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NASA NTRS1999

Lunar Prospector Extended Mission

The National Aeronautics and Space Administration (NASA) selected Lunar Prospector (LP) as one of the discovery missions to conduct solar system exploration science investigations. The mission is NASA's first lunar voyage to investigate key science objectives since Apollo and was launched in January 1998. In keeping with discovery program requirements to reduce total mission cost and utilize new technology, Lunar Prospector's mission design and control focused on the use of innovative and proven trajectory analysis programs. As part of this effort, the Ames Research Center and the Goddard Space Flight Center have become partners in the Lunar Prospector trajectory team to provide the trajectory analysis, maneuver planning, orbit determination support, and product generation. At the end of 1998, Lunar Prospector completed its one-year primary mission at 100 km altitude above the lunar surface. On December 19, 1998, Lunar Prospector entered the extended mission phase. Initially the mission orbit was lowered from 100 km to a mean altitude of 40 km. The altitude of Lunar Prospector varied between 25 and 55 km above the mean lunar geode due to lunar potential effects. After one month, the lunar potential model was updated based upon the new tracking data at 40 km. On January 29, 1999, the altitude was lowered again to a mean altitude of 30 km. This altitude varies between 12 and 48 km above the mean lunar geode. Since the minimum altitude is very close to the mean geode, various approaches were employed to get accurate lunar surface elevation including Clementine altimetry and line of sight analysis. Based upon the best available terrain maps, Lunar Prospector will reach altitudes of 8 km above lunar mountains in the southern polar and far side regions. This extended mission phase of six months will enable LP to obtain science data up to 3 orders of magnitude better than at the mission orbit. This paper details the trajectory design and orbit determination planning and actual results of the Lunar Prospector extended mission including maneuver design, eccentricity & argument of perigee evolution, and lunar potential modeling.

Folta, David↗
NASA NTRS2001

Langmuir Probe Spacecraft Potential End Item Specification Document

This document describes the Langmuir Probe Spacecraft Potential (LPSP) investigation of the plasma environment in the vicinity of the ProSEDS Delta II spacecraft. This investigation will employ a group of three (3) Langmuir Probe Assemblies, LPAs, mounted on the Delta II second stage to measure the electron density and temperature (n(sub e) and T(sub e)), the ion density (n(sub i)), and the spacecraft potential (V(sub s)) relative to the surrounding ionospheric plasma. This document is also intended to define the technical requirements and flight-vehicle installation interfaces for the design, development, assembly, testing, qualification, and operation of the LPSP subsystem for the Propulsive Small Expendable Deployer System (ProSEDS) and its associated Ground Support Equipment (GSE). This document also defines the interfaces between the LPSP instrument and the ProSEDS Delta II spacecraft, as well as the design, fabrication, operation, and other requirements established to meet the mission objectives. The LPSP is the primary measurement instrument designed to characterize the background plasma environment and is a supporting instrument for measuring spacecraft potential of the Delta II vehicle used for the ProSEDS mission. Specifically, the LPSP will use the three LPAs equally spaced around the Delta II body to make measurements of the ambient ionospheric plasma during passive operations to aid in validating existing models of electrodynamic-tether propulsion. These same probes will also be used to measure Delta II spacecraft potential when active operations occur. When the electron emitting plasma contractor is on, dense neutral plasma is emitted. Effective operation of the plasma contactor (PC) will mean a low potential difference between the Delta II second stage and the surrounding plasma and represents one of the voltage parameters needed to fully characterize the electrodynamic-tether closed circuit. Given that the LP already needs to be well away from any near-field disturbances around the Delta II, it is possible to use the same probe with a simple reconfiguration of the electronics to measure potential with respect to the ambient plasma. The LP measurement techniques are outlined in the following text and discussed in detail in the Appendix. The scientific goals of the investigation, the physical and electrical characteristics of the instrument, and the on-orbit measurement requirements are also discussed in this document.

