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NASA NTRS2016

The Effect of Laser Scan Strategy on Distortion and Residual Stresses of Arches Made With Selective Laser Melting

The NASA Marshall Space Flight Center (MSFC) is developing Additive Manufacturing (AM) - both in-space AM for on-demand parts, tools, or structures, and on-earth AM for rapid, reduced-cost, small volume production of complex space-flight hardware. Selective Laser Melting (SLM) is an on-earth AM technology that MSFC is using to build Alloy 718 rocket engine components. An understanding of the SLM-718 material properties is required to design, build, and qualify these components for space flight. Residual stresses and are of particular interest for this AM process, since SLM is a series of approximately 100 micron-wide welds, where highly non-linear heating and cooling, severe thermal gradients and repeated thermal cycling can result in high residual stresses within the component. These stresses may cause degraded material properties, and warp or distort the geometry of the SLM component. The distortions can render the component out-of-tolerance when inspected, and even interrupt or halt the build process if the warped material prevents the SLM machine from operating properly. The component must be scrapped and re-designed, which is time consuming and costly. If residual stresses are better understood, and can be predicted, these effects can be mitigated early in the component's design. the compressive residual stresses in the z-direction were highest in the chess sample, followed by island then continuous. This may be due to the binding nature of the segments

Bagg, Stacey D.↗

NASA NTRS2000

NASA's Advanced Propulsion Technology Activities for Third Generation Fully Reusable Launch Vehicle Applications

NASA's Office of Aeronautics and Space Transportation Technology (OASTT) established the following three major goals, referred to as "The Three Pillars for Success": Global Civil Aviation, Revolutionary Technology Leaps, and Access to Space. The Advanced Space Transportation Program Office (ASTP) at the NASA's Marshall Space Flight Center in Huntsville, Ala. focuses on future space transportation technologies under the "Access to Space" pillar. The Propulsion Projects within ASTP under the investment area of Spaceliner100, focus on the earth-to-orbit (ETO) third generation reusable launch vehicle technologies. The goals of Spaceliner 100 is to reduce cost by a factor of 100 and improve safety by a factor of 10,000 over current conditions. The ETO Propulsion Projects in ASTP, are actively developing combination/combined-cycle propulsion technologies that utilized airbreathing propulsion during a major portion of the trajectory. System integration, components, materials and advanced rocket technologies are also being pursued. Over the last several years, one of the main thrusts has been to develop rocket-based combined cycle (RBCC) technologies. The focus has been on conducting ground tests of several engine designs to establish the RBCC flowpaths performance. Flowpath testing of three different RBCC engine designs is progressing. Additionally, vehicle system studies are being conducted to assess potential operational space access vehicles utilizing combined-cycle propulsion systems. The design, manufacturing, and ground testing of a scale flight-type engine are planned. The first flight demonstration of an airbreathing combined cycle propulsion system is envisioned around 2005. The paper will describe the advanced propulsion technologies that are being being developed under the ETO activities in the ASTP program. Progress, findings, and future activities for the propulsion technologies will be discussed.

