Results for “Hardware Demonstration” — Page 2

NASA NTRS1982

Development of the structural technology of a large deployable antenna

The current NASA-sponsored Antenna Technology Development Program of the offset wrap-rib antenna concept is based on a ground test program of 'proof of concept' hardware whose potential on-orbit performance is based on analytical estimates. The ground demonstration hardware represents a partial 55-meter diameter reflector and feed support structure. Testing will include automated deployment, reflector surface quality evaluation and validation of analytical performance models. Test results and hardware fabrication costs will be used to refine the models that will be the basis for the preliminary design of a 100-meter diameter wrap-rib antenna system. Additionally, the design, processes, tooling, fabrication techniques, fixturing and assembly approaches used for the 'proof of concept' hardware are directly applicable to building flight systems up to 100 meters in diameter.

Wada, B. K.↗

NASA NTRS2017

A PCR Based Microbial Monitoring Alternative Method of Detection and Identification of Microbes Aboard ISS

Previous research has shown that microorganisms and potential human pathogens have been detected on the International Space Station (ISS) with additional introduction of new microflora occurring with every exchange of crew or addition of equipment and supplies. These microbes are readily transferred between crew and subsystems (i.e. ECLSS, environmental control and life support systems). As this can be detrimental to astronaut health and optimal performance of ISS systems, monitoring of systems such as ECLSS to include identification of microbial contaminants could prevent adverse effects on human health and life support systems. Current monitoring on ISS is laborious and utilizes culture based methods followed by sample return to Earth for complete analysis. Future, long-distance spaceflight missions will require real-time monitoring capabilities that enable efficient and rapid assessments of the microbial environment allowing for expedited decisions and more targeted response to cope with anomalies. Polymerase chain reaction (PCR), a molecular microbial monitoring method was chosen and numerous PCR instruments investigated for their potential to perform in microgravity conditions. Using ISS as a test bed for PCR verification in microgravity will enable NASA to assess whether molecular based microbiological sensors may be components of reliable, closed-loop life support and habitation systems in spacecraft, enhancing infrastructure capabilities through increased efficiency, reliability, and time savings by enabling sample analysis on orbit. NASA selected the Water Monitoring Suite as one of the rapid spaceflight hardware demonstration activities utilizing a streamlined process to minimize the time required to fly experimental flight hardware. The RAZOR EX (BioFire Defense, Salt Lake City, UT) system was part of the water monitoring suite and is a commercial off-the-shelf (COTS) real-time PCR instrument designed for field work. The RAZOR EX was originally designed for Department of Defense (DoD) under a small business innovative research (SBIR) grant and is ruggedized, compact and provides a rapid, sample to answer in less than an hour. PCR assays using a fluorescent probe were optimized and spiked with known concentrations of DNA (Pseudomonas aeruginosa) ranging from 0.002 to 20 ng. PCR reagents were lyophilized and configured in customized pouches and tested for flight readiness. Three types of water were used to rehydrate the reagents and demonstrate the fidelity of the PCR reaction in microgravity. Molecular grade deionized water served as a control while filtered and unfiltered ISS potable water served to test for chemical or biological inhibitors. All three types were compared to parallel ground test results. Nine tests were run on ISS (3 of each water type) and the critical threshold cycle (Ct) was compared to parallel ground tests completed at Kennedy Space Center, FL and Johnson Space Center, TX. All concentrations of Pseudomonas aeruginosa DNA were detected. A comparison of the Ct produced in real time PCR indicated similarity between flight and ground samples. There appeared to be no significant difference between flight or ground PCR reactions or between any of the three water types. This testing demonstrated the ability to perform molecular testing during spaceflight operations with similar sensitivity. It will allow for future ground development of molecular protocols and minimize the need for spaceflight testing. Future testing will include development of additional targets including environmental and health related organisms.

