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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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At least 649 records · Page 36
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

A Review Towards the Design Optimization of High Performance Additively Manufactured Rotating Detonation Rocket Engine Injectors

Rotating Detonation Rocket Engines (RDRE) have been marketed primarily for their higher specific impulse potential over constant pressure (CP) liquid rocket engines. However, several other performance advantages exist with RDREs over CP engines such as heat transfer advantages for gas expander cycle, increased completeness of combustion at low chamber L*, compact engine design, reduced coolant channel pressure drop potential, and improved injector C* performance. NASA has paved the way for liquid engine system performance enhancement since the Apollo program and continues to do so with metal additive manufacturing (AM), super-alloy materials, and advanced propulsion concepts. A team of propulsion development engineers at NASA are in the process of developing high-performance 7K lbf class RDRE hardware for their potential use in lander, upper stage, and even launch vehicle applications. Clear advantages have been demonstrated with AM including program cost and schedule reductions of up to 50%. It is well known that injector performance is integrally linked to the global performance of a combustion device. This is especially the case for RDREs since detonation stability is heavily dependent on the mixedness of propellants. A major program goal is to rapidly produce ultra-high-performance AM injectors. This paper reviews the available literature on liquid rocket injector design optimization as well as the experimental work conducted to date on injectors tested in RDREs. Major lessons learned are document and suggestions given towards the design of high-performance liquid RDRE injectors. In addition, the integration of metal AM into the design of liquid RDRE injector schemes is discussed. Finally, several candidate AM RDRE injector elements were produced to obtain their diodicity and cold flow characteristics.

rotating detonation engine↗
NASA NTRSDate not supplied

Thermal Analysis of an In-Space Heat Shield Exposed to a Rocket Plume During Stage Separation

Thermal analyses were conducted to evaluate the thermal response of various individual materials and multi-layer configurations for an in-space heat shield exposed to a rocket plume during stage separation. Frequently used, readily available thermal protection materials consisting of cork, carbon cloth phenolic (CCP), and silica cloth phenolic (SCP) were selected for an initial screening analysis. SCP was chosen as the primary material for further evaluation using an updated thermal environment calculated using computational fluid dynamics (CFD) results. A multi-layer configuration consisting of SCP providing erosion resistance and a Nomex honeycomb providing thermal protection was then evaluated as a solution for more mass-efficient performance. Pyrolysis depth, bondline temperature, back-side temperature, and a thermal factor of safety were used to define the necessary material thickness profile. Adhesives were included in the analyses with considerations for maximum temperature and application method. One dimensional thermal analyses at several stations along the heat shield surface were performed for the initial screening and follow-on analyses. The methodology used standard processes and computer programs applicable to solid rocket motor internal insulation and nozzle thermal analysis such as Chemical Equilibrium and Applications (CEA), Aerotherm Chemical Equilibrium (ACE), Momentum/Energy Integral Technique (MEIT), and Insulation Thermal Response and Ablation Code (ITRAC). The baseline SCP/Nomex honeycomb multi-layer configuration thermal performance predictions satisfied the objectives with an acceptable mass estimate for the design maturity. The EA9673 film adhesive and SCP resin were the best performing bonding agents considered for the SCP/Nomex honeycomb and Nomex honeycomb/structural substrate interfaces. The baseline mass estimate was lowest when the resin was the bonding agent due to the higher maximum service temperature. These thermal analyses evaluated typical internal and external nozzle materials using a calculated thermal environment and heat loads that were lower than a typical rocket motor internal environment but greater than standard external aeroheating.