Hueter, Uwe↗

NASA NTRS1999

High-Performance Bipropellant Engine

TRW, under contract to the NASA Lewis Research Center, has successfully completed over 10 000 sec of testing of a rhenium thrust chamber manufactured via a new-generation powder metallurgy. High performance was achieved for two different propellants, N2O4- N2H4 and N2O4 -MMH. TRW conducted 44 tests with N2O4-N2H4, accumulating 5230 sec of operating time with maximum burn times of 600 sec and a specific impulse Isp of 333 sec. Seventeen tests were conducted with N2O4-MMH for an additional 4789 sec and a maximum Isp of 324 sec, with a maximum firing duration of 700 sec. Together, the 61 tests totalled 10 019 sec of operating time, with the chamber remaining in excellent condition. Of these tests, 11 lasted 600 to 700 sec. The performance of radiation-cooled rocket engines is limited by their operating temperature. For the past two to three decades, the majority of radiation-cooled rockets were composed of a high-temperature niobium alloy (C103) with a disilicide oxide coating (R512) for oxidation resistance. The R512 coating practically limits the operating temperature to 1370 C. For the Earth-storable bipropellants commonly used in satellite and spacecraft propulsion systems, a significant amount of fuel film cooling is needed. The large film-cooling requirement extracts a large penalty in performance from incomplete mixing and combustion. A material system with a higher temperature capability has been matured to the point where engines are being readied for flight, particularly the 100-lb-thrust class engine. This system has powder rhenium (Re) as a substrate material with an iridium (Ir) oxidation-resistant coating. Again, the operating temperature is limited by the coating; however, Ir is capable of long-life operation at 2200 C. For Earth-storable bipropellants, this allows for the virtual elimination of fuel film cooling (some film cooling is used for thermal control of the head end). This has resulted in significant increases in specific impulse performance (15 to 20 sec). To determine the merits of a powder rhenium thrust chamber, Lewis On-Board Propulsion Branch directed TRW (under the Space Storable Rocket Technology Program and the High Pressure Earth Storable Rocket Technology Program) to design, fabricate, and test an engineering model to serve as a technology demonstrator.

Biaglow, James A.↗

NASA NTRS2018

NASA's Space Launch System: Progress Toward Unmatched Exploration Capability

The Space Launch System (SLS) Program delivered the first element of the exploration-class rocket and completed manufacturing of all major structural elements in 2017. The Program continues component integration and testing in 2018 in preparation for the inaugural launch of NASA's new deep space exploration system in fiscal year 2020. SLS represents a new strategic national capability designed for the most challenging human and robotic exploration and is engineered for overall mission success. This paper will discuss the technical and programmatic successes and challenges of the past year and look ahead to plans for 2018 and 2019.

Honeycutt, John↗

NASA NTRSDate not supplied

NASA Space Launch System Prepares for Key Hotfire Test Before Vehicle Integration

NASA this year is working toward the final major integrated hardware and avionics test for its Space Launch System (SLS), the agency’s new super heavy-lift vehicle to send large, strategic payloads to the Moon, Mars and beyond. As the backbone of the Artemis human lunar exploration program, Artemis I SLS operations will then shift to the launch site and integration for the inaugural mission. For this final major test of the first vehicle NASA has built exclusively for deep space exploration since the Saturn V, a NASA/Boeing/Aerojet Rocketdyne team will conduct the final core stage “green run” test at NASA's Stennis Space Center with a dramatic firing of all four core stage engines. This test will validate the operation of the stage structures, main propulsion system, engines, avionics, and software. Following data review, stage inspection, and refurbishment, the stage will be barged to NASA’s Kennedy Space Center to continue integration of the Artemis I launch vehicle. Already underway is assembly of the mission’s five-segment solid rocket boosters. The mission’s upper stage and spacecraft adapters also are staged at the launch site ready for integration. Even as the Artemis I SLS proceeds toward launch later this year, the Artemis II and Artemis III vehicles are coming together, with core stages, engines, boosters, upper stage, and payload accommodations in various stages of manufacturing and/or processing. Planning is also underway for additional core stages and a new, more powerful upper stage that will increase lunar payload mass. SLS is the anchor transportation leg of a plan for sustained human exploration of the Moon, including the first human landing later in the decade. This paper will discuss SLS progress to date and expected 2021 milestones.

Bruce R. Askins↗

NASA NTRSDate not supplied

Overview of the High Reynolds Number Ascent Wind Tunnel Test of the Space Launch System at the National Transonic Facility

