Introduction to Additive Manufacturing for Propulsion and Energy Systems
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Microstructural Evolution and Mechanical Properties of LP-DED NASA HR-1 – A Hydrogen Resistant AM Superalloy for Space Propulsion Applications
The National Aeronautics and Space Administration (NASA) has actively pursued metal additive manufacturing (AM) technologies for spaceflight applications since the late 2000s. AM offers transformative advantages in cost, schedule, part consolidation, and design flexibility. Among the various AM techniques, laser powder directed energy deposition (LP-DED) is particularly well suited for fabricating complex geometries with fine feature resolution. In propulsion systems that utilize high-pressure gaseous hydrogen—such as liquid hydrogen rocket engines—hydrogen environment embrittlement (HEE) presents a serious threat to material performance 1,2 . Mechanical property degradation under these conditions can compromise component reliability, especially under cyclic loading. To address this challenge, NASA developed NASA HR-1 (Hydrogen Resistant-1) as a solution for liquid rocket engine components operating in hydrogen-rich environments, using the LP-DED technique 3-9 . A key component in a liquid rocket engine is the exhaust nozzle, which is typically regeneratively cooled (regen) due to the high heat flux. NASA HR-1 was specifically developed for regen nozzle applications using hydrogen as a propellant, providing resistance to HEE, a critical issue for many materials. The AM version of NASA HR-1 was also formulated to achieve high ultimate tensile strength, along with high yield strength and ductility in this environment 5,6 . Low-cycle fatigue (LCF) is another important consideration in nozzle design, as components are expected to endure multiple starts and missions. Additionally, the LP-DED version of the alloy exhibits improved thermal conductivity compared to its wrought counterpart, which benefits nozzle cooling. Overall, NASA HR-1 offers an excellent balance of high strength, HEE resistance, LCF performance, thermal conductivity, and ductility to meet the demanding requirements of channel-cooled nozzles and other components used with hydrogen and other propellants. The LP-DED–processed NASA HR-1 requires several post-processing heat treatment steps to achieve the material properties desirable for its intended application 6 . These steps include stress relief, homogenization, solution annealing, and aging for precipitation hardening. The stress relief treatment mitigates residual stresses accumulated during the LP-DED process and minimizes the potential for distortion. Homogenization, a common step for AM materials, reduces elemental segregation and promotes recrystallization to develop a more equiaxed grain structure. The subsequent solution annealing treatment heats the part to a solid solution temperature to dissolve the undesirable η-phase that forms during cooling from homogenization, followed by rapid cooling to retain an η-phase–free microstructure. Finally, aging promotes precipitation of the strengthening γ′ phase in the alloy. The integration of compositional design and optimized thermal processing enables high-quality LP-DED NASA HR-1 components with excellent microstructural and mechanical stability. Improved chemical and microstructure homogeneity enhances ductility and fatigue resistance—both critical for safe and reliable operation in high-pressure hydrogen environments. NASA has successfully fabricated and hot-fire tested multiple subscale and full-scale channel wall nozzles using LP-DED NASA HR-1 5,6, 9-14 . These efforts included process refinements to support thin-wall construction and various channel geometries. Throughout development, several key observations emerged. After homogenization, the as-built columnar grain structure transforms into a fully equiaxed microstructure. However, subsequent treatments—such as solution annealing and aging—result in changes that are more difficult to track. The grain structure remains largely unchanged, and the γ′ precipitates, typically 5–10 nm in diameter, are beyond the resolution of scanning electron microscopy (SEM). While transmission electron microscopy (TEM) can resolve these fine precipitates, TEM sample preparation is time-consuming and difficult for LP-DED material. As an alternative, differential scanning calorimetry (DSC) offers a useful, qualitative approach to monitor precipitate evolution throughout different stages of heat treatment. The overall goal is to improve the understanding of how heat treatment affects the microstructure and mechanical performance of LP-DED NASA HR-1. This paper presents heat treatment design considerations, microstructural characterization, mechanical testing – including tensile and LCF testing in both air and hydrogen environments.
