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NASA NTRS2019

Additive Manufacturing and Hot-fire Testing of Bimetallic GRCop-84 and C-18150 Channel-Cooled Combustion Chambers using Powder Bed Fusion and Inconel 625 Hybrid Directed Energy Deposition

Additive manufacturing (AM) is an advanced fabrication technique that is demonstrating tremendous potential to reduce fabrication lead times and costs for liquid rocket engine components. The additive manufacturing technology lends itself to fabricate components with complex features such as internal coolant channels in combustion chambers that would otherwise require complex manufacturing operations. A requirement for high performance engines is to use high conductivity, high strength materials such as copper-alloys for combustion chamber liners to provide adequate wall temperatures and meet subsequent structural margins. A further requirement of this configuration is to minimize weight by defining and fabricating material in discrete locations as required. NASA and Industry partner, Virgin Orbit, have been working to advance these technologies through development of bimetallic additive manufacturing techniques under a public-private partnership through NASA’s Announcement of Collaborative Opportunity (ACO). This partnership is advancing a bimetallic hybrid additively manufactured combustion chamber that integrates Powder Bed Fusion (PBF), specifically Selective Laser Melting (SLM), and Directed Energy Deposition (DED) blown powder techniques to optimize the chamber materials and subsequent assembly. The SLM process is being developed for the combustion chamber liner to use copper-alloys GRCop-84 (Copper-Chrome-Niobium) or C-18150 (Copper-Chrome-Zirconium). The hybrid DED blown powder technology is used to apply an integrated structural jacket and manifolds using an Inconel 625 superalloy on the outer surface of the SLM copper liner. The hybrid DED technology being used on this program is a DMG Mori Seiki AM machining center which integrates the DED blown powder with an integral subtractive (traditional) machining to minimize overall setups. A series of chambers were fabricated using these techniques with GRCop-84/Inconel 625 and C-18150/Inconel and hot-fire tested at NASA Marshall Space Flight Center (MSFC) in LOX/Kerosene (RP-1). This paper describes the process development to integrate these AM technologies into an integrated bimetallic assembly, the design of the chamber, results from hot-fire testing, and further development.

Gradl, Paul↗

NASA NTRS1988

Status Of Sorption Cryogenic Refrigeration

Report reviews sorption refrigeration. Developed for cooling infrared detectors, cryogenic research, and other advanced applications, sorption refrigerators have few moving parts, little vibration, and lifetimes of 10 years or more. Describes types of sorption stages, multistage and hybrid refrigeration systems, power requirements, cooling capacities, and advantages and disadvantages of various stages and systems.

Jones, Jack A.↗

NASA NTRS1991

Design of the cryogenic system for the SAFIRE instrument

One of the primary goals of the NASA Mission to Planet Earth is to improve understanding of the ozone chemistry of the atmosphere over an extended period of time. The Spectroscopy of the Atmosphere using Far Infrared Emission (SAFIRE) instrument is being developed to conduct, for the first time, global measurements of the key ozone chemistry constituents in both the mid- and far-infrared spectral regions. Such remote, long-term observations are made possible by the recent development of compact long-life hybrid cryogenic dewars which are necessary to cool the sensitive detectors to the 3-4 K range. The success of this hybrid concept is based on the use of long-life Stirling cycle cryocoolers to intercept parasitic heat from the internal radiation shields of the superfluid helium dewar. Extensive system trade studies are required to optimize the mass, power, and lifetime of these space-borne cryogenic systems. The SAFIRE Cryogenic Subsystem is described, including the thermal performance trades leading to the chosen system configuration and the important dewar/cryocooler interface issues.

Lee, J. H.↗

NASA NTRS1989

Cryogenic techniques for large superconducting magnets in space

A large superconducting magnet is proposed for use in a particle astrophysics experiment, ASTROMAG, which is to be mounted on the United States Space Station. This experiment will have a two-coil superconducting magnet with coils which are 1.3 to 1.7 meters in diameter. The two-coil magnet will have zero net magnetic dipole moment. The field 15 meters from the magnet will approach earth's field in low earth orbit. The issue of high Tc superconductor will be discussed in the paper. The reasons for using conventional niobium-titanium superconductor cooled with superfluid helium will be presented. Since the purpose of the magnet is to do particle astrophysics, the superconducting coils must be located close to the charged particle detectors. The trade off between the particle physics possible and the cryogenic insulation around the coils is discussed. As a result, the ASTROMAG magnet coils will be operated outside of the superfluid helium storage tank. The fountain effect pumping system which will be used to cool the coil is described in the report. Two methods for extending the operating life of the superfluid helium dewar are discussed. These include: operation with a third shield cooled to 90 K with a sterling cycle cryocooler, and a hybrid cryogenic system where there are three hydrogen-cooled shields and cryostat support heat intercept points.