Gilchrist, Brian↗
NASA NTRS2004

Robotic Subsurface Analyzer and Sample Handler for Resource Reconnaissance and Preliminary Site Assessment for ISRU Activities at the Lunar Cold Traps

Since the 1960s, claims have been made that water ice deposits should exist in permanently shadowed craters near both lunar poles. Recent interpretations of data from the Lunar Prospector-Neutron Spectrometer (LP- NS) confirm that significant concentrations of hydrogen exist, probably in the form of water ice, in the permanently shadowed polar cold traps. Yet, due to the large spatial resolution (45-60 Ian) of the LP-NS measurements relative to these shadowed craters (approx.5-25 km), these data offer little certainty regarding the precise location, form or distribution of these deposits. Even less is known about how such deposits of water ice might effect lunar regolith physical properties relevant to mining, excavation, water extraction and construction. These uncertainties will need to be addressed in order to validate fundamental lunar In Situ Resource Utilization (ISRU) precepts by 2011. Given the importance of the in situ utilization of water and other resources to the future of space exploration a need arises for the advanced deployment of a robotic and reconfigurable system for physical properties and resource reconnaissance. Based on a collection of high-TRL. designs, the Subsurface Analyzer and Sample Handler (SASH) addresses these needs, particularly determining the location and form of water ice and the physical properties of regolith. SASH would be capable of: (1) subsurface access via drilling, on the order of 3-10 meters into both competent targets (ice, rock) and regolith, (2) down-hole analysis through drill string embedded instrumentation and sensors (Neutron Spectrometer and Microscopic Imager), enabling water ice identification and physical properties measurements; (3) core and unconsolidated sample acquisition from rock and regolith; (4) sample handling and processing, with minimized contamination, sample containerization and delivery to a modular instrument payload. This system would be designed with three mission enabling goals, including: (1) a self-contained, low power, low mass, "black box'' configuration for operations from a lander, various classes of rovers or a surface-based platform with human assistance or robotic anchoring mechanisms; (2) reconfigurable and scalable sample handling for delivery to various types of instrumentation, depending on mission requirements; and (3) the use of advanced automation control and diagnostic techniques that will afford local human deployed, remote teleoperation and fully autonomous intelligent operations. Though a great deal of technology has been advanced toward these objectives, the SASH system faces significant design challenges, including the low gravity environment, various levels of autonomy in operations, radiation exposure, dust contamination, and temperature extremes and deltas. Significant input from the scientific and engineering communities, as well as a significant environmental testing program, will be required to guide the design process.

Gorevan, S. P.↗
NASA NTRS1993

Validation of Atmospheric Correction of Airborne Visible/Infrared Imaging Spectrometer (AVIRIS) Radiance Data Based on Radiative Transfer Modeling

An evaluation of atmospheric correction of AVIRIS data using radiative transfer codes LOWTRAN7 and MODTRAN is presented. The algorithm employed is based on a simple model of radiance L at each wavelength at the sensor that can be written approximately LAV=Lp+Tp, where subscript AV referes to AVIRIS, Lp is the path radiance and Tp is the diffuse + direct transmitted radiance of the atmosphere at AVIRIS.

Infrared Mapping↗
NASA NTRS2007

Skeletal Adaptations to Different Levels of Eccentric Resistance Following Eight Weeks of Training

Coupled concentric-eccentric resistive exercise maintains bone mineral density (BMD) during bed rest and aging. PURPOSE: We hypothesized that 8 wks of lower body resistive exercise training with higher ratios of eccentric to concentric loading would enhance hip and lumbar BMD. METHODS: Forty untrained male volunteers (34.9+/-7.0 yrs, 80.9+/-9.8 kg, 178.2+/-7.1 cm; mean+/-SD) were matched for leg press (LP) 1-Repetition Maximum (1-RM) strength and randomly assigned to one of 5 training groups. Concentric load (% 1-RM) was constant across groups, but each group trained with different levels of eccentric load (0, 33, 66, 100, or 138% of concentric) for all training sessions. Subjects performed a periodized supine LP and heel raise (HR) training program 3 d wk-1 for 8 wks using a modified Agaton Fitness System (Agaton Fitness AB, Boden, Sweden). Hip and lumbar BMD (g/sq cm) was measured in triplicate pre- and post-training using DXA (Hologic Discovery ). Pre- and post-training means were compared using the appropriate ANOVA and Tukey's post hoc tests. Within group pre- to post-training BMD was compared using paired t-tests with a Bonferroni adjustment. RESULTS: There was a main effect of training on L1, L2, L3, L4, total lumbar, and greater trochanter BMD, but there were no differences between groups. CONCLUSION: Eights wks of lower body resistive exercise increased greater trochanter and lumbar BMD. Inability to detect group differences may have been influenced by a potentially osteogenic vibration associated with device operation in the 0, 33, and 66% groups.