Superalloy↗
Ion Exchange Equilibrium and Kinetic Properties of Polyacrylate Films and Applications to Chemical Analysis and Environmental Decontamination
One of the goals of the original proposal was to study how cross-linking affects the properties of an ion exchange material(IEM) developed at Lewis Research Center. However, prior to the start of this work, other workers at LERC investigated the effect of cross-linking on the properties of this material. Other than variation in the ion exchange capacity, the chemical characteristics were shown to be independent of the cross-linking agent, and the degree of cross-linking. New physical forms of the film were developed (film, supported film, various sizes of beads, and powder). All showed similar properties with respect to ion exchange equilibria but the kinetics of ion exchange depended on the surface area per unit mass; the powder form of the IEM exchanging much more rapidly than the other forms. The research performed under this grant was directed towards the application of the IEM to the analysis of metal ions at environmental concentrations.
Tanner, Stephen P.↗
Novel Overhang Support Designs for Powder-Based Electron Beam Additive Manufacturing (EBAM)
NASA Marshall Space Flight Center, in collaboration with the University of Alabama, has developed a contact-free support structure used to fabricate overhang-type geometries via EBAM. The support structure is used for 3-D metal-printed components for the aerospace, automotive, biomedical and other industries. Current techniques use support structures to address deformation challenges inherent in 3-D metal printing. However, these structures (overhangs) are bonded to the component and need to be removed in post-processing using a mechanical tool. This new technology improves the overhang support structure design for components by eliminating associated geometric defects and post-processing requirements.
Nabors, Sammy A.↗
Characteristics of a Lunar Landing Configuration Having Various Multiple-Leg Landing-Gear Arrangements
An experimental investigation has been made of some lunar-landing characteristics of a 1/6-scale dynamic model of a landing module having multiple-leg landing-gear systems. Symmetric four-point and five-point systems were investigated. The landing-gear legs were inverted tripod arrangements having a telescoping main strut which incorporated a yielding-metal strap for energy dissipation, hinged V-struts, and circular pads. The landing tests were made by launching a free model onto an impenetrable hard surface (concrete) and onto a powdered-pumice overlay of various depths. Landing motion and acceleration data were obtained for a range of touchdown speeds, touchdown attitudes, and landing-surface conditions. Maximum normal acceleration experienced at the module center of gravity during landings on hard surface or pumice was 2g (full-scale lunar value in terms of earth's gravity) over a wide range of touchdown conditions. acceleration experienced was 12 1/2 radians/sec(exp 2) and maximum longitudinal acceleration was 1 3/4g. The module was very stable with all gear configurations during landings on hard surface (coefficient of friction, micron = 0.4) at all conditions tested. Some overturn instability occurred during landings on powdered pumice (micron = 0.7 to 1.0) depending upon flight path, pitch and yaw attitude, depth of pumice, surface topography, and landing-gear configuration. The effect on stability of roll attitude for the limited amount of roll-attitude landing data obtained was insignificant. Compared with the four-point landing gear, the five-point system with equal maximum gear radius increased landing stability slightly and improved the static stability for subsequent lunar launch. A considerable increase in landing stability in the direction of motion was obtained with an asymmetric four-point gear having two pads offset to increase gear radius by 33 percent in the direction of horizontal flight.
Blanchard, Ulysse J.↗
Integrated structure vacuum tube
High efficiency, multi-dimensional thin film vacuum tubes suitable for use in high temperature, high radiation environments are described. The tubes are fabricated by placing thin film electrode members in selected arrays on facing interior wall surfaces of an alumina substrate envelope. Cathode members are formed using thin films of triple carbonate. The photoresist used in photolithography aids in activation of the cathodes by carbonizing and reacting with the reduced carbonates when heated in vacuum during forming. The finely powdered triple carbonate is mixed with the photoresist used to delineate the cathode locations in the conventional solid state photolithographic manner. Anode and grid members are formed using thin films of refractory metal. Electron flow in the tubes is between grid elements from cathode to anode as in a conventional three-dimensional tube.
