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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↗
NASA NTRS1993

Inertial electrostatic confinement as a power source for electric propulsion

The potential use of an INERTIAL ELECTROSTATIC CONFINEMENT (IEC) power source for space propulsion has previously been suggested by the authors and others. In the past, these discussions have generally followed the charged-particle electric-discharge engine (QED) concept proposed by Bussard, in which the IEC is used to generate an electron beam which vaporizes liquid hydrogen for use as a propellant. However, an alternate approach is considered, using the IEC to drive a 'conventional' electric thruster unit. This has the advantage of building on the rapidly developing technology for such thrusters, which operate at higher specific impulse. Key issues related to this approach include the continued successful development of the physics and engineering of the IEC unit, as well as the development of efficient step-down dc voltage transformers. The IEC operates by radial injection of energetic ions into a spherical vessel. A very high ion density is created in a small core region at the center of the vessel, resulting in extremely high fusion power density in the core. Experiments at the U. of Illinois in small IEC devices (is less than 60 cm. dia.) demonstrated much of the basic physics underlying this concept, e.g. producing 10(exp 6) D-D neutrons/sec steady-state with deuterium gas flow injection. The ultimate goal is to increase the power densities by several orders of magnitude and to convert to D-He-3 injection. If successful, such an experiment would represent a milestone proof-of-principle device for eventual space power use. Further discussion of IEC physics and status are presented with a description of the overall propulsion system and estimated performance.

Miley, G. H.↗
NASA NTRS1993

Inertial electrostatic confinement as a power source for electric propulsion

The potential use of an Inertial Electrostatic Confinement (IEC) power source for space propulsion has previously been suggested by the authors and others. In the past, these discussions have generally followed the charged-particle electric-discharge engine (QED) concept proposed by Bussard, in which the IEC is used to generate an electron beam which vaporizes liquid hydrogen for use as a propellant. However, in the present study, we consider an alternate approach, using the IEC to drive a conventional electric thruster unit. This has the advantage of building on the rapidly developing technology for such thrusters, which operate at higher specific impulse. Key issues related to this approach include the continued successful development of the physics and engineering of the IEC unit, as well as the development of efficient step-down dc voltage transformers. The IEC operates by radial injection of energetic ions into a spherical vessel. A very high ion density is created in a small core region at the center of the vessel, resulting in extremely high fusion power density in the core. Present experiments at the U. of Illinois in small IEC devices (less than 60-cm. dia.) have demonstrated much of the basic physics underlying this concept, e.g. producing approximately 10(exp 6) D-D neutrons/sec steady-state with deuterium gas flow injection. The ultimate goal is to increase the power densities by several orders of magnitude and to convert to D-He-3 injection. If successful, such an experiment would represent a milestone proof-of-principle device for eventual space power use. Further discussion of IEC physics and status will be presented with a description of the overall propulsion system and estimated performance.

Miley, George H.↗
NASA NTRS2014

Firing Room Remote Application Software Development

The Engineering and Technology Directorate (NE) at National Aeronautics and Space Administration (NASA) Kennedy Space Center (KSC) is designing a new command and control system for the checkout and launch of Space Launch System (SLS) and future rockets. The purposes of the semester long internship as a remote application software developer include the design, development, integration, and verification of the software and hardware in the firing rooms, in particular with the Mobile Launcher (ML) Launch Accessories subsystem. In addition, a Conversion Fusion project was created to show specific approved checkout and launch engineering data for public-friendly display purposes.

Pathways↗
NASA NTRS2022

Vision-Based Precision Approach and Landing for Advanced Air Mobility

Advanced Air Mobility (AAM) aircraft require perception systems for precision approach and landing systems (PALS) in urban, suburban, rural, and regional environments. The current state-of-the-art methods approved for automated approach and landing will be difficult to utilize in support of AAM operational concepts. However, there are technology and systems from other applications and lower-TRL research that use vision, IR, radar, and GPS methods to provide baseline perception and sensing requirements for AAM aircraft approach and landing. This paper focuses on vision-based PAL to demonstrate a closed-loop baseline controller while adhering to the Federal Aviation Administration requirements and regulations. The coplanar algorithm determines pose estimation, which feeds into an Extended Kalman filter. Combining IMU with vision creates a sensor fusion navigation solution for GPS-denied environments. The state estimate leads to glideslope and localizer error computations, which will be pertinent for designing and deriving guidance laws and control laws for AAM PALS. The IMU and vision navigation solution provides promising simulation results for AAM PALS, and higher fidelity simulations will include computer graphics rendering and feature correspondence.