English, Kirk L.↗
NASA NTRS2011

Femoral Blood Flow and Cardiac Output During Blood Flow Restricted Leg Press Exercise

Low load blood flow restricted resistance exercise (LBFR) causes muscle hypertrophy that may be stimulated by the local ischemic environment created by the cuff pressure. However, local blood flow (BF) during such exercise is not well understood. PURPOSE: To characterize femoral artery BF and cardiac output (CO) during leg press exercise (LP) performed at a high load (HL) and low load (LL) with different levels of cuff pressure. METHODS: Eleven subjects (men/women 4/7, age 31.4+/-12.8 y, weight 68.9+/-13.2 kg, mean+/-SD) performed 3 sets of supine left LP to fatigue with 90 s of rest in 4 conditions: HL (%1-RM/cuff pressure: 80%/0); LL (20%/0); LBFR(sub DBP) (20%/1.3 x diastolic blood pressure, BP); LBFR(sub SBP) (20%/1.3 x supine systolic BP). The cuff remained inflated throughout the LBFR exercise sessions. Artery diameter, velocity time integral (VTI), and stroke volume (SV) were measured using Doppler ultrasound at rest and immediately after each set of exercise. Heart rate (HR) was monitored using a 3-lead ECG. BF was calculated as VTI x vessel cross-sectional area. CO was calculated as HR x SV. The data obtained after each set of exercise were averaged and used for analyses. Multi-level modeling was used to determine the effect of exercise condition on dependent variables. Statistical significance was set a priori at p< 0.05. RESULTS: Artery diameter did not change from baseline. BF increased (p<0.05) after exercise in each condition except LBFR(sub SBP) in the order of HL (12.73+/-1.42 cm3,mean+/-SE) > LL (9.92+/-0.82 cm3) > LBFR(sub dBP)(6.47+/-0.79 cm3) > LBFR(sub SBP) (3.51+/-0.59 cm3). Blunted exercise induced increases occurred in HR, SV, and CO after LBFR compared to HL and LL. HR increased 45% after HL and LL and 28% after LBFR (p<0.05), but SV increased (p<0.05) only after HL. Consequently, the increase (p<0.05) in CO was greater in HL and LL (approximately 3 L/min) than in LBFR (approximately 1 L/min). CONCLUSION: BF during LBFR(sub SBP) was 1/3 of that observed in LL, which supports the hypothesis that local ischemia stimulates the LBFR hypertrophic response. As the cuff did not compress the artery, the ischemia may have occurred because of the blunted rise in CO or because arterial BP cannot overcome the cuff pressure. As LBFR(sub DBP) effectively reduced BF and CO with cuff pressures less than systolic BP, future studies should investigate the hypertrophic potential of LBFR at even lower cuff pressures.

Everett, M. E.↗
NASA NTRS2012

Sensitivity of Cirrus and Mixed-phase Clouds to the Ice Nuclei Spectra in McRAS-AC: Single Column Model Simulations

The salient features of mixed-phase and ice clouds in a GCM cloud scheme are examined using the ice formation parameterizations of Liu and Penner (LP) and Barahona and Nenes (BN). The performance of LP and BN ice nucleation parameterizations were assessed in the GEOS-5 AGCM using the McRAS-AC cloud microphysics framework in single column mode. Four dimensional assimilated data from the intensive observation period of ARM TWP-ICE campaign was used to drive the fluxes and lateral forcing. Simulation experiments where established to test the impact of each parameterization in the resulting cloud fields. Three commonly used IN spectra were utilized in the BN parameterization to described the availability of IN for heterogeneous ice nucleation. The results show large similarities in the cirrus cloud regime between all the schemes tested, in which ice crystal concentrations were within a factor of 10 regardless of the parameterization used. In mixed-phase clouds there are some persistent differences in cloud particle number concentration and size, as well as in cloud fraction, ice water mixing ratio, and ice water path. Contact freezing in the simulated mixed-phase clouds contributed to transfer liquid to ice efficiently, so that on average, the clouds were fully glaciated at T approximately 260K, irrespective of the ice nucleation parameterization used. Comparison of simulated ice water path to available satellite derived observations were also performed, finding that all the schemes tested with the BN parameterization predicted 20 average values of IWP within plus or minus 15% of the observations.