Christina Khodadad↗

NASA NTRS2014

Qualitative Event-Based Fault Isolation under Uncertain Observations

For many systems, automatic fault diagnosis is critical to ensuring safe and efficient operation. Fault isolation is performed by analyzing measured signals from the system, and reasoning over the system behavior to determine which faults have occurred, based on models of predicted faulty behavior. For dynamic systems, reasoning may be performed using qualitative analysis of the differences between measured signals and their predicted values, in which observations take the form of qualitative symbols. Such an approach is quick to isolate faults, but depends critically on correct generation of the qualitative symbols from the signals. In this paper, we develop an approach to qualitative event-based fault isolation for dynamic systems that is robust to incorrect qualitative observations. Observations are treated as uncertain, where multiple interpretations of an observation, each with its own probability, are considered. By interpreting observed symbols in a probabilistic manner, the approach degrades gracefully as the number of incorrectly-generated symbols increases. The approach is demonstrated on an electrical power system testbed, and experiments using real data obtained from the hardware demonstrate the improved fault isolation performance in the presence of incorrect symbol generation.

Daigle, Matthew↗

NASA NTRS2015

Update on Risk Reduction Activities for a Liquid Advanced Booster for NASA's Space Launch System

The stated goals of NASA's Research Announcement for the Space Launch System (SLS) Advanced Booster Engineering Demonstration and/or Risk Reduction (ABEDRR) are to reduce risks leading to an affordable Advanced Booster that meets the evolved capabilities of SLS; and enable competition by mitigating targeted Advanced Booster risks to enhance SLS affordability. Dynetics, Inc. and Aerojet Rocketdyne (AR) formed a team to offer a wide-ranging set of risk reduction activities and full-scale, system-level demonstrations that support NASA's ABEDRR goals. For NASA's SLS ABEDRR procurement, Dynetics and AR formed a team to offer a series of full-scale risk mitigation hardware demonstrations for an affordable booster approach that meets the evolved capabilities of the SLS. To establish a basis for the risk reduction activities, the Dynetics Team developed a booster design that takes advantage of the flight-proven Apollo-Saturn F-1. Using NASA's vehicle assumptions for the SLS Block 2, a two-engine, F-1-based booster design delivers 150 mT (331 klbm) payload to LEO, 20 mT (44 klbm) above NASA's requirements. This enables a low-cost, robust approach to structural design. During the ABEDRR effort, the Dynetics Team has modified proven Apollo-Saturn components and subsystems to improve affordability and reliability (e.g., reduce parts counts, touch labor, or use lower cost manufacturing processes and materials). The team has built hardware to validate production costs and completed tests to demonstrate it can meet performance requirements. State-of-the-art manufacturing and processing techniques have been applied to the heritage F-1, resulting in a low recurring cost engine while retaining the benefits of Apollo-era experience. NASA test facilities have been used to perform low-cost risk-reduction engine testing. In early 2014, NASA and the Dynetics Team agreed to move additional large liquid oxygen/kerosene engine work under Dynetics' ABEDRR contract. Also led by AR, the objectives of this work are to demonstrate combustion stability and measure performance of a 500,000 lbf class Oxidizer-Rich Staged Combustion (ORSC) cycle main injector. A trade study was completed to investigate the feasibility, cost effectiveness, and technical maturity of a domestically produced Atlas V engine that could also potentially satisfy NASA SLS payload-to-orbit requirements via an advanced booster application. Engine physical dimensions and performance parameters resulting from this study provide the system level requirements for the ORSC risk reduction test article. The test article is scheduled to complete critical design review this fall and begin testing in 2017. Dynetics has also designed, developed, and built innovative tank and structure assemblies using friction stir welding to leverage recent NASA investments in manufacturing tools, facilities, and processes, significantly reducing development and recurring costs. The full-scale cryotank assembly was used to verify the structural design and prove affordable processes. Dynetics performed hydrostatic and cryothermal proof tests on the assembly to verify the assembly meets performance requirements. This paper will discuss the ABEDRR engine task and structures task achievements to date and the remaining effort through the end of the contract.

