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NASA NTRSDate not supplied

Development of Laser Powder Bed Fusion NASA HR-2 for Hydrogen Sensitive Liquid Rocket Engine 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. AM has provided new design and manufacturing opportunities to reduce cost and schedule, consolidate parts, and optimize performance. Laser Powder Bed Fusion (L-PBF) is one of the most commonly used AM processes to fabricate components that have complex shape and need fine feature resolution. Due to exposure to high pressure gaseous hydrogen, mechanical property degradation caused by hydrogen environment embrittlement (HEE) is a critical concern for many materials in liquid hydrogen propulsion systems. NASA has identified the need to develop and advance new materials in unique engine applications using liquid hydrogen as a propellant. One such material being developed at NASA Marshall Space Flight Center is L-PBF NASA HR-2 (Hydrogen Resistant-2), a high-strength Fe-Ni-based superalloy resistant to HEE. The chemistry of NASA HR-2 was formulated to meet requirements for key liquid rocket engine (LRE) components that operate in high-pressure hydrogen environments. Initial development and material characterization found NASA HR-2 has excellent L-PBF printability and its microstructure evolves well after heat treatment. This new alloy has undergone fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing across a range of temperatures. Tensile testing was performed in pressurized gaseous hydrogen (GH2) environment to assess its resistance to HEE. L-PBF NASA HR-2 has an average yield stress of 95 ksi, ultimate tensile stress of 165 ksi, and very high fracture elongation at 34 - 36% when tested in a 5 ksi high pressure hydrogen environment. The tensile property data confirms hydrogen has little influence on its ductility, strength, and fracture behavior. L-PBF NASA HR-2 is a promising option for many hydrogen sensitive LRE components that require exceptional resistance to HEE. The development of L-PBF NASA HR-2 is funded under the grants provided by Jacobs TIPI program and the Liquid Engine Office at NASA Marshall Space Flight Center. This paper will provide an overview of the L-PBF process development, material characterization, mechanical and thermophysical properties, and LRE hardware development for NASA HR-2.

NASA HR-2↗

DOE OSTI2025

Floquet–Bloch manipulation of the Dirac gap in a topological antiferromagnet

Floquet–Bloch manipulation, achieved by driving a material periodically with a laser pulse, is a method that enables the engineering of electronic and magnetic phases in solids by effectively modifying the structure of their electronic bands. However, the application of Floquet–Bloch manipulation in topological magnetic systems, particularly those with inherent disorder, remains largely unexplored. Here, in this study, we realize Floquet–Bloch manipulation of the Dirac surface-state mass of the topological antiferromagnet MnBi 2 Te 4 . Using time- and angle-resolved photoemission spectroscopy, we show that opposite helicities of mid-infrared circularly polarized light result in substantially different Dirac mass gaps in the antiferromagnetic phase, despite the equilibrium Dirac cone being massless. We explain our findings in terms of a Dirac fermion with a random mass. Our results underscore Floquet–Bloch manipulation as a powerful tool for controlling topology, even in the presence of disorder, and for uncovering properties of materials that may elude conventional probes.

42 ENGINEERING↗

NASA NTRS1985

1985 International Geoscience and Remote Sensing Symposium (IGARSS '85), University of Massachusetts, Amherst, October 7-9, 1985, Digest. Volumes 1 & 2