Betancourt, R. Morales↗
NASA NTRS2016

A New Algorithm for Detecting Cloud Height using OMPS/LP Measurements

The Ozone Mapping and Profiler Suite Limb Profiler (OMPS/LP) ozone product requires the determination of cloud height for each event to establish the lower boundary of the profile for the retrieval algorithm. We have created a revised cloud detection algorithm for LP measurements that uses the spectral dependence of the vertical gradient in radiance between two wavelengths in the visible and near-IR spectral regions. This approach provides better discrimination between clouds and aerosols than results obtained using a single wavelength. Observed LP cloud height values show good agreement with coincident Cloud-Aerosol Lidar and Infrared Pathfinder Satellite Observation (CALIPSO) measurements.

Chen, Zhong↗
NASA NTRS2017

The 2013 FLEX-US Airborne Campaign at the Parker Tract Loblolly Pine Plantation in North Carolina, USA

The first European Space Agency (ESA) and NASA collaboration in an airborne campaign to support ESA's FLuorescence EXplorer (FLEX) mission was conducted in North Carolina, USA during September-October 2013 (FLEX-US 2013) at the Parker Tract Loblolly Pine (LP) Plantation (Plymouth, NC, USA). This campaign combined two unique airborne instrument packages to obtain simultaneous observations of solar-induced fluorescence (SIF), LiDAR-based canopy structural information, visible through shortwave infrared (VSWIR) reflectance spectra, and surface temperature, to advance vegetation studies of carbon cycle dynamics and ecosystem health. We obtained statistically significant results for fluorescence, canopy temperature, and tower fluxes from data collected at four times of day over two consecutive autumn days across an age class chronosequence. Both the red fluorescence (F685) and far-red fluorescence (F740) radiances had highest values at mid-day, but their fluorescence yields exhibited different diurnal responses across LP age classes. The diurnal trends for F685 varied with forest canopy temperature difference (canopy minus air), having a stronger daily amplitude change for young vs. old canopies. The Photochemical Reflectance Index (PRI) was positively correlated with this temperature variable over the diurnal cycle. Tower measurements from mature loblolly stand showed the red/far-red fluorescence ratio was linearly related to canopy light use efficiency (LUE) over the diurnal cycle, but performed even better for the combined morning/afternoon (without midday) observations. This study demonstrates the importance of diurnal observations for interpretation of fluorescence dynamics, the need for red fluorescence to understand canopy physiological processes, and the benefits of combining fluorescence, reflectance, and structure information to clarify canopy function versus structure characteristics for a coniferous forest.

chlorophyll fluorescence; diurnal responses; red S↗
NASA NTRS2017

Towards A Representation of Vertically Resolved Ozone Changes in Reanalyses

The Solar Backscatter Ultraviolet Radiometer (SBUV) instruments on NASA and NOAA spacecraft provide a long-term record of total-column ozone and deep-layer partial columns since about 1980. These data have been carefully processed to extract long-term trends and offer a valuable resource for ozone monitoring. Studies assimilating limb-sounding observations in the Goddard Earth Observing System (GEOS) data assimilation system (DAS) demonstrate that vertical ozone gradients in the upper troposphere and lower stratosphere (UTLS) are much better represented than with the deep-layer SBUV observations. This is exemplified by the use of retrieved ozone from the EOS Microwave Limb Sounder (EOS-MLS) instrument in the MERRA-2 reanalysis, for the period after 2004. This study examines the potential for extending the use of limb-sounding observations at earlier times and into the future, so that future reanalyses may be more applicable to the study of long-term ozone changes.Historical data are available from NASA instruments: the Limb Infrared Monitor of the Stratosphere (LIMS: 1978-1979); the Upper Atmospheric Research Satellite (UARS: 1991-1995); Sounding of the Atmosphere using Broadband Emission Radiometry (SABER: 2000-onwards). For the post EOS-MLS period, the joint NASA-NOAA Ozone Monitoring and Profiling Suite Limb Profiler (OMPS-LP) instrument was launched on the Suomi-NPP platform in 201x and is planned for future platforms. This study will examine two aspects of these data pertaining to future reanalyses. First, the feasibility of merging the EOS-MLS and OMPS-LP instruments to provide a long-term record that extends beyond the potential lifetime of EOS-MLS. If feasible, this would allow for long-term monitoring of ozone recovery in a three-dimensional reanalysis context. Second, the skill of the GEOS DAS in ingesting historical data types will be investigated. Because these do not overlap with EOS-MLS, use will be made of system statistics and evaluation using independent datasets. Impacts of using a complete ozone chemistry module will also be considered.