Transonic, high Reynolds number wind tunnel testing for the Space Launch System (SLS) ascent flight environment was conducted in the National Transonic Facility (NTF) at the NASA Langley Research Center from December 2019 to April 2021. The test was sponsored by the SLS Program and the NASA Engineering & Safety Center with the ob- jective of assessing and characterizing Reynolds number effects on the ascent aerodynamics of the SLS launch vehicle. The cryogenic test article was a 1.75%-scale representation of the SLS Block 1 Cargo configuration that was fabricated mostly out of stainless steel, but with several additive-manufactured components including the Solid Rocket Booster (SRB) attach brackets and the SRB nozzles. This was the first use of additive manufacturing on structural components of a cryogenic model in the NTF, therefore post-fabrication material testing and inspections were performed to satisfy safety requirements. Force & moment and surface pressure data were acquired for Mach numbers between 0.50 and 0.95 over a range of Reynolds numbers based on core stage diameter between 2x10^6 and a maximum of 40x10^6 corresponding to 45% of flight Reynolds number. Additionally, flow visualization data using Pressure Sensitive Paint were acquired with a focus on the SRB forward attach area, which is susceptible to Reynolds number sensitivity at transonic speeds. This pa- per provides an overview of the test campaign including details on the unique test article and the experimental setup and test execution. General test findings and observations are also presented, but the majority of the test results and data analyses are provided in a companion paper.

Space Launch System↗

NASA NTRSDate not supplied

Overview of the High Reynolds Number Ascent Wind Tunnel Test of the Space Launch System at the National Transonic Facility

Transonic, high Reynolds number wind tunnel testing for the Space Launch System (SLS) ascent flight environment was conducted in the National Transonic Facility (NTF) at the NASA Langley Research Center from December 2019 to April 2021. The test was sponsored by the SLS Program and the NASA Engineering & Safety Center with the ob- jective of assessing and characterizing Reynolds number effects on the ascent aerodynamics of the SLS launch vehicle. The cryogenic test article was a 1.75%-scale representation of the SLS Block 1 Cargo configuration that was fabricated mostly out of stainless steel, but with several additive-manufactured components including the Solid Rocket Booster (SRB) attach brackets and the SRB nozzles. This was the first use of additive manufacturing on structural components of a cryogenic model in the NTF, therefore post-fabrication material testing and inspections were performed to satisfy safety requirements. Force & moment and surface pressure data were acquired for Mach numbers between 0.50 and 0.95 over a range of Reynolds numbers based on core stage diameter between 2x10^6 and a maximum of 40x10^6 corresponding to 45% of flight Reynolds number. Additionally, flow visualization data using Pressure Sensitive Paint were acquired with a focus on the SRB forward attach area, which is susceptible to Reynolds number sensitivity at transonic speeds. This paper provides an overview of the test campaign including details on the unique test article and the experimental setup and test execution. General test findings and observations are also presented, but the majority of the test results and data analyses are provided in a companion paper.

Space Launch System↗

NASA NTRS1973

Space Shuttle Main Engine program status

Performance, weight, and reusability of the Space Shuttle Main Engine, the next generation rocket engine, are important factors in achieving the Space Shuttle mission. The design features of the engine contributing to the achievement of these engine demands are discussed. Many new fabrication methods, material applications, and innovations incorporated into the engine are presented. The engine program is now in the second year of the 47 months development period. The current status of activities in engineering, manufacturing, and test are reviewed. The Design Verification Specification approach to engine development is compared to the development programs for Saturn/Apollo engines.

Kirby, F. M.↗

NASA NTRS1986

Fiber-reinforced superalloy composites provide an added performance edge

Fiber reinforcements are being explored as a means to increasing the performance of superalloys past 980 C. Fiber-reinforced superalloys (FRS), particularly tungsten FRS (TFRS) are candidate materials for rocket-engine turbopump blades for advanced Shuttle engines and in airbreathing and other rocket engines. Refractory metal wires are the reinforcement of choice due to tolerance to fiber/matrix interactions. W alloy fibers have a maximum tensile strength of 2165 MPa at 1095 C and a 100 hr creep rupture strength at stresses up to 1400 MPa. A TFRS has the potential of a service temperature 110 C over the strongest superalloy. Manufacturing processes being evaluated to realize the FRS components are summarized, together with design features which will be introduced in turbine blades to take advantage of the FRS materials and to extend their surface life.

