810 oxide dispersion strengthened (ODS) alloy, which was specifically developed for extreme temperatures. This Ni-Co-Cr based alloy was created using integrated computational materials engineering (ICME) techniques to focus on a new class of materials with exceptional temperature and oxidation-resistant properties. The GRX-810 alloy utilizes AM processes to incorporate nano-scale yttria particles throughout its microstructure, resulting in remarkable enhancements. Compared to traditional Nickel-based superalloys, the GRX-810 alloy offers a two-fold increase in tensile strength, 1,000-fold better creep properties, and two-fold improvement in oxidation resistance. NASA successfully demonstrated the development and manufacturing of components using the GRX-810 alloy through laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Extensive efforts were made to model, evaluate metallurgical properties, develop heat treatment processes, characterize the microstructure, and determine mechanical properties. The GRX-810 alloy was specifically designed for aerospace applications, including liquid rocket engine injectors, preburners, turbines, and hot-section components, capable of withstanding temperatures up to 1,100 °C. The objective of this alloy development is to bridge the temperature gap between traditional Nickel-based superalloys and refractory alloys. This paper provides a comprehensive comparison of the GRX-810 alloy with other aerospace alloys, discussing its microstructure, mechanical properties, processing advancements, component development, and hot-fire testing results. The ultimate goal of this development was to elevate the Technology Readiness Level (TRL) of the GRX-810 alloy, enabling its integration into NASA and commercial aerospace applications.

GRX-810↗
NASA NTRSDate not supplied

Simulating Sulfate Aerosol Size in the Hunga Tonga Plume: Comparisons with Observations

Using the NASA GEOS Chemistry Climate Model (CCM) coupled to a detailed sectional aerosol microphysical model, we have simulated the January 2022 Hunga Tonga-Hunga Ha’apai (HTHH) plume. We have developed a version of the Global Modeling Initiative (GMI) chemistry mechanism to include the requisite sulfur chemistry and coupled it to the Community Aerosol and Radiation Model for Atmospheres (CARMA) sectional aerosol microphysics within the GEOS CCM. Our simulations focus on the lifecycle of stratospheric sulfur injected by the eruption–from the oxidation of the injected sulfur dioxide to the nucleation, growth, coagulation, hydration, and eventual settling of the volcanic sulfate aerosol particles. In order to constrain the simulated microphysics, we focus on comparing our model to observations with aerosol size information, namely in-situ particle counter observations and multi-wavelength satellite observations from OMPS-LP and SAGE-III. This eruption provides an interesting test case for our model; both the modeled gas-phase chemistry as well as the modeled aerosol microphysics are perturbed by the massive injection of water that accompanied the primary sulfur emissions from the eruption.

aerosols↗
NASA NTRS2024

Extreme Temperature Additively Manufactured GRX-810 Alloy Development and Hot-fire Testing for Liquid Rocket Engines

Additive manufacturing (AM) has revolutionized component design for liquid rocket engines by offering rapid manufacturing capabilities. This has led to significant opportunities for development and flight programs in the propulsion industry, resulting in cost and schedule savings, as well as performance improvements through new designs and alloy development. A noteworthy example is the GRX-810 oxide dispersion strengthened (ODS) alloy, which was specifically developed for extreme temperatures. This Ni-Co-Cr based alloy was created using integrated computational materials engineering (ICME) techniques to focus on a new class of materials with exceptional temperature and oxidation-resistant properties. The GRX-810 alloy utilizes AM processes to incorporate nano-scale yttria particles throughout its microstructure, resulting in remarkable enhancements. Compared to traditional Nickel-based superalloys, the GRX-810 alloy offers a two-fold increase in tensile strength, 1,000-fold better creep properties, and two-fold improvement in oxidation resistance. NASA successfully demonstrated the development and manufacturing of components using the GRX-810 alloy through laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Extensive efforts were made to model, evaluate metallurgical properties, develop heat treatment processes, characterize the microstructure, and determine mechanical properties. The GRX-810 alloy was specifically designed for aerospace applications, including liquid rocket engine injectors, preburners, turbines, and hot-section components, capable of withstanding temperatures up to 1,100 °C. The objective of this alloy development is to bridge the temperature gap between traditional Nickel-based superalloys and refractory alloys. This paper provides a comprehensive comparison of the GRX-810 alloy with other aerospace alloys, discussing its microstructure, mechanical properties, processing advancements, component development, and hot-fire testing results. The ultimate goal of this development was to elevate the Technology Readiness Level (TRL) of the GRX-810 alloy, enabling its integration into NASA and commercial aerospace applications.

GRX-810↗