The present conference on remote sensing instrumentation considers topics in water resources research, planetary remote sensing and mathematical geophysics, sea ice behavior in view of the Cold Regions Research and Engineering Laboratories pond measurements, Shuttle Imaging Radar-B (SIR-B) system performance and calibration results, geological applications of remote sensing, and microwave scattering from vegetation. Further attention is given to atmospheric probing with lasers, image processing for remote sensing, forest inventory and condition assessment, atmospheric remote sensing, SIR-B geological results, the reflectance, emission, and scattering characteristics of vegetation, sea ice sensing, multipolarization SAR results, the theoretical modeling of surfaces and volumes, crop condition assessment and productivity estimates, and SIR-B results for vegetation cover. Also considered are the microwave remote sensing of soil moisture, advanced sensors, advanced information extraction, wind and wave remote observations, results from the ESA Remote Sensing satellite, large area crop and land cover statistics, SIR-B results for directional ocean wave spectra, seasonal snow cover, ice sheets, and lake ice, fundamental research in terrain remote sensing, image classification methods, vegetation stress detection, remote sensing of coastal processes, SAR systems and calibration, electromagnetic geophysical methods and signal processing, image processing techniques, and SAR internal wave measurements.

Carver, K. R.↗

NASA NTRS2012

Design and Performance Optimizations of Advanced Erosion-Resistant Low Conductivity Thermal Barrier Coatings for Rotorcraft Engines

Thermal barrier coatings will be more aggressively designed to protect gas turbine engine hot-section components in order to meet future rotorcraft engine higher fuel efficiency and lower emission goals. For thermal barrier coatings designed for rotorcraft turbine airfoil applications, further improved erosion and impact resistance are crucial for engine performance and durability, because the rotorcraft are often operated in the most severe sand erosive environments. Advanced low thermal conductivity and erosion-resistant thermal barrier coatings are being developed, with the current emphasis being placed on thermal barrier coating toughness improvements using multicomponent alloying and processing optimization approaches. The performance of the advanced thermal barrier coatings has been evaluated in a high temperature erosion burner rig and a laser heat-flux rig to simulate engine erosion and thermal gradient environments. The results have shown that the coating composition and architecture optimizations can effectively improve the erosion and impact resistance of the coating systems, while maintaining low thermal conductivity and cyclic oxidation durability

Zhu, Dongming↗

NASA NTRS2002

Acoustic and Laser Doppler Anemometer Results for Confluent, 22-Lobed, and Unique-Lobed Mixer Exhaust Systems for Subsonic Jet Noise Reduction

The objective of this task was to develop a design methodology and noise reduction concepts for high bypass exhaust systems which could be applied to both existing production and new advanced engine designs. Special emphasis was given to engine cycles with bypass ratios in the range of 4:1 to 7:1, where jet mixing noise was a primary noise source at full power takeoff conditions. The goal of this effort was to develop the design methodology for mixed-flow exhaust systems and other novel noise reduction concepts that would yield 3 EPNdB noise reduction relative to 1992 baseline technology. Two multi-lobed mixers, a 22-lobed axisymmetric and a 21-lobed with a unique lobe, were designed. These mixers along with a confluent mixer were tested with several fan nozzles of different lengths with and without acoustic treatment in GEAE's Cell 41 under the current subtask (Subtask C). In addition to the acoustic and LDA tests for the model mixer exhaust systems, a semi-empirical noise prediction method for mixer exhaust system is developed. Effort was also made to implement flowfield data for noise prediction by utilizing MGB code. In general, this study established an aero and acoustic diagnostic database to calibrate and refine current aero and acoustic prediction tools.

Salikuddin, M.↗

NASA NTRS2002

NASA's Photon-Counting SLR2000 Satellite Laser Ranging System: Progress and Applications

NASA's new unmanned SLR2000 system is designed to track, with millimeter precision and using single photon returns, a constellation of roughly 24 retroreflector-equipped satellites, which range in altitude from about 300 km to 20,000 km. Totally autonomous operation and a common engineering configuration are expected to greatly reduce station operations costs relative to NASA's current manned systems. The system has also been designed with a goal of significantly lowering replication costs. All of the prototype components and subsystems have been completed and tested and have substantially met the original specifications. The prototype system is presently undergoing final integration and testing in a dedicated shelter with an azimuth tracking dome synchronized to the optical tracking mount. The facility also features a number of security features such as security cameras and sensors designed to detect power or thermal control problems or entry by unauthorized personnel. Field tests are in progress. The present paper provides an overview of the various subsystems and test results to date. The meteorological subsystem, which has operated successfully in the field for almost three years, consists of several sensors which measure: (1) pressure, temperature, and relative humidity; (2) wind speed and direction; (3) ground visibility and precipitation; and (4) local cloud cover as a function of station azimuth and elevation (day and night). A "pseudo-operator" software program interprets the sensor readings and modifies satellite tracking priorities based on local meteorological conditions.