Crocker, Andrew M.↗

NASA NTRS2004

Demonstration of a 10-m Solar Sail System

The NASA In-Space Propulsion (ISP) program has been sponsoring system design development and hardware demonstration activities of solar sail technology over the past 16 months. Efforts to validate by test a moderate-scale (10-m) 1/4 symmetry ground demonstration sail system are nearly complete. Results of testing and analytical model validation of component and assembly functional, strength, stiffness, shape, and dynamic behavior are discussed.

Murphy, David M.↗

NASA NTRS1995

Vaccum Gas Tungsten Arc Welding, phase 1

This two year program will investigate Vacuum Gas Tungsten Arc Welding (VGTAW) as a method to modify or improve the weldability of normally difficult-to-weld materials. VGTAW appears to offer a significant improvement in weldability because of the clean environment and lower heat input needed. The overall objective of the program is to develop the VGTAW technology and implement it into a manufacturing environment that will result in lower cost, better quality and higher reliability aerospace components for the space shuttle and other NASA space systems. Phase 1 of this program was aimed at demonstrating the process's ability to weld normally difficult-to-weld materials. Phase 2 will focus on further evaluation, a hardware demonstration and a plan to implement VGTAW technology into a manufacturing environment. During Phase 1, the following tasks were performed: (1) Task 11000 Facility Modification - an existing vacuum chamber was modified and adapted to a GTAW power supply; (2) Task 12000 Materials Selection - four difficult-to-weld materials typically used in the construction of aerospace hardware were chosen for study; (3) Task 13000 VGTAW Experiments - welding experiments were conducted under vacuum using the hollow tungsten electrode and evaluation. As a result of this effort, two materials, NARloy Z and Incoloy 903, were downselected for further characterization in Phase 2; and (4) Task 13100 Aluminum-Lithium Weld Studies - this task was added to the original work statement to investigate the effects of vacuum welding and weld pool vibration on aluminum-lithium alloys.

Weeks, J. L.↗

NASA NTRS1993

Diskless supercomputers: Scalable, reliable I/O for the Tera-Op technology base

Computing is seeing an unprecedented improvement in performance; over the last five years there has been an order-of-magnitude improvement in the speeds of workstation CPU's. At least another order of magnitude seems likely in the next five years, to machines with 500 MIPS or more. The goal of the ARPA Teraop program is to realize even larger, more powerful machines, executing as many as a trillion operations per second. Unfortunately, we have seen no comparable breakthroughs in I/O performance; the speeds of I/O devices and the hardware and software architectures for managing them have not changed substantially in many years. We have completed a program of research to demonstrate hardware and software I/O architectures capable of supporting the kinds of internetworked 'visualization' workstations and supercomputers that will appear in the mid 1990s. The project had three overall goals: high performance, high reliability, and scalable, multipurpose system.

Katz, Randy H.↗

NASA NTRS2010

NASA Docking System (NDS) Technical Integration Meeting

This slide presentation reviews the NASA Docking System (NDS) as NASA's implementation of the International Docking System Standard (IDSS). The goals of the NDS, is to build on proven technologies previously demonstrated in flight and to advance the state of the art of docking systems by incorporating Low Impact Docking System (LIDS) technology into the NDS. A Hardware Demonstration was included in the meeting, and there was discussion about software, NDS major system interfaces, integration information, schedule, and future upgrades.

Lewis, James L.↗

NASA NTRS2017

Expansion of Microbial Monitoring Capabilities on the International Space Station (ISS)

