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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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NASA NTRSDate not supplied

Nuclear Thermal Propulsion Material Trade for Additively Manufactured Regenerative Chambers

Nuclear thermal propulsion (NTP) is a game changing technology with advantages over chemical propulsion systems for deep space missions but comes with many engineering challenges. This paper focuses on the challenge of material selection for a regeneratively-cooled chamber for use in a nuclear environment with minimal design margins. Chemical compatibility with reactants and products following energy extraction (be it through combustion or neutron bombardment) must be considered. Similarly, mechanical and thermophysical properties (e.g., density, thermal conductivity, yield strength, etc.) as functions of temperature are critical. While hydrogen embrittlement environment (HEE) is a risk and consideration for traditional chemical combustion chambers, application in a nuclear thermal engine adds additional material compatibility and resilience requirements to long-term nuclear radiation exposure. Chamber materials in this trade included, but were not limited to, A-286, Haynes 230, Haynes 282, CRES 347, GRCop-42, GRCop-84, Inconel 625, JBK-75, and NASA HR-1. The material trade focuses on modern additive manufacturing techniques and hypothetical geometric constraints.

Nuclear Thermal Propulsion↗
NASA NTRSDate not supplied

Current State of NASA Continuously Rotating Detonation Cycle Engine Development

NASA is currently investigating continuous detonation cycle engines for the application of lander and interplanetary space exploration missions. The performance benefits of a detonation cycle engine may allow for a broader design trade space and more compact geometry required for future missions to the Moon and onwards towards Mars. However, the technology readiness level (TRL) within the US was found to be low with several major risk factors that require understanding prior to full engine system development. One area of uncertainty is the extreme heat loads expected during thermal steady state conditions. To achieve this, an announcement for collaborative opportunity (ACO) partnership between IN Space LLC and NASA Marshall Space Flight Center (MSFC) was established to explore integration of additive manufacturing (AM) processes and the high conductance copper-based alloys, GRCop-42 and GRCop-84. This work outlines the hot fire testing of a 7K lbf thrust class fully AM GRCop-alloy rotating detonation rocket engine (RDRE). Two annular thrust chamber configurations emulating a lander engine system were tested with LOx/GH2 and LOx/LCH4. In both configurations, select hardware was actively cooled using de-ionized water and regeneratively cooled using LCH4. All primary hardware survived long duration tests to thermal steady state up to 133 seconds in a single burn. In total, 18 starts and 802 seconds of duration were achieved with and without visual confirmation of waves present. The proportion of burned propellant, or level of complete combustion, was found to be high compared to the theoretically achievable mean chamber pressure in all cases.

Thomas Teasley↗
NASA NTRSDate not supplied

Nuclear Thermal Propulsion Material Trade for Additively Manufactured Regenerative Chambers

Nuclear thermal propulsion (NTP) is a game changing technology with advantages over chemical propulsion systems for deep space missions but comes with many engineering challenges. This paper focuses on the challenge of material selection for a regeneratively-cooled chamber for use in a nuclear environment with minimal design margins. Chemical compatibility with reactants and products following energy extraction (be it through combustion or neutron bombardment) must be considered. Similarly, mechanical and thermophysical properties (e.g., density, thermal conductivity, yield strength, etc.) as functions of temperature are critical. While hydrogen embrittlement environment (HEE) is a risk and consideration for traditional chemical combustion chambers, application in a nuclear thermal engine adds additional material compatibility and resilience requirements to long-term nuclear radiation exposure. Chamber materials in this trade included, but were not limited to, A-286, Haynes 230, Haynes 282, CRES 347, GRCop-42, GRCop-84, Inconel 625, JBK-75, and NASA HR-1. The material trade focuses on modern additive manufacturing techniques and hypothetical geometric constraints.

Nuclear Thermal Propulsion↗
NASA NTRSDate not supplied

Thin-wall Internal Channel Geometry and Surface Enhancements for Heat Exchangers using Laser Powder Directed Energy Deposition

Additive Manufacturing (AM) has offered many new design and manufacturing opportunities for components across various industries. As AM evolves there is a need to better understand outputs of the process including geometric limitations, surface texture, and post-processing surface enhancements for specific application requirements. One possible application area of AM are components using thin-wall (~1 mm) microchannel heat exchangers for subsystems across aerospace and industrial applications. Laser Powder Bed Fusion (L-PBF) is a common process for complex internal channels but the build diameter is limited to approximately 600 mm. Laser Powder Directed Energy Deposition (LP-DED) is being evaluated to produce thin-wall microchannel heat exchangers at scales beyond the L-PBF process. Successful deployment of the LP-DED technology requires characterization of geometric features from the process and potential improvements to the surface using post-processing. Surface texture, inclusive of roughness and waviness, is one of the critical attributes of AM that effects the friction factor and pressure drop within a heat exchanger and lacks data for the LP-DED process. This presentation will provide an overview of the characterization work completed of the LP-DED process for thin-walls and small channel geometry representative of various high performance alloys including NASA HR-1 and GRCop-42. An overview of the experiments conducted with varying LP-DED parameters, evaluation of various internal channel geometry, geometric build features, and resulting surface texture will be provided along with a summary of conclusions from these experiments. This study presents characterization of 2.5 mm microchannels using LP-DED, mechanisms that cause the surface texture which include powder adherence and material droop, and angled walls have a significant impact on the thickness and surface texture. Results will also be presented on various surface enhancement processes that allow for tuning of the wetting surface for friction factor, heat transfer, or fatigue life performance requirements.