Green, M. A.↗

NASA NTRS1988

LDR cryogenics

A brief summary from the 1985 Large Deployable Reflector (LDR) Asilomar 2 workshop of the requirements for LDR cryogenic cooling is presented. The heat rates are simply the sum of the individual heat rates from the instruments. Consideration of duty cycle will have a dramatic effect on cooling requirements. There are many possible combinations of cooling techniques for each of the three temperatures zones. It is clear that much further system study is needed to determine what type of cooling system is required (He-2, hybrid or mechanical) and what size and power is required. As the instruments, along with their duty cycles and heat rates, become better defined it will be possible to better determine the optimum cooling systems.

Nast, T.↗

NASA NTRS2005

An evolving trio of hybrid stars: C111

Hybrid stars are a class of cool, luminous single stars originally identified based on the appearance of their ultraviolet IUE spectra. C IV emission is present (signifying temperatures of at least lo5 K), and asymmetric emission cores of Mg I1 are found, accompanied by absorption features at low and high velocities, indicating a massive stellar wind and circumstellar material. Many members of this class have been identified and X-rays have been detected from most hybrids. They represent the critical evolutionary state between coronal-like objects and the Alpha Ori-like objects and assume a pivotal role in the definition of coronal evolution, atmospheric heating processes, and mechanisms to drive winds of cool stars.

Sonneborn, George↗

NASA NTRS2009

Long-Lived Venus Lander Conceptual Design: How To Keep It Cool

Surprisingly little is known about Venus, our neighboring sister planet in the solar system, due to the challenges of operating in its extremely hot, corrosive, and dense environment. For example, after over two dozen missions to the planet, the longest-lived lander was the Soviet Venera 13, and it only survived two hours on the surface. Several conceptual Venus mission studies have been formulated in the past two decades proposing lander architectures that potentially extend lander lifetime. Most recently, the Venus Science and Technology Definition Team (STDT) was commissioned by NASA to study a Venus Flagship Mission potentially launching in the 2020- 2025 time-frame; the reference lander of this study is designed to survive for only a few hours more than Venera 13 launched back in 1981! Since Cytherean mission planners lack a viable approach to a long-lived surface architecture, specific scientific objectives outlined in the National Science Foundation Decadal Survey and Venus Exploration Advisory Group final report cannot be completed. These include: mapping the mineralogy and composition of the surface on a planetary scale determining the age of various rock samples on Venus, searching for evidence of changes in interior dynamics (seismometry) and its impact on climate and many other key observations that benefit with time scales of at least a full Venus day (Le. daylight/night cycle). This report reviews those studies and recommends a hybrid lander architecture that can survive for at least one Venus day (243 Earth days) by incorporating selective Stirling multi-stage active cooling and hybrid thermoacoustic power.

Dyson, Ridger W.↗

NASA NTRS1985

On the outer atmospheres of hybrid stars

Deep exposures with the IUE satellite have been obtained in order to search for high-temperature emission from stars with cool winds. Iota Aur and Theta Her are confirmed as hybrid stars, and an additional hybrid object, Gamma Aql, has been discovered. The emission line fluxes of the hybrid stars are analyzed to establish the emission measure distribution and, as far as possible, the electron density. The discovery of variable, high-velocity Mg II circumstellar absorption in Gamma Aql, Theta Her, and Alpha TrA is reported. Very long exposure of the latter show that cool material is being accelerated to velocities of at least 180 km/s. These observations suggest that high-velocity mass loss is more common than previously thought.

Hartmann, L.↗

NASA NTRS1988

Characterization of direct readout Si:Sb and Si:Ga infrared detector arrays for space-based astronomy

Preliminary test results from the evaluation of Si:Sb and Si:Ga 58 x 62-element infrared detector arrays are presented. These devices are being characterized under background conditions and readout rates representative of operation in orbiting, crogenically-cooled infrared observatories. The arrays are hybridized to silicon direct-readout multiplexers which allow random-access and nondestructive readout. Array performance optimization is being conducted with a flexible microcomputer-based drive and readoaut electronics system. Preliminary Si:Sb measurements indicate a sense node capacitance of 0.06 pF, peak (28-micron) responsivity above 3 A/W at 2V bias, read noise of 130 rms e(-), dark current approximately 10 e(-)/s, and a well capacity greater than 10 to the 5th e(-). The limited test data available on the performance of the Si:Ga array are also discussed.