Microbial monitoring is one of the tools that the National Aeronautics and Space Administration (NASA) uses on the International Space Station (ISS) to help maintain crew health and safety. In combination with regular housekeeping and disinfection when needed, microbial monitoring provides important information to the crew about the quality of the environment. Rotation of astronauts, equipment, and cargo on the ISS can affect the microbial load in the air, surfaces, and water. The current ISS microbial monitoring methods are focused on culture-based enumeration during flight and require a significant amount of crew time as well as long incubation periods of up to 5 days there by proliferating potential pathogens. In addition, the samples require return to Earth for complete identification of the microorganisms cultivated. Although the current approach assess the quality of the ISS environment, molecular technology offers faster turn-around of information particularly beneficial in an off-nominal situation. In 2011, subject matter experts from industry and academia recommended implementation of molecular-based technologies such as quantitative real-time polymerase chain reaction (qPCR) for evaluation to replace current, culture-based technologies. The RAZOR EX (BioFire Defense, Inc, Salt Lake City, UT) a ruggedized, compact, COTS (commercial off the shelf) qPCR instrument was tested, evaluated and selected in the 2 X 2015 JSC rapid flight hardware demonstration initiative as part of the Water Monitoring Suite. RAZOR EX was launched to ISS on SpaceX-9 in July 2016 to evaluate the precision and accuracy of the hardware by testing various concentrations of DNA in microgravity compared to ground controls. Flight testing was completed between September 2016 and March 2017. Data presented will detail the hardware performance of flight testing results compared to ground controls. Future goals include additional operational ground-based testing and assay development to determine if this technology can meet spaceflight microbial monitoring requirements.

Khodadad, Christina L.↗

NASA NTRSDate not supplied

The Trash Compaction Processing System (TCPS) Technology Demonstration and Risk Reduction Updates FY23-FY24

The Next STEP Phase BTrash Compaction Processing System (TCPS) is being developed for a technology demonstration on the International Space Station(ISS) to process common spacecraft consumables trash such as food packaging and clothing to reduce trash storage volume, recover water, safen(e.g. reduce biological activity), and shape the trash for storage, jettison, reuse (e.g.,radiation shielding) and/or recycling. Sierra Space is developing the flight demonstration hardware and National Aeronautics and Space Administration(NASA) continues to conduct risk reduction activities to exploreoperational scenarios, setting the stage for successful on-orbit tests. After the flight demonstration on ISS, the TCPS becomes available to be infused into NASA short-and long-term missions.This paper will discuss the rationale for the updated requirement definitions outlined in the 2023 International Conference on Environmental System TCPS paper and the ongoing risk reduction activities. In addition, drawing from lessons learned in the development of the TCPS, a discussion of other compression technologies will be introduced for various mission types.

Trash Compaction Processing System↗

NASA NTRSDate not supplied

The Trash Compaction Processing System (TCPS) Technology Demonstration and Risk Reduction Updates FY23-FY24 Presentation

The Next STEP Phase BTrash Compaction Processing System (TCPS) is being developed for a technology demonstration on the International Space Station(ISS) to process common spacecraft consumables trash such as food packaging and clothing to reduce trash storage volume, recover water, safen(e.g. reduce biological activity), and shape the trash for storage, jettison, reuse (e.g.,radiation shielding) and/or recycling. Sierra Space is developing the flight demonstration hardware and National Aeronautics and Space Administration(NASA) continues to conduct risk reduction activities to exploreoperational scenarios, setting the stage for successful on-orbit tests. After the flight demonstration on ISS, the TCPS becomes available to be infused into NASA short-and long-term missions.This paper will discuss the rationale for the updated requirement definitions outlined in the 2023 International Conference on Environmental System TCPS paper and the ongoing risk reduction activities. In addition, drawing from lessons learned in the development of the TCPS, a discussion of other compression technologies will be introduced for various mission types.

Trash Compaction Processing System↗

NASA NTRS2011

Fission Surface Power Systems (FSPS) Project Final Report for the Exploration Technology Development Program (ETDP): Fission Surface Power, Transition Face to Face