Additive Manufacturing↗
NASA NTRSDate not supplied

NASA's Compact High-Efficiency Rotating Detonation Rocket Engine for Mars Interplanetary Missions

NASA has successfully test fired a novel and compact liquid propulsion system known as a Rotating Detonation Rocket Engine. This is a specially designed ring-shaped thrust chamber that leverages additive manufacturing techniques and novel alloys such as GRCop-42 and GRX-810. The extreme combustion event, known as a detonation, reduces the combustion chamber length requirements down to a few inches while equivalent constant pressure rocket thrust chambers are on the order of feet. This is primarily due to rapid completion of combustion by the high-pressure detonation, an order of magnitude faster than deflagration combustion. In addition, the ring shape allows for rapid expansion of the combustion products. Depending on the thrust class and design supersonic area ratio, the full RDRE can be anywhere from 10% to 50% shorter than a traditional liquid rocket assuming the same exit diameter but is dependent on a number of design assumptions. This may enable substantial mass savings, cost savings, and broader design trade space for various mission architectures. Finally, the engine system has potential for higher Isp at identical average chamber pressure, which is currently being assessed by NASA. Experimental data obtained from testing in 2022 identified the feasibility of the novel propulsion system while multiple test series scheduled throughout 2023 and 2024 target closing the remaining critical technical gaps preventing widespread use of the technology amongst industry.

Thomas Teasley↗
NASA NTRSDate not supplied

Survivability of NASA’s 10k RDRE

Rotating detonation rocket engines (RDRE) have widespread global industry and academic interest. Lessons learned in survivability is critical to furthering this technology. To support RDRE development, NASA hot-fire tested several 10k lbf thrust class thrust chamber assemblies with various propellent combinations including liquid oxygen/ liquid methane, liquid oxygen/ liquid hydrogen, and liquid oxygen/RP-1. The thrust chamber assemblies include injectors, inner bodies, and outer bodies that were additively manufactured (AM) laser powder bed fusion (L-PBF) GRCop-42. This paper will cover hardware damage identified in the 2023 and 2024 RDRE testing campaigns and lessons learned to improve survivability for future RDREs. Particularly notable were the findings concerning the number of detonation waves formed and their effects on the bolted interface and its sealing.

Tessa M. Fedotowsky↗
NASA NTRS2024

ECI Final Report: Closing of Critical Technology Gaps for Rotating Detonation Rocket Engines

NASA has successfully fired several configurations of a dual regenerative 10K lbf class Rotating Detonation Rocket Engines using cryogenic liquid methane, liquid hydrogen, and RP-1 as fuel and liquid or gaseous oxygen as the oxidizer. In addition, 3 hot fire test phases were conducted to evaluate parametrically varying combustor geometries using a subscale 500-1K lbf class thruster RDRE. Several studies were successfully completed to evaluate the impacts of contraction ratio, annulus L’, heat transfer through calorimetry, and varying injector designs. Laser powder bed fusion GRCop-42, GRX-810, and C-103 alloys were used for the outer bodies, inner bodies, nozzles, and injector variations. The development of RDRE technology is only now possible with additive manufacturing techniques and these specialized alloys. Critical design parameters, design rules of thumb, and operability limitations have been identified. Major lessons learned in the development of critical components have also been documented. All critical technology gaps have been demonstrated at one scale or another and closed. A major finding of this work is that the combustion efficiency of the RDRE is far superior to that of the traditional liquid rocket engine requiring an order of magnitude lower chamber volume and residence time to react. Because of this, the design trade space opens up significantly. More compact chamber geometries are now possible with potential mass savings and significant length savings possible to flight geometries. In addition, the ceiling for the technology, in terms of Isp, has not yet been reached. It is likely that an additional ~10% better Isp over equivalent state-of-the-art combustion devices may be achieved over the next decade should the technology continue to be developed. This technology has been shown to be viable for near term infusion (2-5 years) into space missions and enable cost effective space access for US industry. This final report documents all major findings from this early career initiative (ECI) project and lays out what is needed post ECI.