Petrasek, D. W.↗

NASA NTRS2008

System Engineering on the Use for Ares I,V - the Simpler, the Better

The Ares I and Ares V Vehicles will utilize the J-2X rocket engine developed for NASA by the Pratt & Whitney Rocketdyne Company. The J-2X is an improved higher power version of the original J-2 engine used during the Apollo program. With higher power and updated requirements for safety and performance, the J-2X becomes a new engine using state-of-the-art design methodology, materials and manufacturing processes. The implementation of Systems Engineering (SE) principles enables the rapid J-2X development program to remain aligned with the ARES I and V vehicle programs, Meeting the aggressive development schedule is a challenge. Coordinating the best expertise thai NASA and PWR have to offer requires effectively utilizing resources at multiple sites. This presents formidable communication challenges. SE allows honest and open discussions of issues and problems. This simple idea is often overlooked in large and complex SE programs. Regular and effective meetings linking SE objectives to component designs are used to voice differences of opinions with customer and contractor in attendance so that the best mutual decisions can be made on the shortest possible schedule. Regular technical interchange meetings on secure program wide computer networks and CM processes are effective,in the "Controlled Change" process that exemplifies good SE. Good communication is a key effective SE implementation. The System of Systems approach is the vision of the Orion program which facilitates the establishment of dynamic SE processes at all levels including the engine. SE enables requirements evolution by facilitating organizational and process agility. Flow down and distribution of requirements is controlled by Allocation Reports which breakdown numerical design objectives (weight, reliability, etc.) into quanta goals for each component area. Linked databases of design and verification requirements helps eliminate redundancy and potential mistakes inherent m separated systems. Another tool, the Architecture Design Description, is being used to control J-2X system architecture and effectively communicate configuration changes to those involved in the design process. But the proof is in successful program accomplishment. The SE is the methodology being used to meet the challenge of completing J-2X engine certification 2 years ahead of any engine program ever developed at PWR. The Ares I SE system of systems has delivered according to expectations thus far. All major design reviews (SRR. PDR, CDR) have been successfully conducted to satisfy overall program objectives using SE as the basis for accomplishment. The paper describes SE tools and techniques utilized to achieve this success.

Kelly, William↗

NASA NTRS2010

Tight Fits for Americas Next Moon Rocket, Ares V

America has begun the development of a new heavy lift rocket which will enable humans to return to the moon and reach even farther destinations. Five decades ago, the National Aeronautics and Space Administration designed a system (called Saturn/Apollo) to carry men to the moon and back; the rocket which boosted them to the moon was the Saturn V. Saturn V was huge relative to contemporary rockets and is still the largest rocket ever launched. The new moon rocket is called Ares V. It will insert 40% more payload into low earth orbit than Saturn V; and after docking with the crew spacecraft, it will insert 50% more payload onto the translunar trajectory than Saturn V. The current design of Ares V calls for two liquid-fueled stages and 2 "strap-on" solid rockets. The solid rockets are extended-length versions of the solid rockets used on the Shuttle. The diameter of the liquid stages is at least as large as the first stage of the Saturn V; the height of the lower liquid stage (called the core stage) is longer than the external tank of the Shuttle. Huge rockets require huge infrastructure and, during the Saturn/Apollo era, America invested significantly in manufacturing, assembly and launch facilities which are still in use today. Since the Saturn/Apollo era, America has invested in additional infrastructure for the Shuttle program. Ares V must utilize this existing infrastructure, with reasonable modifications. Building a rocket with 50% more capability in the same buildings, testing it in the same test stands, shipping on the same canals under the same bridges, assembling it in the same building, rolling it to the pad on the same crawler, and launching it from the same launch pad is an engineering and logistics challenge which goes hand-in-hand with designing the structure, tanks, turbines, engines, software, etc. necessary to carry such a large payload to earth orbit and to the moon. This paper quantitatively discusses the significant "tight fits" that are constraining Ares V. The engineers designing and building the infrastructure for the Saturn/Apollo program usually added margins and growth capability; sometimes the size of existing facilities (such as the width of a draw bridge) was not a constraint. Ares V may utilize the "extra" space in the existing facilities and expand other tight fits. Some of the tight fits cannot be overcome without great expense; raising the roof on the Vertical Assembly Building for example. Other tight fits are easily overcome; the transporter at the manufacturing facility for the core stage can pass under low ceilings and later over a dike (without dragging the middle) by retracting or extending the struts which support the stage. Tight fits discussed in this paper include manufacturing (jigs, widths, heights, and local transportation), testing (test stand sizes and crane capability), transportation to the test stands and the launch site (barge, waterway, and rail), assembly (VAB internal dimensions and door size), roll-out limits, and launch pad size.