The Fission Surface Power Systems Project became part of the ETDP on October 1, 2008. Its goal was to demonstrate fission power system technology readiness in an operationally relevant environment, while providing data on fission system characteristics pertinent to the use of a fission power system on planetary surfaces. During fiscal years 08 to 10, the FSPS project activities were dominated by hardware demonstrations of component technologies, to verify their readiness for inclusion in the fission surface power system. These Pathfinders demonstrated multi-kWe Stirling power conversion operating with heat delivered via liquid metal NaK, composite Ti/H2O heat pipe radiator panel operations at 400 K input water temperature, no-moving-part electromagnetic liquid metal pump operation with NaK at flight-like temperatures, and subscale performance of an electric resistance reactor simulator capable of reproducing characteristics of a nuclear reactor for the purpose of system-level testing, and a longer list of component technologies included in the attached report. Based on the successful conclusion of Pathfinder testing, work began in 2010 on design and development of the Technology Demonstration Unit (TDU), a full-scale 1/4 power system-level non-nuclear assembly of a reactor simulator, power conversion, heat rejection, instrumentation and controls, and power management and distribution. The TDU will be developed and fabricated during fiscal years 11 and 12, culminating in initial testing with water cooling replacing the heat rejection system in 2012, and complete testing of the full TDU by the end of 2014. Due to its importance for Mars exploration, potential applicability to missions preceding Mars missions, and readiness for an early system-level demonstration, the Enabling Technology Development and Demonstration program is currently planning to continue the project as the Fission Power Systems project, including emphasis on the TDU completion and testing.

Palac, Donald T.↗

NASA NTRS2023

NASA Kennedy Space Center Swamp Works: Innovation Methods for Advanced Research & Technology Development

Kennedy Space Center’s (KSC) Swamp Works, provides government and commercial space ventures with the technologies required for working and living on the surfaces of the Moon or other planets and bodies in our solar system. The Swamp Works team establishes agile, innovative and cost effective exploration mission solutions through leveraging of partnerships across NASA, industry and academia. Concepts start small and build up efficiently, with lean development processes and a hands on approach. Testing is performed in early stages to drive design improvements and progressively increase Technology Readiness Levels (TRL). Swamp Works provides concepts, architecture studies and trades, designs, data, technology development, technology demonstration hardware, flight hardware, testing, flight support and knowledge in support of the development of surface systems. This paper will summarize the state of the art in innovation methods, and it will compare the various other methods to how innovation is accomplished at the NASA KSC Swamp Works. Since 2013, Swamp Works has developed a wide variety of technologies, and has demonstrated viable methods for innovation while also collaborating with other government agencies, industry and academia to support space exploration. These methods focus on agile design, test, build iterations where each cycle of prototyping results in improved knowledge and designs. Failures are tole rated in the early stages of these iterations, since the overall development cycle is shorter more efficient and cost effective by retiring risk early in the cycle. Momentum is maintained and the development teams remain highly motivated by the high level of team work, technical excellence, engagement and creative freedom.

Robotic Mining↗

NASA NTRS1994

Instrumentation for In-Flight SSME Rocket Engine Plume Spectroscopy

This paper describes instrumentation that is under development for an in-flight demonstration of a plume spectroscopy system on the space shuttle main engine. The instrumentation consists of a nozzle mounted optical probe for observation of the plume, and a spectrometer for identification and quantification of plume content. This instrumentation, which is intended for use as a diagnostic tool to detect wear and incipient failure in rocket engines, will be validated by a hardware demonstration on the Technology Test Bed engine at the Marshall Space Flight Center.

Madzsar, George C.↗

NASA NTRS2026

Reliability Models and Demonstration of a Fault-Tolerant Motor Concept for Vertical Takeoff and Landing Vehicles