Evan Kawamura↗
NASA NTRS2019

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

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

Katsarelis, Colton↗
NASA NTRS2001

Micro Navigator

Miniature high-performance low-mass space avionics systems are desired for planned future outer planetary exploration missions (i.e. Europa Orbiter/Lander, Pluto-Kuiper Express). The spacecraft fuel and mass requirements enabling orbit insertion is the driving requirement. The Micro Navigator is an integrated autonomous Guidance, Navigation & Control (GN&C)micro-system that would provide the critical avionics function for navigation, pointing, and precision landing. The Micro Navigator hardware and software allow fusion of data from multiple sensors to provide a single integrated vehicle state vector necessary for six degrees of freedom GN&C. The benefits of this MicroNavigator include: 1) The Micro Navigator employs MEMS devices that promise orders of magnitude reductions in mass power and volume of inertial sensors (accelerometers and gyroscopes), celestial sensing devices (startracker, sun sensor), and computing element; 2) The highly integrated nature of the unit will reduce the cost of flight missions. a) The advanced miniaturization technologies employed by the Micro Navigator lend themselves to mass production, and therefore will reduce production cost of spacecraft. b) The integral approach simplifies interface issues associated with discrete components and reduces cost associated with integration and test of multiple components; and 3) The integration of sensors and processing elements into a single unit will allow the Micro Navigator to encapsulate attitude information and determination functions into a single object. This is particularly beneficial for object-oriented software architectures that are used in advanced spacecraft. Additional information is contained in the original extended abstract.

Blaes, B. R.↗
NASA NTRSDate not supplied

Advanced and Additive Manufacturing Technologies for Liquid Rocket Engine Components

Overview of advanced manufacturing and additive manufacturing development at NASA for liquid rocket engines. Presentation includes various material, process, design, and hot-fire testing developments demonstrating the use of advanced components for liquid rocket engines on launch vehicles and in-space systems.

Additive Manufacturing↗
NASA NTRS2008

Ion Beam Propulsion Study

The Ion Beam Propulsion Study was a joint high-level study between the Applied Physics Laboratory operated by NASA and ASRC Aerospace at Kennedy Space Center, Florida, and Berkeley Scientific, Berkeley, California. The results were promising and suggested that work should continue if future funding becomes available. The application of ion thrusters for spacecraft propulsion is limited to quite modest ion sources with similarly modest ion beam parameters because of the mass penalty associated with the ion source and its power supply system. Also, the ion source technology has not been able to provide very high-power ion beams. Small ion beam propulsion systems were used with considerable success. Ion propulsion systems brought into practice use an onboard ion source to form an energetic ion beam, typically Xe+ ions, as the propellant. Such systems were used for steering and correction of telecommunication satellites and as the main thruster for the Deep Space 1 demonstration mission. In recent years, "giant" ion sources were developed for the controlled-fusion research effort worldwide, with beam parameters many orders of magnitude greater than the tiny ones of conventional space thruster application. The advent of such huge ion beam sources and the need for advanced propulsion systems for exploration of the solar system suggest a fresh look at ion beam propulsion, now with the giant fusion sources in mind.

Source record↗
NASA NTRS1987

Selection of high temperature thermal energy storage materials for advanced solar dynamic space power systems

Under the direction of NASA's Office of Aeronautics and Technology (OAST), the NASA Lewis Research Center has initiated an in-house thermal energy storage program to identify combinations of phase change thermal energy storage media for use with a Brayton and Stirling Advanced Solar Dynamic (ASD) space power system operating between 1070 and 1400 K. A study has been initiated to determine suitable combinations of thermal energy storage (TES) phase change materials (PCM) that result in the smallest and lightest weight ASD power system possible. To date the heats of fusion of several fluoride salt mixtures with melting points greater than 1025 K have been verified experimentally. The study has indicated that these salt systems produce large ASD systems because of their inherent low thermal conductivity and low density. It is desirable to have PCMs with high densities and high thermal conductivities. Therefore, alternate phase change materials based on metallic alloy systems are also being considered as possible TES candidates for future ASD space power systems.