Degnan, John J.↗

NASA NTRS1987

Ultrasonic NDE of structural ceramics for power and propulsion systems

A review of research investigations of several ultrasonic evaluation techniques applicable to structural ceramics for advanced heat engines is presented. This review highlights recent work conducted under the sponsorship of and at the Lewis Research Center. Results obtained with scanning acoustic microscopy, scanning laser acoustic microscopy, photo acoustic microscopy, and scanning electron acoustic microscopy are compared. In addition to these flaw imaging techniques, microstructure characterization by analytical ultrasonics is described. The techniques were evaluated by application to research samples of monolithic silicon nitride and silicon carbide in the form of discs and bars containing naturally occurring and deliberately-introduced flaws and microstructural anomalies. Strengths and limitations of the techniques are discussed.

Vary, Alex↗

NASA NTRS1996

Rayleigh Scattering Measurements in NASA Lewis Wind Tunnels

Two applications of Rayleigh scattering for measuring flow parameters in wind tunnels are described. The first is the measurement of one velocity component and static temperature in the vicinity of a 12 % scale advanced short takeoff and vertical landing (ASTOVL) aircraft model in the Lewis 9 ft by 15 ft low speed wing tunnel. The model was equipped with high temperature and high pressure air supplies to simulate lift nozzles and suction systems to simulate engine inlets. The second application is a feasibility study to measure flow properties in a 4 inch by 10 inch supersonic wind tunnel This technique uses an injection seeded, frequency doubled Nd:YAG laser tuned to an absorption band of iodine.

Seasholtz, Richard↗

DOE OSTI2025

High-emissivity, thermally robust emitters for high power density thermophotovoltaics

Thermal radiative energy transport is essential for high-temperature energy harvesting technologies, including thermophotovoltaics (TPVs) and grid-scale thermal energy storage. However, the inherently low emissivity of conventional high-temperature materials constrains radiative energy transfer, thereby limiting system performance and technoeconomic viability. Here, in this study, we demonstrate ultrafast femtosecond laser-material interactions to transform diverse materials into near-blackbody surfaces with broadband spectral emissivity above 0.96. This enhancement arises from hierarchically engineered light-trapping microstructures enriched with nanoscale features, effectively decoupling surface optical properties from bulk thermomechanical properties. These laser-blackened surfaces (LaBS) exhibit exceptional thermal stability, retaining high emissivity for over 100 h at temperatures exceeding 1,000°C, even in oxidizing environments. When applied as TPV thermal emitters, Ta LaBS double electrical power output from 2.19 to 4.10 W cm −2 at 2,200°C while sustaining TPV conversion efficiencies above 30%. This versatile, largely material-independent technique offers a scalable and economically viable pathway to enhance emissivity for advanced thermal energy applications.

laser-blackened surfaces↗

NASA NTRS2000

A New Digital Holographic Instrument for Measuring Microphysical Properties of Contrails in the SASS (Subsonic Assessment) Program