This report documents the completion of the Revolutionary Vertical Lift Technology Project Annual Performance Indicator 24-3.2.4.1: “Apply and document reliability prediction for high reliability motor concept.” Two modeling tools were completed for calculation of reliability of fault-tolerant (FT) motors, and key FT operations of a modular FT motor were demonstrated experimentally. The two models are complementary tools for the stakeholder and user community. Both models employ Markov chain theory. The first model is a time-homogeneous Markov chain model, and the second is a time-inhomogeneous Markov-Weibull model. This report’s main sections are as follows: 1.0 Introduction, 2.0 Theory, 3.0 Motor Reliability Models, 4.0 Validation of FT Operation by Hardware Demonstration, and 5.0 Concluding Remarks. Novel contributions to the field include development of a modular FT motor concept for electrified vertical takeoff and landing (eVTOL) application, solution methods to solve the reliability calculations, development of figures of merit, and the introduction of “linked chains” to formulate a building-block approach for time-inhomogeneous Markov-Weibull modeling of motor reliability. Example case studies have been completed, and results are provided and discussed herein. A four-module FT motor concept was developed to a preliminary-design level of detail. This eVTOL FT motor concept was designed for galvanic, magnetic, and thermal isolation of stator winding faults. The reliability of the concept motor was calculated using a time-inhomogeneous Markov chain model. Employing average failure rate as a metric, 570 times greater reliability was achieved as compared to a baseline motor without fault tolerance. A demonstrator motor was built and tested. The testing demonstrated the key features of FT operation and validated the essential premises of the FT motor concepts presented herein. The experiments included successful demonstration of the feasibility of the following four key FT features: (1) terminal open-circuit operation, (2) thermal isolation after fault, (3) terminal short-circuit operation, and (4) internal short-circuit operation. These works indicate that FT modular motor drives offer promise for addressing the daunting reliability gap that electric aircraft propulsor drives are facing relative to the best conventional motor drive technology that is available today.

Electric Motor↗

NASA NTRS1986

Non-intrusive speed sensor

In Phase I of the Non-Intrusive Speed Sensor program, a computerized literature search was performed to identify candidate technologies for remote, non-intrusive speed sensing applications in Space Shuttle Main Engine (SSME) turbopumps. The three most promising technologies were subjected to experimental evaluation to quantify their performance characteristics under the harsh environmental requirements within the turbopumps. Although the infrared and microwave approaches demonstrated excellent cavitation immunity in laboratory tests, the variable-source magnetic speed sensor emerged as the most viable approach. Preliminary design of this speed sensor encountered no technical obstacles and resulted in viable and feasible speed nut, sensor housing, and sensor coil designs. Phase II of this program developed the variable-source magnetic speed sensor through the detailed design task and guided the design into breadboard fabrication. The speed sensor and its integral speed nut were evaluated at both unit and system level testing. The final room-temperature and cryogenic spin testing of the hardware demonstrated that the sensor was capable of generating sufficient output signal to enable remote speed sensing from 1500 to 40000 rpm over a speed nut/sensor separation of 3.5 inches.

Wyett, L.↗

NASA NTRSDate not supplied

Integral Channel Nozzles and Heat Exchangers using Additive Manufacturing Directed Energy Deposition NASA HR-1 Alloy

Heat exchangers for use in propulsion applications are very critical components because they must be efficient, compact and light and often operate with working fluids at extreme temperatures or pressures or both. Various components and systems use heat exchangers such as combustion chambers of gas turbines and internal combustion engines, fuel cells (air supply and thermal management), electric batteries (thermal management), evaporators and recuperators of waste-heat-to-power systems, and rocket engines. Even if the results are more generally applicable, the heat exchangers applications to which this study is more closely related are regeneratively cooled rocket nozzles and chambers, and repressurization systems for the launch vehicles. These components are often thin-walled and contain pressurized fluids, like propellants at cryogenic or elevated temperatures. Given that the environments that these propulsion components must endure are challenging, the manufacturing to meet these specifications often require long lead times due to specialty processes and unique tooling associated with the combined thin-wall integral channel and large-scale structures. Additive manufacturing (AM) offers programmatic advantages for reduction in processing time and cost in addition to various technical advantages, including the possibility to achieve enhanced hardware complexity targeted to superior performance, part consolidation, and the capability of processing of novel alloys. While AM is already being utilized for heat exchanger components in propulsion applications, almost all these AM components are made by means of Laser Powder Bed Fusion (L-PBF). L-PBF allows for fine features but is rather limited with respect to the overall size of the components that can be manufactured. Recent developments are maturing the Laser Powder Directed Energy Deposition (LP-DED) process which may be used, for example, to make integral channel thin-wall regeneratively-cooled rocket nozzles with diameters greater than 1 m. This paper highlights some integral channel heat exchanger demonstrator hardware applications of LP-DED, as well as the characterization of this process in combination with the use of the NASA HR-1 alloy. To properly utilize LP-DED for heat exchanger manufacturing, various aspects are being characterized such as geometry limitations, measurement of surface texture and geometric angled surfaces, surface enhancements for internal channels, and material evaluation. NASA HR-1 (FeNi-Cr) is a high strength hydrogen resistant superalloy developed for use in aerospace applications, such as heat exchangers. Some aspects and considerations about the design of heat exchangers are summarized together with data relevant to LP-DED manufacturing in combination with the NASA HR-1 alloy. Microchannels were successful deposited down to 2.54 mm and 1 mm wall thickness, wall angles of 30°, both with high reproducibility. It was also found that the areal surface roughness is highly dependent on the size of the powder feedstock used for deposition. The characterization of these LP-DED features is critical for fluid flow and heat transfer predictions as it can be exploited to enhance heat transfer at the cost of increased pressure drop.