Lacy, Dovie E.↗
NASA NTRS1987

Selection of high temperature thermal energy storage materials for advanced solar dynamic space power systems

Under the direction of NASA's Office of Aeronautics and Technology (OAST), the NASA Lewis Research Center has initiated an in-house thermal energy storage program to identify combinations of phase change thermal energy storage media for use with a Brayton and Stirling Advanced Solar Dynamic (ASD) space power system operating between 1070 and 1400 K. A study has been initiated to determine suitable combinations of thermal energy storage (TES) phase change materials (PCM) that result in the smallest and lightest weight ASD power system possible. To date the heats of fusion of several fluoride salt mixtures with melting points greater than 1025 K have been verified experimentally. The study has indicated that these salt systems produce large ASD systems because of their inherent low thermal conductivity and low density. It is desirable to have PCMs with high densities and high thermal conductivities. Therefore, alternate phase change materials based on metallic alloy systems are also being considered as possible TES candidates for future ASD space power systems.

Lacy, Dovie E.↗
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 NTRS2022

NASA System-Wide Safety Wildland Firefighting Operations Workshop Report

On March 9-11, 2022, NASA’s System-Wide Safety Wildland Firefighting Operations Workshop engaged the broader wildland firefighting management ecosystem in a safety-oriented discussion via a virtual platform. This enabled a better understanding of how NASA and community expertise can be leveraged in the safe development of current and future firefighting systems and operations. The goals of the workshop were to: (1) identify and prioritize the top safety-oriented risks, gaps in capabilities, and emerging technologies to enhance wildland firefighting for both near-term and far-term concepts, with a specific focus on aviation operations and (2) engage the stakeholder community in defining emergent safety-oriented scope, roles, responsibilities, and procedures for agents undergoing increasingly complex wildland firefighting operations in information-rich, but uncertain environments. Workshop participants were solicited from wildland firefighting stakeholders across government, industry, and academia. All levels of government were engaged, as NASA sought attendees from federal, state, local, and tribal government agencies. Industry participants from traditional wildland firefighting domains such as data visualization and equipment manufacturers were invited, and corporate attendees from novel application domains such as aerial robotics and autonomous systems were present as well. The top three findings were as follows: (1) Enhancing situation awareness is a safety priority, especially in the use of aerial assets; (2) Timely access to information along with data fusion and integrated displays will enhance safety-critical decision-making both inside and outside aviation contexts; and (3) Tailorable standards and common operating pictures in the field will enhance inter-agency cooperation in the wildland firefighting lifecycle and enable the optimal use of limited resources such as aerial assets. The workshop helped inform NASA of the relevant safety-related wildland firefighting concerns and aided the broader ecosystem in understanding the potential safety-oriented role NASA might play in this community. Increased engagement with crucial governmental stakeholders (e.g., U.S. Forest Service, CAL FIRE, etc.) along with industry partners in cutting- edge information -centric domains is a fundamental next step. Additionally, the workshop findings will help define the first of a series of operationally challenging demonstrations, held in concert with strategic ecosystem partners, known as the Safety Demonstrator Series for NASA’s System-Wide Safety project. The first demonstration is set in the wildland firefighting application domain and will: (1) examine high risk operational scenarios to reduce their overall risk via services, functions or capabilities that act as risk mitigators (or transfer that risk to automated systems better able to tolerate it) and (2) explore novel tools and technologies that will enhance safety margins by enabling non-traditional or neoteric operational paradigms.

wildland firefighting↗
NASA NTRS1982

Advances in cryogenic engineering. Volume 27 - Proceedings of the Cryogenic Engineering Conference, San Diego, CA, August 11-14, 1981

Applications of superconductivity are considered, taking into account MHD and fusion, generators, transformers, transmission lines, magnets for physics, cryogenic techniques, electrtronics, and aspects of magnet stability. Advances related to heat transfer in He I are discussed along with subjects related to theat transfer in He II, refrigeration of superconducting systems, refrigeration and liquefaction, dilution and magnetic refrigerators, refrigerators for space applications, mass transfer and flow phenomena, and the properties of fluids. Developments related to cryogenic applications are also explored, giving attention to bulk storage and transfer of cryogenic fluids, liquefied natural gas operations, space science and technology, and cryopumping. Topics related to cryogenic instrumentation and controls include the production and use of high grade silicon diode temperature sensors, the choice of strain gages for use in a large superconducting alternator, microprocessor control of cryogenic pressure, and instrumentation, data acquisition and reduction for a large spaceborne helium dewar.