SPEC incorporated designed, built and operated a new instrument, called a pi-Nephelometer, on the NASA DC-8 for the SUCCESS field project. The pi-Nephelometer casts an image of a particle on a 400,000 pixel solid-state camera by freezing the motion of the particle using a 25 ns pulsed, high-power (60 W) laser diode. Unique optical imaging and particle detection systems precisely detect particles and define the depth-of-field so that at least one particle in the image is almost always in focus. A powerful image processing engine processes frames from the solid-state camera, identifies and records regions of interest (i.e. particle images) in real time. Images of ice crystals are displayed and recorded with 5 micron pixel resolution. In addition, a scattered light system simultaneously measures the scattering phase function of the imaged particle. The system consists of twenty-eight 1-mm optical fibers connected to microlenses bonded on the surface of avalanche photo diodes (APDs). Data collected with the pi-Nephelometer during the SUCCESS field project was reported in a special issue of Geophysical Research Letters. The pi-Nephelometer provided the basis for development of a commercial imaging probe, called the cloud particle imager (CPI), which has been installed on several research aircraft and used in More than a dozen field programs.

Lawson, R. Paul↗

NASA NTRS1996

Mixing Process in Ejector Nozzles Studied at Lewis' Aero-Acoustic Propulsion Laboratory

The NASA Lewis Research Center has been studying mixing processes in ejector nozzles for its High Speed Research (HSR) Program. This work is directed at finding ways to minimize the noise of a future supersonic airliner. Much of the noise such an airplane would generate would come from the nozzle, where a hot, high-speed jet exits the engine. Several different nozzle configurations were used to produce nozzle systems with different acoustical and aerodynamic characteristics. The acoustical properties were measured by an array of microphones in an anechoic chamber, and the aerodynamics were measured by traditional pressure and temperature instruments as well as by Laser Doppler Velocimetry (LDV), a technique for visualizing the airflow pattern without disturbing it. These measurements were put together and compared for different configurations to examine the relationships between mixing and noise generation. The mixer-ejector nozzle with the installed flow-visualization windows (foreground), the optical equipment and the supporting structure for the Laser Doppler Velocimetry flow visualization (midfield), and the sound-absorbing wedges used to create an anechoic environment for acoustic testing (background) is shown. The High Speed Research Program is a NASA-funded effort, in cooperation with the U.S. aerospace industry, to develop enabling technologies for a future supersonic airliner. One of the technological barriers being addressed is noise generated during near-airport operation. The mixer-ejector nozzle concept is being examined as a way to reduce jet noise while maintaining thrust. Ambient air is mixed with the high-velocity engine exhaust to reduce the jet velocity and hence the noise generated by the jet. The model was designed and built by Pratt & Whitney under NASA contract. The test, completed in June 1995, was conducted in Lewis' Aero-Acoustic Propulsion Laboratory.

Source record↗

NASA NTRS2011

Using Innovative Techniques for Manufacturing Rocket Engine Hardware

Many of the manufacturing techniques that are currently used for rocket engine component production are traditional methods that have been proven through years of experience and historical precedence. As we enter into a new space age where new launch vehicles are being designed and propulsion systems are being improved upon, it is sometimes necessary to adopt new and innovative techniques for manufacturing hardware. With a heavy emphasis on cost reduction and improvements in manufacturing time, manufacturing techniques such as Direct Metal Laser Sintering (DMLS) are being adopted and evaluated for their use on J-2X, with hopes of employing this technology on a wide variety of future projects. DMLS has the potential to significantly reduce the processing time and cost of engine hardware, while achieving desirable material properties by using a layered powder metal manufacturing process in order to produce complex part geometries. Marshall Space Flight Center (MSFC) has recently hot-fire tested a J-2X gas generator discharge duct that was manufactured using DMLS. The duct was inspected and proof tested prior to the hot-fire test. Using the Workhorse Gas Generator (WHGG) test setup at MSFC?s East Test Area test stand 116, the duct was subject to extreme J-2X gas generator environments and endured a total of 538 seconds of hot-fire time. The duct survived the testing and was inspected after the test. DMLS manufacturing has proven to be a viable option for manufacturing rocket engine hardware, and further development and use of this manufacturing method is recommended.