Additive Manufacturing↗

NASA NTRSDate not supplied

Integral Channel Nozzles and Heat Exchangers using Additive Manufacturing Directed Energy Deposition NASA HR-1 Alloy

Heat exchangers for use in propulsion applications are very critical components because they must be efficient, compact and light and often operate with working fluids at extreme temperatures or pressures or both. Various components and systems use heat exchangers such as combustion chambers of gas turbines and internal combustion engines, fuel cells (air supply and thermal management), electric batteries (thermal management), evaporators and recuperators of waste-heat-to-power systems, and rocket engines. Even if the results are more generally applicable, the heat exchangers applications to which this study is more closely related are regeneratively cooled rocket nozzles and chambers, and repressurization systems for the launch vehicles. These components are often thin-walled and contain pressurized fluids, like propellants at cryogenic or elevated temperatures. Given that the environments that these propulsion components must endure are challenging, the manufacturing to meet these specifications often require long lead times due to specialty processes and unique tooling associated with the combined thin-wall integral channel and large-scale structures. Additive manufacturing (AM) offers programmatic advantages for reduction in processing time and cost in addition to various technical advantages, including the possibility to achieve enhanced hardware complexity targeted to superior performance, part consolidation, and the capability of processing of novel alloys. While AM is already being utilized for heat exchanger components in propulsion applications, almost all these AM components are made by means of Laser Powder Bed Fusion (L-PBF). L-PBF allows for fine features but is rather limited with respect to the overall size of the components that can be manufactured. Recent developments are maturing the Laser Powder Directed Energy Deposition (LP-DED) process which may be used, for example, to make integral channel thin-wall regeneratively-cooled rocket nozzles with diameters greater than 1 m. This paper highlights some integral channel heat exchanger demonstrator hardware applications of LP-DED, as well as the characterization of this process in combination with the use of the NASA HR-1 alloy. To properly utilize LP-DED for heat exchanger manufacturing, various aspects are being characterized such as geometry limitations, measurement of surface texture and geometric angled surfaces, surface enhancements for internal channels, and material evaluation. NASA HR-1 (FeNi-Cr) is a high strength hydrogen resistant superalloy developed for use in aerospace applications, such as heat exchangers. Some aspects and considerations about the design of heat exchangers are summarized together with data relevant to LP-DED manufacturing in combination with the NASA HR-1 alloy. Microchannels were successful deposited down to 2.54 mm and 1 mm wall thickness, wall angles of 30°, both with high reproducibility. It was also found that the areal surface roughness is highly dependent on the size of the powder feedstock used for deposition. The characterization of these LP-DED features is critical for fluid flow and heat transfer predictions as it can be exploited to enhance heat transfer at the cost of increased pressure drop.

additive manufacturing↗