Mckelvey, Mark E.↗

NASA NTRSDate not supplied

In-Situ XRD/XRF to Support Life Detection on Mars

X-ray diffraction / X-ray fluorescence (XRD/XRF) analysis provides the most comprehensive mineralogical / compositional characterization of rocks and soils of any flight-capable technique. XRD data provide quantitative mineralogy (including abundance of X-ray amorphous materials) and crystal chemistry (structure, elemental composition and valence state), and XRF data provide complimentary major, minor, and some trace element abundances. Both types of data are important in evaluating habitability (environment of formation) and biosignature preservation/degradation (post-depositional diagenetic change). Whether or not a relict biosignature is detected, the mineral assemblage and its geochemistry can be used to determine the habitability of an ancient environment (e.g., salinity, pH, temperature), and to identify potential sources of energy for life (e.g., elements in different redox states). In this respect, a null result (a habitable environment lacking evidence of life) can play an important role in constraining the parameters of the search. Conversely, diagenetic alteration (taphonomic change) resulting from post-depositional variations in temperature, pressure or fluid chemistry can preserve evidence of biogenicity, erase such evidence completely or indeed can provide for post-depositional habitable conditions in the subsurface. XRD / XRF data are critical to these determinations. The CheMin instrument on the Mars Science Laboratory (MSL) Curiosity rover is the first XRD instrument flown in space. CheMin operates in transmission geometry with a Co X-ray source to minimize fluorescence from iron. Diffracted photons are collected with an energy-sensitive charge-coupled device (CCD). The position of the diffracted photons provides structural information for minerals, whereas the energy of sample-generated X-ray fluorescence photons provides elemental information, though these XRF data are qualitative. Mineralogical data from the CheMin XRD identified the three circumstances above: habitable depositional environments (e.g., Yellowknife Bay), habitable subsurface/diagenetic environments (e.g., throughout the Murray formation), and diagenetic conditions that may destroy evidence of habitability (e.g., oxidative and acidic environments at Vera Rubin ridge). Technological advances in X-ray technology and lessons learned from the operation of CheMin on Mars have resulted in a next-generation XRD/XRF, called CheMinX. Replacement of CheMin’s CCD with an array of hybrid pixel detectors and improvements in focusing optics dramatically decrease analysis time (15 minutes vs. 22 hours for MSL-CheMin) and result in a better angular resolution (0.18 vs. 0.30 °2θ for MSL-CheMin). This increased resolution improves mineral detection, including discrimination between types of pyroxenes, which is not possible with MSL-CheMin data. The hybrid pixel detectors do not require cooling like the MSL-CheMin CCD, therefore reducing the power needed to operate CheMinX. CheMinX has a silicon-drift detector (SDD) to measure fluoresced photons, enabling the quantification of major, minor, and some trace elements via XRF. XRD/XRF data are collected simultaneously in CheMinX, obviating the need for multiple compositional instruments. The CheMinX design also improves upon MSL-CheMin’s sample handling. Instead of sample cells on wheel, which are often not reusable and add complexity in commanding the instrument, CheMinX has single-use cells in a cartridge/dispenser configuration. Because of these improvements, CheMinX is an ideal instrument for Discovery-class life-detection missions, including Mars Life Explorer that was recommended for development in the Planetary Science and Astrobiology Decadal Survey 2023-2032.

E B Rampe↗

NASA NTRS1982

Superfluid-supercritical helium tradeoff analysis for the Shuttle Infrared Telescope Facility (SIRTF)

A comparative study is made of three methods for obtaining the required cooling of the SIRTF. The first is a supercritical helium system in which the 2 K temperatures are obtained by a Joule-Thomson expander; the second is a superfluid (He II) helium system; and the third is a hybrid system in which supercritical helium provides the major cooling and small He II reservoirs supply specific detector cooling. The superfluid helium system is found to offer superior performance; it would be the system to use if funding were available. The comparative study gives equal weight to performance, operations, and cost. From this point of view, the hybrid system is selected as the best compromise to obtain an operational SIRTF.

Gier, H. L.↗

NASA NTRS1984

Air-Conditioning for Electric Vehicles

Combination of ammonia-absorption refrigerator, roof-mounted solar collectors, and 200 degrees C service electric-vehicle motor provides evaporative space-heating/space cooling system for electric-powered and hybrid fuel/electric vehicles.

Popinski, Z.↗

NASA NTRS1988

Sorption cryogenic refrigeration - Status and future

The operation principles of sorption cryogenic refrigeration are discussed. Sorption refrigerators have virtually no wear-related moving parts, have negligible vibration, and offer extremely long life (at least ten years), making it possible to obtain efficient, long life and low vibration cooling to as low as 7 K for cryogenic sensors. The physisorption and chemisorption systems recommended for various cooling ranges down to 7 K are described in detail. For long-life cooling at 4-5 K temperatures, a hybrid chemisorption-mechanical refrigeration system is recommended.