ML↗
NASA NTRS2019

Ozone Vertical Profile Satellite Measurements by S-NPP OMPS, Aura MLS, and Sentinel-5P TROPOMI

NASA has been monitoring ozone variations from space since 1970 with the launch of the Backscatter Ultraviolet instrument (BUV) on Nimbus- 4. Ozone in the Earth’s stratosphere and troposphere plays a crucial role in protecting life from harmful solar UV radiation, and it also influences Earth’s climate. The vertical distribution of ozone is used in modeling forecasts, verifying model analysis and simulations, and improving the measurement of tropospheric ozone that is a toxic constituent of air pollution. The Microwave Limb Sounder (MLS) on the EOS Aura spacecraft has been monitoring long-term continuous stratosphere ozone vertical behaviors since 2004. The Ozone Mapper Profile Suite (OMPS) on the Suomi National Polar-orbiting Partnership (S-NPP) was launched in 2011. Two of its three instruments, the Limb Profiler (LP) and the Nadir Profiler (NP), are designed to map ozone profiles with full global coverage (~6 days for NP) and a high level of vertical accuracy (1-km reporting record for LP) in the stratosphere and upper troposphere. The TROPOspheric Monitoring Instrument (TROPOMI) on the Copernicus Sentinel-5 Precursor (S5P), launched in 2017, aims to retrieve ozone profiles in both the troposphere and up to top-of-atmosphere (TOA) by using UV radiation measurements in a spectral range of 270-320 nm. S5P/TROPOMI ozone profile products are planned to become available in April 2020. This presentation will concentrate on satellite ozone vertical profile data collections from OMPS and MLS which are archived at the NASA Goddard Earth Sciences Data and Information Services Center (GES DISC). TROPOMI ozone vertical profiles for the troposphere and to top-of-atmosphere will become available at NASA GES DISC in 2020. The presentation briefly explores their potential complementary usability in determining three-dimensional ozone global distributions with high temporal and spatial resolutions.

Zeng, Jian↗
NASA NTRS2021

The Long-term Transport and Radiative Impacts of the 2017 British Columbia Pyrocumulonimbus Smoke Aerosols in the Stratosphere

Interactions of meteorology with wildfires in British Columbia, Canada during August 2017 led to three major pyrocumulonimbus (pyroCb) events that resulted in the injection of large amounts of smoke aerosols and other combustion products at the local upper troposphere and lower stratosphere (UTLS). These plumes of UTLS smoke with elevated values of aerosol extinction and backscatter compared to the background state were readily tracked by multiple satellite-based instruments as they spread across the Northern Hemisphere (NH). The plumes were observed in the lower stratosphere for about 8-10 months following the fire injections, with a stratospheric aerosol e-folding time of about 5 months. To investigate the radiative impacts of these events on the Earth system, we performed a number of simulations with the Goddard Earth Observing System (GEOS) atmospheric general circulation model (AGCM). Observations from multiple remote-sensing instruments were used to calibrate the injection parameters (location, amount, composition and heights) and optical properties of the smoke aerosols in the model. The resulting simulations of three-dimensional smoke transport were evaluated for a year from the day of injections using daily observations from OMPS-LP (Ozone Mapping Profiler Suite Limb Profiler). The model simulated rate of ascent, hemispheric spread and residence time (or e-folding time) of the smoke aerosols in the stratosphere are in close agreement with OMPS-LP observations. We found that both aerosol self-lofting and the large-scale atmospheric motion play important roles in lifting the smoke plumes from near the tropopause altitudes (~12 km) to about 22-23 km into the atmosphere. Further, our estimations of the radiative impacts of the pyroCb-emitted smoke aerosols showed that the smoke caused an additional warming of the atmosphere by about 0.6-1 W/m2 (zonal mean) that persisted for about 2-3 months after the injections in regions north of 40oN. The surface experienced a comparable magnitude of cooling. The atmospheric warming is mainly located in the stratosphere, coincident with the location of the smoke plumes, leading to an increase in zonal mean shortwave (SW) heating rates of 0.02-0.04 K/day during September 2017.