Betts, Erin M.↗

DOE OSTI2024

Mechanical Engineering Safety Note 1012910313-AA: CEA LTIC Structural Integrity

The LRU Target Insert Cryostat (LTIC) is the end effector of the NIF Cryogenic Target Positioner (CryoTarpos), which houses a cooling system to support cryogenic target experiments at NIF. The LTIC maintains a target at micron level positional stability and millikelvin level temperature stability during a NIF shot and is also subject to a portion of the blast load governed by the solid angle subtended by the blast shield at the front of the system. This MESN evaluates loading of the CEA LTIC, a redesigned LTIC to be fielded at Laser Megajoule (LMJ) in France, which has been designed to lay out requirements agreed upon between LLNL and CEA personnel. The LMJ version of CryoTarpos is referred to as the PCC. A high-level system overview of the LTIC on the PCC is shown.

42 ENGINEERING↗

NASA NTRSDate not supplied

High-Speed Visualization of Spray Breakup in a Rotating Detonation Combustor Using Laser Induced Fluorescence

Rotating detonation engines (RDEs) represent a novel propulsion technology where incoming reactants are consumed by a self-sustaining detonation wave that travels azimuthally around an annular combustion chamber. In theory, the operating mode of these devices approximates a constant-volume combustion Humphry cycle. This represents a 5-15% increase in thermal efficiency over current rockets and air breathing systems operating on constant-pressure combustion Brayton cycles. The use of liquid fuels in RDEs represent unique challenges in terms of performance and operability. However, the fundamental physics involved in spray breakup, evaporation, and combustion are not well understood inside these devices. This research seeks to provide direct insight into these processes by adding a single liquid fuel injector into an otherwise hydrogen-air RDE to evaluate the breakup and refill dynamics. Visualization is performed by 200-1000 kHz laser induced fluorescence of liquid phase diesel (355 nm) and or kerosene (266 nm).

Detonation↗

NASA NTRS1984

Laser Docking System

The Laser Docking System (LDS) consists of passive docking aids (reflectors) placed on the target vehicle in a known location and orientation. These reflectors are acquired and tracked by means of a modulated laser beam located on the interceptor vehicle. The LDS enables the interceptor vehicle to analyze the return (reflected) signal in order to determine both relative position and relative attitude of the target vehicle during stationkeeping and docking. Laser ranging experiments have been accomplished at NASA, and from these experiments have evolved laser docking concepts. The concepts include angle and attitude measurement which are capable of providing all of the information needed for automatic docking control by the interceptor vehicle. Several designs are being compared. Plans include the development and testing of: first a breadboard model, then an engineering model, and finally qualification and flight systems.

Erwin, H. O.↗

NASA NTRS1993

Orbit transfer rocket engine technology program

An advanced near term (1990's) space-based Orbit Transfer Vehicle Engine (OTVE) system was designed, and the technologies applicable to its construction, maintenance, and operations were developed under Tasks A through F of the Orbit Transfer Rocket Engine Technology Program. Task A was a reporting task. In Task B, promising OTV turbomachinery technologies were explored: two stage partial admission turbines, high velocity ratio diffusing crossovers, soft wear ring seals, advanced bearing concepts, and a rotordynamic analysis. In Task C, a ribbed combustor design was developed. Possible rib and channel geometries were chosen analytically. Rib candidates were hot air tested and laser velocimeter boundary layer analyses were conducted. A channel geometry was also chosen on the basis of laser velocimeter data. To verify the predicted heat enhancement effects, a ribbed calorimeter spool was hot fire tested. Under Task D, the optimum expander cycle engine thrust, performance and envelope were established for a set of OTV missions. Optimal nozzle contours and quick disconnects for modularity were developed. Failure Modes and Effects Analyses, maintenance and reliability studies and component study results were incorporated into the engine system. Parametric trades on engine thrust, mixture ratio, and area ratio were also generated. A control system and the health monitoring and maintenance operations necessary for a space-based engine were outlined in Task E. In addition, combustor wall thickness measuring devices and a fiberoptic shaft monitor were developed. These monitoring devices were incorporated into preflight engine readiness checkout procedures. In Task F, the Integrated Component Evaluator (I.C.E.) was used to demonstrate performance and operational characteristics of an advanced expander cycle engine system and its component technologies. Sub-system checkouts and a system blowdown were performed. Short transitions were then made into main combustor ignition and main stage operation.