Andrew T Hiatt↗
NASA NTRSDate not supplied

An Updated Model for the Effect of Atmospheric Absorption on Sounding Rockets

A very high-resolution R > 20,000 Far Ultraviolet full-disk, solar spectrograph will be launched in the Spring of 2023. This paper describes the in-flight wavelength calibration techniques and the fortuitous retrieval of Earth’s thermospheric information during the flight. Building and calibration of the Full-sun Ultraviolet Rocket Spectrograph (FURST) is currently underway. The purpose of this instrument is to obtain the highest resolution and most complete Far Ultra-Violet (FUV) spectra of the full disk Sun. This so-called "Sun-as-a-star" spectra will allow direct comparisons between our Sun and other stars measured by the Hubble Space Telescope(HST) and the upcoming James Webb Space Telescope (JWST). The Solar Physics groups at NASA Marshall Space Flight Center (MSFC) and Montana State University (MSU) have been developing the tools and procedures necessary to achieve the high spectral resolution goal. These include, among other things, improved tracking of error propagation, in-situ monitoring of the camera gain with a radioactive Fe-55 source, and the development of a simulated spectral calibration map under a noisy diagnostic-lamp signal. This mapping introduces a clocked CCD in order to obtain sub-pixel spectral resolution and overcome the Nyquist limit by about a factor of 2. Aside from the main purpose of FURST, we have been investigating the effect of absorption in the upper atmosphere at sounding-rocket altitudes (about 100-300 km). We present here an improved model of the optical depth caused by the thermospheric Oxygen cross-section and H and O self-absorption. This data-based model uses concentric spherical shells to account for the curvature of the Earth’s atmosphere and refraction. Using these calculations, we present the anticipated effect on the signal received by FURST, how that signal changes over the course of the flight-path These absorption peaks would provide wavelength fiducials at line-center that might add to in-flight calibration of the instrument. Many studies have found ways to correct for these so-called "Telluric" lines. However, it may be that these lines can in fact be a useful tool to further improve our calibration, rather than simply a nuisance to be corrected for! Finally, we discuss the inversion problem: how we could take actual flight data and back-out the atmospheric data (such as density and temperature) from any such sounding rocket flight that shows evidence of atmospheric absorption.

Nicolas Donders↗
NASA NTRSDate not supplied

Optimization of Rocket Engine Components using Multi-Metallic Additive Manufacturing

Additive manufacturing (AM) is advancing many applications of component design for liquid rocket engines. AM has been demonstrated in various rocket component applications using a variety of monolithic metal alloys, many of which are traditional alloys for extreme environments. 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-metallic 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. NASA’s Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project has designed and manufactured a series of additively manufactured (AM) coupled combustion chambers, nozzles, and other engine components to advance new AM processes and materials with the goal of reducing cost and schedule for engine manufacturing. These designs incorporated multimetallic AM, which further enabled carbon-fiber composite overwrap to reduce overall thrust chamber assembly (TCA) mass. 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 GRCop-based alloys and superalloys, Inconel 625 or NASA HR-1. One unique development that will be presented is the combustion chamber and nozzle as a single component by using freeform integrated DED to build the nozzle directly onto the aft end of the chamber. The various aspects of the additive manufacturing processes and challenges, materials characterization and mechanical testing, and hot-fire testing of bimetallic components in a relevant rocket engine environment will be discussed.

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 NTRS1964

Rocket-motor spin-test apparatus

Rocket motor spin test apparatus capable of subjecting solid rocket motors to dynamic spin or roll environments encountered in flight

FLIGHT TEST INSTRUMENT↗
NASA NTRS1966

Rocket propagation experiment

Electron densities and collision frequencies from Nike-Apache rocket firings, results of eclipse experiment in South America, and instrumentation for rocket propagation studies

ELECTRON DENSITY↗
NASA NTRS1953

Experimental investigation of a lightweight rocket chamber

Experiments have been conducted with a jacketed rocket combustion chamber that was fabricated by hydraulic-forming from sheet metal. Rocket combustion chambers made by this method have been used successfully. Runs with these combustion chambers have been made at over-all heat-transfer rates 1.7 Btu per square inch per second with water cooling and also ammonia as a regenerative coolant.