pyrocumulonimbus (pyroCb) events↗
NASA NTRSDate not supplied

Landing Humans and Human-Class Cargo on the Moon and Mars

For more than a decade, efforts have been ongoing at NASA’s Marshall Space Flight Center (MSFC) in Huntsville, Alabama, to land humans and large, human-rated cargo on planetary bodies like the Moon and Mars. This work continues today under the Center’s Lander Programs (LP) office. Recognizing MSFC’s heritage, NASA stood up the Human Landing System program at the Center in August 2019 to be responsible for spacecrafts that will land the next American astronauts on the Moon under Artemis. With work well underway for the historic Artemis III mission to land the first woman and first person of color on the lunar surface through the Appendix H Option A contract with SpaceX, LP is focused on the development of landers that will support the Agency’s long-term Artemis efforts at the Moon and NASA’s future at Mars. In March 2022, NASA announced its plan to solicit a second industry provider in addition to SpaceX to develop and demonstrate a lander that meets the program’s extended set of requirements for missions beyond Artemis III. Under the umbrella of Sustaining Lunar Development, these requirements will meet NASA’s needs for recurring, long-term access to the lunar surface, such as accommodating an increased crew size and delivering more mass to the surface. Additionally, NASA plans to leverage crewed lander development activities to procure and certify the design of landers capable of human-class cargo delivery. This paper will examine how the Lander Program office at MSFC is bridging from the initial demonstration phase of development for the Human Landing System program to the Sustaining Lunar Development phase and feeding forward to Mars. The requirements and lines of effort for landing humans and human class cargo will be discussed, as well as near-term and future milestones for the program.

Lemuel Carpenter↗
NASA NTRSDate not supplied

Monitoring the 2022 Hunga Tonga-Hunga Ha'apai Aerosol Cloud Using Space-Based Observations

- We will analyze the volcanic plume progression, spread and properties using space-based observations - OMPS LP, SAGE III/ISS, CALIPSO, TROPOMI - OMPS LP and SAGE III/ISS are limb instruments that measure the aerosol vertical profiles globally, while CALIPSO is a LIDAR that measures the backscatter and depolarization ratio of the aerosol profiles. -TROPOMI is a UV instrument that measures SO2 and absorbing aerosol total column - Volcanic plume in the upper stratosphere - The main plume in middle stratosphere - Volcanic aerosol transport to SH/NH - Volcanic aerosol optical properties

Atmospheric Science↗
NASA NTRSDate not supplied

Parameter, Post-Processing Sensitivities, and Qualification Approach of Laser Powder Bed Fusion Hydrogen Resistant Alloy NASA HR-1

Metal additive manufacturing (AM) processes are being used to enable economical manufacturing of legacy alloys as well as advancing new alloys. Laser powder bed fusion (L-PBF) is a metal AM process that has high maturity and being used to produce a variety of parts for space applications including complex propulsion components. The National Aeronautics and Space Administration (NASA) has identified the need to develop and advance new materials in unique space applications such as high-pressure hydrogen environments. NASA HR-1 is a high strength Fe-Ni based superalloy designed to resist high pressure hydrogen environment embrittlement (HEE), oxidation, and corrosion that has been successfully adapted to laser powder directed energy deposition (LP-DED). Insights gained from the NASA HR-1 development for LP-DED have guided the development process for L-PBF. However, adapting NASA HR-1 to L-PBF posed new challenges due to the distinct differences between the additive manufacturing processes. During parameter development, sensitivities were observed in post-processing that necessitated additional optimization of heat treatments. Additionally, the variations in thickness and how it influenced the microstructural response during heat treatment was characterized. Understanding these sensitivities is important to qualification of the material in a L-PBF machine. This ensures that the microstructures and properties of the material maintain consistency in production. This presentation will cover parameter development along with post-processing challenges and solutions will be discussed in addition to key material properties as it pertains to application performance and qualification per NASA-STD-6030. Improvements made by developing a derivative alloy, NASA HR-2, will be highlighted through preliminary small scale parameter development, material characterization, and initial property testing.

NASA HR-1↗
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↗