Dimeff, J.↗
Compatibilities of YBa2Cu3O(9-delta) type phase in quintenary systems Y-Ba-Cu-O-X (impurity)
Isothermal phase diagrams at various oxygen pressures were studied by powder diffraction and chemical analytical methods. The components, Y, Ba, Cu, and O (specifically O2, O2-, and O2 sup 2-) are treated, together with C (specifically CO2 and CO2 sup 2-), alkaline metals, Mg, alkaline earths, Sc, 3-d and 4-f elements. Effects of the substitutions at the structural sites of YBa2Cu3O(9-delta) on T sub c are discussed with respect to changes in crystallochemical characteristics of the substituted phase and to the nature of the substituents.
Karen, P.↗
Characteristics of a Lunar Landing Configuration Having Various Multiple-Leg Landing-Gear Arrangements
An experimental investigation has been made of some lunar-landing characteristics of a 1/6-scale dynamic model of a landing module having multiple-leg landing-gear systems. Symmetric four-point and five-point systems and an asymmetric four-point system were investigated. The landing-gear legs were inverted tripod arrangements having a telescoping main strut which incorporated a yielding-metal strap for energy dissipation, hinged V-struts, and circular pads. The landing tests were made by launching a free model onto an impenetrable hard surface (concrete) and onto a powdered-pumice overlay of various depths. Landing motion and acceleration data were obtained for a range of touchdown speeds, touchdown speeds, touch attitudes, and landing-surface conditions. Symmetric four-point and five-point systems and an Maximum normal acceleration experienced at the module center of gravity during landings on hard surface or pumice was 2g (full-scale lunar value in terms of earth's gravity) over a wide range of touchdown conditions. Maximum angular acceleration experienced was 12-1/2 radians/sec(exp 2) and maximum longitudinal acceleration was 1-3/4 g. The module was very stable with all gear configurations during landings on hard surface (coefficient of friction, microns=0.4) at all conditions tested. Some overturn instability occurred during landings on powdered pumice (microns=0.7 to 1.0) depending upon flight path, pitch and yaw attitude, depth of pumice, surface topography, and landing-gear configuration. The effect of stability of roll attitude for the limited amount of roll-attitude landing data obtained was insignificant. Compared with the four-point system, the five-point system with equal maximum gear radius increased landing stability slightly and improved the static stability for subsequent lunar launch. A considerable increase in landing stability in the direction of motion was obtained with an asymmetric four-point gear having two pads offset to increase gear radius by 33 percent in the direction of horizontal flight.
Blanchard, Ulysse J.↗
Additive Manufacture of Refractory Metals for Aerospace Applications
High temperature refractory metals are required for a number of high temperature propulsion applications. Refractory metals are expensive, difficult to manufacture with high buy-to-fly ratios, and few vendors. Additive manufacture (AM) is used to produce C103, Molybdenum (Mo), and Tungsten (W) reaction chamber and thrust stand-off as well as Iridium ultra-fine lattice catalysts for integration into 1 N green propulsion thrusters. Refractory AM is in development and like traditional AM alloys requires substantial post-processing to include powder heat treatment, surface finish enhancement, inspection, and machining before placed in service. The combination of limited feedstock sources, high temperature processing, oxygen sensitivity, fracture prone nature, and need for elevated temperature mechanical testing limit the number of qualified facilities capable of post-processing AM refractory materials, which add to cost and schedule constraints. However, properly implemented refractory metal AM can overcome existing manufacture limitations by greatly increasing design flexibility, new material options, reduced price, decreased lead-time, and leverage the ever growing AM commercial supply base.
Refractory metal additive manufacture↗
Additive Manufacture of Refractory Metals for Aerospace Applications
High temperature refractory metals are required for a number of high temperature propulsion applications. Refractory metals are expensive, difficult to manufacture with high buy-to-fly ratios, and few vendors. Additive manufacture (AM) is used to produce C103, Molybdenum (Mo), and Tungsten (W) reaction chamber and thrust stand-off as well as Iridium ultra-fine lattice catalysts for integration into 1 N green propulsion thrusters. Refractory AM is in development and like traditional AM alloys requires substantial post-processing to include powder heat treatment, surface finish enhancement, inspection, and machining before placed in service. The combination of limited feedstock sources, high temperature processing, oxygen sensitivity, fracture prone nature, and need for elevated temperature mechanical testing limit the number of qualified facilities capable of post-processing AM refractory materials, which add to cost and schedule constraints. However, properly implemented refractory metal AM can overcome existing manufacture limitations by greatly increasing design flexibility, new material options, reduced price, decreased lead-time, and leverage the ever growing AM commercial supply base.