Gustafson, N. B.↗

NASA NTRSDate not supplied

Development of Laser Powder Bed Fusion NASA HR-2 for Hydrogen Sensitive Liquid Rocket Engine 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 2000s. AM has provided new design and manufacturing opportunities to reduce cost and schedule, consolidate parts, and optimize performance. Laser Powder Bed Fusion (L-PBF) is one of the most commonly used AM processes to fabricate components of complex shape requiring fine feature resolution. Due to exposure to high-pressure gaseous hydrogen, mechanical property degradation caused by hydrogen environment embrittlement (HEE) is a critical concern for many materials in liquid hydrogen propulsion systems. NASA has identified the need to develop and advance new materials in unique engine applications using liquid hydrogen as a propellant. One such material being developed at NASA Marshall Space Flight Center is L-PBF NASA HR-2 (Hydrogen Resistant-2), a high-strength Fe-Ni-based superalloy resistant to HEE. The chemistry of NASA HR-2 was formulated to meet requirements for key liquid rocket engine (LRE) components that operate in high-pressure hydrogen environments. Initial development and material characterization found that NASA HR-2 has excellent L-PBF printability, and its microstructure evolves well after heat treatment. This new alloy has undergone fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing across a range of temperatures. Tensile testing was performed in a pressurized gaseous hydrogen (GH2) environment to assess its resistance to HEE. L-PBF NASA HR-2 has an average yield stress of 95 ksi, an ultimate tensile stress of 165 ksi, and a very high fracture elongation of 34 - 36% when tested in a high-pressure (5 ksi) hydrogen environment. The tensile property data confirms hydrogen has little influence on HR-2’s ductility, strength, and fracture behavior. L-PBF NASA HR-2 is a promising option for many hydrogen-sensitive LRE components that require exceptional resistance to HEE. This paper will provide an overview of the L-PBF process development, material characterization, mechanical and thermophysical properties, and LRE hardware development for NASA HR-2.

Po S Chen↗

NASA NTRS2019

Technology Readiness Assessment for HEEET TPS

The HEEET project was conceived to develop a heatshield with a high performance ablative thermal protection material that can withstand the extreme entry environment produced as a result of rapid deceleration during high speed entry into Venus, Saturn, Uranus or higher speed entry into Earth's atmosphere. Successful maturation of HEEET supports future New Frontiers and Discovery AO's, as well as Flagship and directed missions in the longer term. In addition, HEEET has the potential to evolve and to support re-entry to Earth, for missions such as Mars Sample Return.The primary goal of the HEEET Project was to develop an ablative TPS heat-shield based on woven TPS technology to Technology Readiness Level (TRL) 6. Key evidence to support the TRL evaluation includes: Demonstration of reproducible manufacturing of a dual layer material over a range of thicknesses and integrated on to a heatshield engineering test unit at a scale that is applicable to near term Discovery as the highest priority and future NF missions as secondary priority set of missions. Demonstration of predictable and stable performance of the dual layer TPS over a range of entry environments that are applicable to near term Discovery and NF missions of interest to SMD.Includes completion of coupon arc jet and laser testing and development of a mid-fidelity thermal response model that correlates with test results. Demonstration of flight heatshield system design for a range of sizes and loads that are relevant to near term Discovery and NF missions of interest to SMD. Includes completion of structural testing to validate analytic thermal/structural models and development of a material property database. Includes structural testing of a ~1m Engineering Test Unit under relevant entry loads.

Gage, Peter↗