Jones, Jack A.↗

NASA NTRS1992

Rosat X-ray All-Sky Survey observations of hybrid stars

Data from the Rosat All-Sky Survey for nine hybrid stars, objects showing spectroscopic evidence for cool massive winds and 500,000-K material, are presented. Two of the nine stars were detected above a limiting flux threshold of 2 x 10 exp -13 ergs/sq cm s. The K3 III star Delta And was detected just at this threshold. The K4 III star Alpha TrA was measured at 8 x 10 exp -13 ergs/sq cm s. Since these detections were made in both low- and high-energy bands of the Rosat 0.1-2.4-keV passband, it is suggested that the emissions originate in coronae of about 10 exp 7 K.

Haisch, Bernhard↗

NASA NTRS2000

8-9 and 14-15 Micron Two-Color 640x486 GaAs/AlGaAs Quantum Well Infrared Photodetector (QWIP) Focal Plane Array Camera

An optimized long-wavelength two-color Quantum Well Infrared Photodetector (QWIP) device structure has been designed. This device structure was grown on a three inch semi-insulating GaAs substrate by molecular beam epitaxy (MBE). This wafer was processed into several 640x486 format monolithically integrated 8-9 and 14-15 micron two color (or dual wavelength) QWIP focal plane arrays (FPAs). These FPAs were then hybridized to 640x486 silicon CMOS readout multiplexers. A thinned (i.e., substrate removed) FPA hybrid was integrated into a liquid helium cooled dewar to perform electrical and optical characterization and to demonstrate simultaneous two-color imagery. The 8-9 micron detectors in the FPA have shown background limited performance (BLIP) at 70 K operating temperature, at 300 K background with f/2 cold stop. The 14-15 micron detectors of the FPA have reached BLIP at 40 K operating temperature at the same background conditions. In this presentation we discuss the performance of this long-wavelength dualband QWIP FPA in quantum efficiency, detectivity, noise equivalent temperature difference (NEAT), uniformity, and operability.

Gunapala, S. D.↗

NASA NTRS1987

Plasma Rocket With Hybrid Exhaust Plume

Proposed plasma rocket, described in report, generates hybrid exhaust plume comprising annular layer of relatively cool neutral gas around plasma core. Plasma and gas intermix, providing gradual radial transition between the two. Amount of gas injected adjusted to control propulsive efficiency; relatively cool gas boundary layer at surface of nozzle insulates nozzle from high plasma temperature.

Chang, Franklin R.↗

NASA NTRS1986

Medium-energy electrons and heavy ions in Jupiter's magnetosphere - Effects of lower hybrid wave-particle interactions

A theory of medium-energy (about keV) electrons and heavy ions in Jupiter's magnetosphere is presented. Lower hybrid waves are generated by the combined effects of a ring instability of neutral wind pickup ions and the modified two-stream instability associated with transport of cool Iogenic plasma. The quasi-linear energy diffusion coefficient for lower hybrid wave-particle interactions is evaluated, and several solutions to the diffusion equation are given. Calculations based on measured wave properties show that the noise substantially modifies the particle distribution functions. The effects are to accelerate superthermal ions and electrons to keV energies and to thermalize the pickup ions on time scales comparable to the particle residence time. The S(2+)/S(+) ratio at medium energies is a measure of the relative contribution from Iogenic thermal plasma and neutral wind ions, and this important quantity should be determined from future measurements. The theory also predicts a preferential acceleration of heavy ions with an accleration time that scales inversely with the root of the ion mass. Electrons accelerated by the process contribute to further reionization of the neutral wind by electron impact, thus providing a possible confirmation of Alfven's critical velocity effect in the Jovian magnetosphere.

Barbosa, D. D.↗

NASA NTRS1994

Using CLIPS in the domain of knowledge-based massively parallel programming

The Program Development Environment (PDE) is a tool for massively parallel programming of distributed-memory architectures. Adopting a knowledge-based approach, the PDE eliminates the complexity introduced by parallel hardware with distributed memory and offers complete transparency in respect of parallelism exploitation. The knowledge-based part of the PDE is realized in CLIPS. Its principal task is to find an efficient parallel realization of the application specified by the user in a comfortable, abstract, domain-oriented formalism. A large collection of fine-grain parallel algorithmic skeletons, represented as COOL objects in a tree hierarchy, contains the algorithmic knowledge. A hybrid knowledge base with rule modules and procedural parts, encoding expertise about application domain, parallel programming, software engineering, and parallel hardware, enables a high degree of automation in the software development process. In this paper, important aspects of the implementation of the PDE using CLIPS and COOL are shown, including the embedding of CLIPS with C++-based parts of the PDE. The appropriateness of the chosen approach and of the CLIPS language for knowledge-based software engineering are discussed.

Dvorak, Jiri J.↗