Refractory metal additive manufacture↗
Summary of Liquid Oxygen/Hydrogen, Direct Metal Laser Sintering Injector Testing and Evaluation Effort at Marshall Space Flight Center
The last several years have witnessed a significant advancement in the area of additive manufacturing technology. One area that has seen substantial expansion in application has been laser sintering (or melting) in a powder bed. This technology is often termed 3D printing or various acronyms that may be industry, process, or company specific. Components manufactured via 3D printing have the potential to significantly reduce development and fabrication time and cost. The usefulness of 3D printed components is influenced by several factors such as material properties and surface roughness. This paper details three injectors that were designed, fabricated, and tested in order to evaluate the utility of 3D printed components for rocket engine applications. The three injectors were tested in a hot‐fire environment with chamber pressures of approximately 1400 psia. One injector was a 28 element design printed by Directed Manufacturing. The other two injectors were identical 40 element designs printed by Directed Manufacturing and Solid Concepts. All the injectors were swirl‐coaxial designs and were subscale versions of a full‐scale injector currently in fabrication. The test and evaluation programs for the 28 element and 40 element injectors provided a substantial amount of data that confirms the feasibility of 3D printed parts for future applications. The operating conditions of previously tested, conventionally manufactured injectors were reproduced in the 28 and 40 element programs in order to contrast the performance of each. Overall, the 3D printed injectors demonstrated comparable performance to the conventionally manufactured units. The design features of the aforementioned injectors can readily be implemented in future applications with a high degree of confidence.
Barnett, Gregory↗
Simple bonding technique for high-temperature ceramic coatings
Coatings, consisting of zirconia powder bonded with orthophosphoric acid and a small amount of hydrofluoric acid, are hard, strong, and refractory, resist thermal shock, and provide good thermal protection. After the aqueous coating is applied to a metallic surface, only a 600 deg F cure is required before service.
Accountius, O. E.↗
Sialons as high temperature insulators
Sialons were evaluated for application as high temperature electrical insulators in contact with molybdenum and tungsten components in hard vacuum applications. Both D.C. and variable frequency A.C. resistivity data indicate the sialons to have electrical resistivity similar to common oxide in the 1000 C or higher range. Metallographic evaluations indicate good bonding of the type 15R ALN polytype to molybdenum and tungsten. The beta prime or modified silicon nitride phase was unacceptable in terms of vacuum stability. Additives effect on electrical resistivity. Similar resistivity decreases were produced by additions of molybdenum or tungsten to form cermets. The use of hot pressing at 1800 C with ALN, Al2 O3 and Si3N4 starting powders produced a better product than did a combination of SiO2 and AIN staring powders. It was indicated that sialons will be suitable insulators in the 1600K range in contact with molybdenum or tungsten if they are produced as a pure ceramic and subsequently bonded to the metal components at temperatures in the 1600K range.
Phillips, W. M.↗
Low-Wear Ball-Bearing Separator
Proposed ball-bearing separator for use in cryogenic pump stronger and more resistant to wear. Consists of molded plastic-and-metal composite ring imbued with solid lubricant and containing embedded metal ring. Obtains combination of strength and lubricity. Before molding and machining, ring includes tooling portion for handling and indexing. Molded composite blend of PTFE and fluorinated ethylene/propylene (FEP) filled with brass and bronze powder and molybdenum disulfide powder.
Hawkinson, Elden L.↗
Silver-palladium braze alloy recovered from masking materials
Method for recovering powdered silver-palladium braze alloy from an acrylic spray binder and rubber masking adhesive used in spray brazing is devised. The process involves agitation and dissolution of masking materials and recovery of suspended precious metal particles on a filter.
Cierniak, R.↗
Inorganic photochromic and cathodochromic recording materials.