ENGINES, ROCKET↗
NASA NTRSDate not supplied

Advanced and Additive Manufacturing Technologies for Liquid Rocket Engine Components

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

Additive Manufacturing↗
NASA NTRSDate not supplied

A Review Towards the Design Optimization of High-Performance Additively Manufactured Rotating Detonation Rocket Engine Injectors

Rotating Detonation Rocket Engines (RDRE) have been marketed primarily for their higher specific impulse potential over constant pressure (CP) liquid rocket engines. However, several other performance advantages exist such as heat transfer advantages for gas expander cycle, increased completeness of combustion at low chamber L*, compact engine design, reduced coolant channel pressure drop potential, and improved injector C* performance. NASA has paved the way for liquid engine system performance enhancement since the Apollo program and continues to do so with metal additive manufacturing (AM), new advanced materials, and advanced propulsion concepts. A team of propulsion development engineers at NASA are in the process of developing high-performance 7K lbf class RDRE hardware for their potential use in lander, upper stage, and even launch vehicle applications. Clear advantages have been demonstrated with AM including program cost and schedule reductions of up to 50%. It is well known that injector performance is integrally linked to the global performance of a combustion device. This is especially the case for RDREs since detonation stability is heavily dependent on the mixedness of propellants. A major goal of this work is to identify what has been done in the open experimental literature and what injectors design features are conducive to high performance in the detonation cycle. This paper reviews the available literature and reports the primary gaps in the knowledge base needed by the pressure gain combustion (PGC) community. Major conclusions are documented, and suggestions given towards the design of high-performance liquid RDRE injectors. In addition, the integration of metal AM into the design of liquid RDRE injector schemes is included.

rotating detonation rocket engine↗
NASA NTRS1963

MODELING TECHNIQUES FOR LIQUID PROPELLANT ROCKET COMBUSTION PROCESSES

A qualitative physical processes description of stable and unstable combustion in rockets is presented to establish the basis for choosing model hardware design criteria. It is concluded that it is not possible to scale rocket combustion processes in the usual sense of the term. The studies conducted at Rocketdyne have shown that model chambers which satisfactorily model the steady state behavior of large engines must be designed to maintain (1) the propellant injection density, and (2) the chamber to throat Contraction ratio (hence chamber pressure). For studies of destructive acoustic modes of combustion instability a third parameter, the frequency, must also be maintained.

COMBUSTION↗
NASA NTRS1964

The Effects of Wind on Sounding Rockets

A theory to account for the effects of wind on sounding rockets is developed and discussed. A rapid method for calculating the effects of wind is presented. The results of a series of calculations are compared with experimental values. Several suggestions are made to reduce the sensitivity of sounding rockets to winus and to provide better predictions.

SOUNDING ROCKET↗
NASA NTRS1964

Effect of Thrustor Arcing on Ion Rocket System Design

Arcing between the electrodes of an ion rocket thrustor is investigated for the effect it will have on the overall design of ion rocket systems. The effect of generator, transformer, and inserted impedances on system stability and efficiency, and on operating lifetime of thrustor components are considered. Rate of arcing, preferential arc paths, speed of arc interruption, and response of thrustors to voltage transients are also discussed. The study indicates that arcing is a system hazard and that arcing rates are of prime importance in the design and development of thrustors, thrustor arrays, and system components. Two system models for reducing the hazard are proposed, based on principles developed herein, published data, and experience available from operation of nine-module electron-bombardment thrustor array. Experimental investigation of these models is presently underway.

THRUSTOR↗
NASA NTRS1965

Investigation of light hydrocarbon fuels with flox mixtures as liquid rocket propellants final report, 30 jun. 1964 - 30 jun. 1965

An analysis was completed for determination of the most promising hydrocarbon fuels for use with flox in upper stage rocket engines. Experimental rocket firings in uncooled, transpiration cooled, and regeneratively cooled thrust chambers were conducted using flox with methane, propane, butene-1, and a eutectic blend of pentane and isopentane. Experimental heated tube heat transfer and hypergolicity tests were conducted, and laboratory determinations of physical properties of various blends of hydrocarbon compounds were made.

HYDROCARBON FUEL↗