Thomas Teasley↗
NASA NTRSDate not supplied

Heat Transfer Measurements of NASA Liquid Kerosene/Oxygen Rotating Detonation Rocket Engine

The RDRE has been identified as a viable high performance propulsion system with numerous advantages over the state-of-the-art (SOA) liquid rocket engine. NASA has been investigating this combustion device for applications ranging from lander, upper stage, thruster, and hypersonics. All of the activities funded to date have been focused on closing major technology gaps preventing the RDRE from being used more broadly by industry. One of those gaps include the prediction and management of heat transfer to the walls from the extreme combustion environment. This work overviews the heat transfer measurements made using new and existing hardware. A liquid oxygen / liquid RP-1 RDRE was tested utilizing a calorimeter outer body and outer body nozzle extension. An actively cooled inner body with axial running cooling channels was also used. A bimetallic GRCop-42 / Monel K500 injector was developed and demonstrated to be a viable technology for RDRE environments. Trends in bulk heat loads are discussed along with a direct comparison to constant pressure theory predictions of wall heat transfer. The experimental data obtained in this investigation showed similar heat fluxes to constant pressure theory indicating deflagration may have dominated the flow field. Only a single detonation wave was observed in all tests which imparted a significant dynamic load (vibration) on the test article making measurement of combustor performances extremely challenging. Both accelerometer and load cell data corroborate the extreme G-forces measured. The single wave mode yielded relatively low performances compared with other hot fire test data sets available. This leads to the conclusion that a single detonation wave in this geometry is not sufficient for high performance. Wave multiplicity, or rather, a specific number of waves may yield higher performances.

Thomas Teasley↗
NASA NTRSDate not supplied

Calorimeter Heat Flux Trends in NASA’s Subscale Rotating Detonation Rocket Engine

A calorimeter-style rotating detonation rocket engine (RDRE) outer chamber body was designed, additively manufactured in GRCop-42, and hot-fire tested in test cell 105 at NASA Marshall Space Flight Center (MSFC) in Huntsville, AL in August 2024. Steady-state, spatially resolved heat flux and chamber pressure were measured at 13 and 9 locations from the injector face, respectively, for a variety of test conditions and hardware configurations with gaseous methane and oxygen propellants. The 2-in. diameter highly instrumented design, enabled by metal additive manufacturing (AM), allowed for simultaneous measurement of heat flux and chamber pressure through 44 long duration hot-fire tests without failure. Of the 44 tests, only 3 of the tests featured chamber pressures below 100 psia and are discussed in this work. Heat flux trends for this subscale hardware are explored with respect to local propellant mass flux for several different injectors, chamber lengths, and chamber “subsonic” area ratios (contraction ratios). Results show that for increasing chamber pressure, a reduced amount of energy per kilogram of propellant is transferred to the wall. Switching injectors affects the near-face heat flux and chamber pressure profiles. Chamber length does not noticeably affect the heat flux profile but increases bulk heat load. A subsonic area ratio greater than 1 reduces heat losses to the wall compared to a straight annulus case. Equivalence ratio shift did not significantly affect heat flux. Computational fluid dynamics (CFD) and conjugate heat transfer (CHT) analyses were performed to delineate 3-D heat transfer and coolant mass flow maldistribution effects and create a calorimeter transfer function to transform heat flux data and mitigate the profile distortions. Additional CFD/CHT simulations were performed using experimental data as boundary conditions to assess local nucleate boiling propensity during testing and to assess projected hot wall temperatures for future fatigue assessment. Vapor fractions were observed locally for several cases. It is anticipated that this effort will provide a common framework for coolant system design/analysis in calorimeter systems for rocket-based and air-breathing combustors, ensuring greater repeatability in calorimetry measurements across the research community.

Joseph Hernandez-McCloskey↗
NASA NTRSDate not supplied

Advancing GRCop-based Bimetallic Additive Manufacturing to Optimize Component Design and Applications for Liquid Rocket Engines