Discussion of studies at RCA Laboratories of the properties of rare-earth-doped CaF2, transition-metal-doped SrTiO3 and iron- or sulfur-doped sodalite as photochromic materials which change color during light or electron beam exposures. Particular attention is given to their photochromic characteristics in single-crystal and powder forms and to their cathodochromic properties in powder form. Details are given on the photochromic mechanisms, spectra, optical density, thermal decay rates, and coloring and bleaching efficiency of their single crystals and on the diffuse reflectance spectra, saturated photochromic contrast ratio, switching and erase sensitivities, and cathodochromic excitation of their photochromic powders. The many attractive characteristics of these materials when used in display storage systems are indicated.
Duncan, R. C., Jr.↗
Fabrication of Iron-Containing Carbon Materials From Graphite Fluoride
Carbon materials containing iron alloy, iron metal, iron oxide or iron halide were fabricated. Typical samples of these metals were estimated to contain 1 iron atom per 3.5 to 5 carbon atoms. Those carbon materials containing iron alloy, iron metal, and/or Fe3O4 were magnetic. The kinetics of the fabrication process were studied by exposing graphite fluoride (CF(0.68)) to FeCl3 over a 280 to 420 C temperature range. Between 280 and 295 C, FeCl3 quickly entered the structure of CF(0.68), broke the carbon-fluorine bonds, and within 10 to 30 min, completely converted it to carbon made up of graphite planes between which particles of crystalline FeF3 and noncrystalline FeCl3 were located. Longer reaction times (e.g., 28 hr) or higher reaction temperatures (e.g., 420 C) produced materials containing graphite, a FeCl3-graphite intercalation compound, FeCl2(center dot)4H2O, and FeCl2(center dot)2H2O. These products were further heat treated to produce iron-containing carbon materials. When the heating temperature was kept in the 750 to 850 C range, and the oxygen supply was kept at the optimum level, the iron halides in the carbon structure were converted to iron oxides. Raising the heat to temperatures higher than 900 C reduced such iron oxides to iron metal. The kinetics of these reactions were used to suggest processes for fabricating carbon materials containing iron alloy. Such processes were then tested experimentally. In one of the successful trial runs, commercially purchased CF(0.7) powder was used as the reactant, and NiO was added during the final heating to 1200 C as a source of both nickel and oxygen. The product thus obtained was magnetic and was confirmed to be a nickel-iron alloy in carbon.
Hung, Ching-cheh↗
Use of a Tantalum Liner to Reduce Bore Erosion and Increase Muzzle Velocity in Two-Stage Light Gas Guns
Muzzle velocities and gun erosion predicted by earlier numerical simulations of two stage light gas guns with steel gun tubes were in good agreement with experimental values. In a subsequent study, simulations of high performance shots were repeated with rhenium (Re) gun tubes. Large increases in muzzle velocity (2 - 4 km/sec) were predicted for Re tubes. In addition, the hydrogen-produced gun tube erosion was, in general, predicted to be zero with Re tubes. Tantalum (Ta) has some mechanical properties superior to those of Re. Tantalum has a lower modulus of elasticity than Re for better force transmission from the refractory metal liner to an underlying thick wall steel tube. Tantalum also has greater ductility than Re for better survivability during severe stress/strain cycles. Also, tantalum has been used as a coating or liner in military powder guns with encouraging results. Tantalum has, however, somewhat inferior thermal properties to those of rhenium, with a lower melting point and lower density and thermal conductivity. The present study was undertaken to see to what degree the muzzle velocity gains of rhenium gun tubes (over steel tubes) could be achieved with tantalum gun tubes. Nine high performance shots were modeled with a new version of our CFD gun code for steel, rhenium and tantalum gun tubes. For all except the highest velocity shot, the results with Ta tubes were nearly identical with those for Re tubes. Even for the highest velocity shot, the muzzle velocity gain over a steel tube using Ta was 82% of the gain obtained using Re. Thus, the somewhat inferior thermal properties of Ta (when compared to those of Re) translate into only very slightly poorer overall muzzle velocity performance. When this fact is combined with the superior mechanical properties of Ta and the encouraging performance of Ta liners/coatings in military powder guns, tantalum is to be preferred over Re as a liner/coating material for two stage light gas guns to increase muzzle velocity and reduce bore erosion.
Launchers↗