Jaap, John↗

NASA NTRS1999

DRACO Flowpath Performance and Environments

The Advanced Space Transportation (AST) project office has challenged NASA to design, manufacture, ground-test and flight-test an axisymmetric, hydrocarbon-fueled, flight-weight, ejector-ramjet engine system testbed no later than 2005. To accomplish this, a multi-center NASA team has been assembled. The goal of this team, led by NASA-Marshall Space Flight Center (MSFC), is to develop propulsion technologies that demonstrate rocket and airbreathing combined-cycle operation (DRACO). Current technical activities include flowpath conceptual design, engine systems conceptual design, and feasibility studies investigating the integration and operation of the DRACO engine with a Lockheed D-21B drone. This paper focuses on the activities of the Flowpath Systems Product Development Team (PDT), led by NASA-Glenn Research Center (GRC) and supported by NASA-MSFC and TechLand Research, Inc. The objective of the Flowpath PDT at the start of the DRACO program was to establish a conceptual design of the flowpath aerodynamic lines, determine the preliminary performance, define the internal environments, and support the DRACO testbed concept feasibility studies. To accomplish these tasks, the PDT convened to establish a baseline flowpath concept. With the conceptual lines defined, cycle analysis tasks were planned and the flowpath performance and internal environments were defined. Additionally, sensitivity studies investigating the effects of inlet reference area, combustion performance, and combustor/nozzle materials selection were performed to support the Flowpath PDT design process. Results of these tasks are the emphasis of this paper and are intended to verify the feasibility of the DRACO flowpath and engine system as well as identify the primary technical challenges inherent in the flight-weight design of an advanced propulsion technology demonstration engine. Preliminary cycle performance decks were developed to support the testbed concept feasibility studies but are not discussed further in this paper.

Komar, D. R.↗

NASA NTRS2000

Fault Tree in the Trenches, A Success Story

Getting caught up in the explanation of Fault Tree Analysis (FTA) minutiae is easy. In fact, most FTA literature tends to address FTA concepts and methodology. Yet there seems to be few articles addressing actual design changes resulting from the successful application of fault tree analysis. This paper demonstrates how fault tree analysis was used to identify and solve a potentially catastrophic mechanical problem at a rocket motor manufacturer. While developing the fault tree given in this example, the analyst was told by several organizations that the piece of equipment in question had been evaluated by several committees and organizations, and that the analyst was wasting his time. The fault tree/cutset analysis resulted in a joint-redesign of the control system by the tool engineering group and the fault tree analyst, as well as bragging rights for the analyst. (That the fault tree found problems where other engineering reviews had failed was not lost on the other engineering groups.) Even more interesting was that this was the analyst's first fault tree which further demonstrates how effective fault tree analysis can be in guiding (i.e., forcing) the analyst to take a methodical approach in evaluating complex systems.