Additive manufacturing (AM) is advancing many applications of component design for liquid rocket engines. The ability to rapidly design and manufacture components has provided significant opportunities for development and flight programs across the propulsion industry. AM has demonstrated significant advantages that include cost and schedule savings in addition to performance improvements through new design opportunities. While these performance advantages can be in the characteristics of complex design features, they can also be in the form of new materials. AM has been demonstrated in these various component applications using a variety of metal alloys, many of which are traditional alloys for extreme environments. Additional developments were completed using AM to provide new alloys and maturing these material uses for high performance applications. Almost all of the prior developments across component applications have focused on single-alloys in these AM processes. NASA and industry partners have focused in recent years to advance processing to create bimetallic and multicomponent AM processes and materials. The role of multi-alloy AM offers advantages since it can further optimize weight, optimize reliability and performance by increasing the strength to weight ratio of a component, and can optimize materials for various engineering requirements. This is particularly important in liquid rocket engine combustion devices that must reject heat in high heat flux environments yet maintain adequate structural margins under high operational pressure. NASA has been exploring several AM processes, materials, and applications for combustion devices, specifically combustion chambers, injectors, nozzles, and ignition systems. These components require fine geometric features for internal flow or cooling functionality. They experience high thermal gradients across thin-walls and must survive high pressures and temperatures from propellants and the combustion process. A copper-based alloy is normally used to provide high thermal conductivity, but at the detriment of increased weight if used as a single alloy in an AM chamber. Various AM processes were demonstrated on these components using a copper-based alloy/superalloy bimetallic solution. The AM processes being explored individually and in combination for bimetallic applications include Laser Powder Bed Fusion (L-PBF), Laser Powder Directed Energy Deposition (LP-DED), and cold spray. The combination of bimetallic material combinations explored in this research include copper-based material primarily and superalloys, Inconel 625 or NASA HR-1. The various aspects of the additive manufacturing processes and challenges, materials characterization, and the testing of bimetallic components in a relevant environment will be discussed.

Additive Manufacturing↗
NASA NTRSDate not supplied

Advancing GRCop-based Bimetallic Additive Manufacturing to Optimize Component Design and Applications for Liquid Rocket Engines

Additive manufacturing (AM) is advancing many applications of component design for liquid rocket engines. The ability to rapidly design and manufacture components has provided significant opportunities for development and flight programs across the propulsion industry. AM has demonstrated significant advantages that include cost and schedule savings in addition to performance improvements through new design opportunities. While these performance advantages can be in the characteristics of complex design features, they can also be in the form of new materials. AM has been demonstrated in these various component applications using a variety of metal alloys, many of which are traditional alloys for extreme environments. Additional developments were completed using AM to provide new alloys and maturing these material uses for high performance applications. Almost all of the prior developments across component applications have focused on single-alloys in these AM processes. NASA and industry partners have focused in recent years to advance processing to create bimetallic and multicomponent AM processes and materials. The role of multi-alloy AM offers advantages since it can further optimize weight, optimize reliability and performance by increasing the strength to weight ratio of a component, and can optimize materials for various engineering requirements. This is particularly important in liquid rocket engine combustion devices that must reject heat in high heat flux environments yet maintain adequate structural margins under high operational pressure. NASA has been exploring several AM processes, materials, and applications for combustion devices, specifically combustion chambers, injectors, nozzles, and ignition systems. These components require fine geometric features for internal flow or cooling functionality. They experience high thermal gradients across thin-walls and must survive high pressures and temperatures from propellants and the combustion process. A copper-based alloy is normally used to provide high thermal conductivity, but at the detriment of increased weight if used as a single alloy in an AM chamber. Various AM processes were demonstrated on these components using a copper-based alloy/superalloy bimetallic solution. The AM processes being explored individually and in combination for bimetallic applications include Laser Powder Bed Fusion (L-PBF), Laser Powder Directed Energy Deposition (LP-DED), and cold spray. The combination of bimetallic material combinations explored in this research include copper-based material primarily and superalloys, Inconel 625 or NASA HR-1. The various aspects of the additive manufacturing processes and challenges, materials characterization, and the testing of bimetallic components in a relevant environment will be discussed.

Additive Manufacturing↗
NASA NTRSDate not supplied

Advancement of Extreme Environment Additively Manufactured Alloys for Next Generation Space Propulsion Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into propulsion development and flight applications. NASA matured commonly used aerospace alloys from various alloy families (Nickel, Copper, Stainless and Steel, Aluminum, and Titanium-based) through detailed AM process and heat treatment characterization, in addition to mechanical and thermophysical testing. While these alloys are actively used in many propulsion applications, there is a need for ongoing AM optimized alloys using integrated computational materials engineering (ICME) and process development for high performance applications. The applications targeted are liquid rocket engines; advanced propulsion systems; and in-space propulsion with high heat fluxes, high pressure, and/or that use propellants that can degrade alloys (e.g., hydrogen). This paper highlights the characterization and physical properties of the more common AM alloys using laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Additionally, this paper discusses some of the ongoing novel alloy development and maturation using AM for use in these harsh environments, such as GRCop42, GRCop-84, NASA HR-1, GRX-810, and C-103. The results from these processes demonstrated that AM could enable rapid development and ongoing efforts for optimized alloys using ICME, yielding higher performances. These alloys have undergone modeling, fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing campaigns. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL) through high duty-cycle testing. A background and overview of these novel AM-enabled alloys and AM processing developments including metallurgical and mechanical property studies is presented here. The latest advancement in the parallel component development and hot-fire testing and future developments for these alloys is also discussed.

Additive Manufacturing↗