Fast, R. W.↗
NASA NTRS2009

Demonstration of Super Cooled Ice as a Phase Change Material Heat Sink for Portable Life Support Systems

A phase change material (PCM) heat sink using super cooled ice as a nontoxic, nonflammable PCM is being developed. The latent heat of fusion for water is approximately 70% larger than most paraffin waxes, which can provide significant mass savings. Further mass reduction is accomplished by super cooling the ice significantly below its freezing temperature for additional sensible heat storage. Expansion and contraction of the water as it freezes and melts is accommodated with the use of flexible bag and foam materials. A demonstrator unit has been designed, built, and tested to demonstrate proof of concept. Both testing and modeling results are presented along with recommendations for further development of this technology.

Leimkuehler, Thomas O.↗
NASA NTRS1973

Development of forming and joining technology for TD-NiCr sheet

Forming joining techniques and properties data were developed for thin-gage TD-NiCr sheet in the recrystallized and unrecrystallized conditions. Theoretical and actual forming limit data are presented for several gages of each type of material for five forming processes: brake forming, corrugation forming, joggling, dimpling and beading. Recrystallized sheet can be best formed at room temperature, but unrecrystallized sheet requires forming at elevated temperature. Formability is satisfactory with most processes for the longitudinal orientation but poor for the transverse orientation. Dimpling techniques require further development for both material conditions. Data on joining techniques and joint properties are presented for four joining processes: resistance seam welding (solid-state), resistance spot welding (solid-state), resistance spot welding (fusion) and brazing. Resistance seam welded (solid-state) joints with 5t overlap were stronger than parent material for both material conditions when tested in tensile-shear and stress-rupture. Brazing studies resulted in development of NASA 18 braze alloy (Ni-16Cr-15Mo-8Al-4Si) with several properties superior to baseline TD-6 braze alloy, including lower brazing temperture, reduced reaction with Td-Ni-Cr, and higher stress-rupture properties.

Torgerson, R. T.↗
NASA NTRS2004

Cryogenic Test Results of Hextek Mirror

A 250 mm diameter lightweight borosilicate mirror has been interferometrically tested from room-temperature down to 30 K at the X-Ray Calibration Facility (XRCF) at Marshall Space Flight Center (MSFC). The minor blank was manufactured by Hextek Corporation using a high-temperature gas fusion process and was then polished at MSFC. It is a sandwich-type mirror consisting of a thin face-sheet (approx.1.5 mm thick), a core structure (20 mm thick, approx.43 mm diameter cells, & 0.5-1.2 mm thick walls), and a thin back-sheet (3 mm thick). The mirror has a 2500 mm spherical radius-of- curvature @/lo). The areal density is 14 kg/sq m. The mirror was tested in the 1 m x 2 m chamber using an Instantaneous Phase Interferometer (PI) from ADE Phase Shift Technologies. The mirror was tested twice. The first test measured the change in surface figure from ambient to 30 K and the repeatability of the change. An attempt was then made by QED Technologies to cryo-figure the mirror using magnetorheological finishing. The second test measured the effectiveness of the cryo- figuring. This paper will describe the test goals, the test instrumentation, and the test results for these cryogenic tests.

Hadaway, James↗
NASA NTRS1998

Representation and Integration of Scientific Information

The objective of this Joint Research Interchange with NASA-Ames was to investigate how the Tsimmis technology could be used to represent and integrate scientific information. The main goal of the Tsimmis project is to allow a decision maker to find information of interest from such sources, fuse it, and process it (e.g., summarize it, visualize it, discover trends). Another important goal is the easy incorporation of new sources, as well the ability to deal with sources whose structure or services evolve. During the Interchange we had research meetings approximately every month or two. The funds provided by NASA supported work that lead to the following two papers: Fusion Queries over Internet Databases; Efficient Query Subscription Processing in a Multicast Environment.

Source record↗