Long, R. Allen↗

NASA NTRS2012

Materials Advance Chemical Propulsion Technology

In the future, the Planetary Science Division of NASA's Science Mission Directorate hopes to use better-performing and lower-cost propulsion systems to send rovers, probes, and observers to places like Mars, Jupiter, and Saturn. For such purposes, a new propulsion technology called the Advanced Materials Bipropellant Rocket (AMBR) was developed under NASA's In-Space Propulsion Technology (ISPT) project, located at Glenn Research Center. As an advanced chemical propulsion system, AMBR uses nitrogen tetroxide oxidizer and hydrazine fuel to propel a spacecraft. Based on current research and development efforts, the technology shows great promise for increasing engine operation and engine lifespan, as well as lowering manufacturing costs. In developing AMBR, ISPT has several goals: to decrease the time it takes for a spacecraft to travel to its destination, reduce the cost of making the propulsion system, and lessen the weight of the propulsion system. If goals like these are met, it could result in greater capabilities for in-space science investigations. For example, if the amount (and weight) of propellant required on a spacecraft is reduced, more scientific instruments (and weight) could be added to the spacecraft. To achieve AMBR s maximum potential performance, the engine needed to be capable of operating at extremely high temperatures and pressure. To this end, ISPT required engine chambers made of iridium-coated rhenium (strong, high-temperature metallic elements) that allowed operation at temperatures close to 4,000 F. In addition, ISPT needed an advanced manufacturing technique for better coating methods to increase the strength of the engine chamber without increasing the costs of fabricating the chamber.

Source record↗

NASA NTRS1985

Ceramics for advanced O2/H2 application

Ceramics are prime candidate materials for advanced rocket engines because they possess high-temperature capability, a tolerance for aggressive environments, and low density. A program was conducted to assess the applicability of structural ceramics to advanced versions of the Space Shuttle main engine (SSME). Operating conditions of ceramic turbine components were defined and each component in the hot-gas path was assessed in regard to materials selection, manufacturing process and feasibility, and relative structural reliability. The conclusion is that ceramic components would be viable in advanced SSME turbopumps.

Carpenter, H. W.↗

NASA NTRS2011

NASA's Space Launch System Progress Report

Exploration beyond Earth will be an enduring legacy for future generations, confirming America's commitment to explore, learn, and progress. NASA's Space Launch System (SLS) Program, managed at the Marshall Space Flight Center, is responsible for designing and developing the first exploration-class rocket since the Apollo Program's Saturn V that sent Americans to the Moon. The SLS offers a flexible design that may be configured for the MultiPurpose Crew Vehicle and associated equipment, or may be outfitted with a payload fairing that will accommodate flagship science instruments and a variety of high-priority experiments. Both options support a national capability that will pay dividends for future generations. Building on legacy systems, facilities, and expertise, the SLS will have an initial lift capability of 70 metric tons (mT) and will be evolvable to 130 mT. While commercial launch vehicle providers service the International Space Station market, this capability will surpass all vehicles, past and present, providing the means to do entirely new missions, such as human exploration of asteroids and Mars. With its superior lift capability, the SLS can expand the interplanetary highway to many possible destinations, conducting revolutionary missions that will change the way we view ourselves, our planet and its place in the cosmos. To perform missions such as these, the SLS will be the largest launch vehicle ever built. It is being designed for safety and affordability - to sustain our journey into the space age. Current plans include launching the first flight, without crew, later this decade, with crewed flights beginning early next decade. Development work now in progress is based on heritage space systems and working knowledge, allowing for a relatively quick start and for maturing the SLS rocket as future technologies become available. Together, NASA and the U.S. aerospace industry are partnering to develop this one-of-a-kind asset. Many of NASA's space centers across the country will provide their unique expertise to the Space Launch System endeavor. Unique infrastructure to be used includes the Michoud Assembly Facility for tank manufacturing, Stennis Space Center for engine testing, and Kennedy Space Center for processing and launch. As this panel will discuss, the SLS team is dedicated to doing things differently-from applying lean oversight/insight models to smartly using legacy hardware and existing facilities. Building on the foundation laid by over 50 years of human and scientific space flight--and on the lessons learned from the Apollo, Space Shuttle, and Constellation Programs-the SLS team has delivered both technical trade studies and business case analyses to ensure that the SLS architecture will be safe, affordable, reliable, and sustainable.

Singer, Joan A.↗

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 NTRSDate not supplied

Metal Additive Manufacturing Developments for Propulsion Applications

NASA has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the 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 various 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 powder bed fusion (PBF), directed energy deposition (DED), and solid-state AM processes. The results from these processes have demonstrated that AM can enable rapid development of new alloy systems that can yield higher performances across various metal AM processes. 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 various AM-enabled novel alloys, a comparison across the AM processes, and 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 and use of various AM processes 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↗