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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 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
NASA NTRS2024

Extreme Temperature Additively Manufactured GRX-810 Alloy Development and Hot-fire Testing for Liquid Rocket Engines

Additive manufacturing (AM) has revolutionized component design for liquid rocket engines by offering rapid manufacturing capabilities. This has led to significant opportunities for development and flight programs in the propulsion industry, resulting in cost and schedule savings, as well as performance improvements through new designs and alloy development. A noteworthy example is the GRX-810 oxide dispersion strengthened (ODS) alloy, which was specifically developed for extreme temperatures. This Ni-Co-Cr based alloy was created using integrated computational materials engineering (ICME) techniques to focus on a new class of materials with exceptional temperature and oxidation-resistant properties. The GRX-810 alloy utilizes AM processes to incorporate nano-scale yttria particles throughout its microstructure, resulting in remarkable enhancements. Compared to traditional Nickel-based superalloys, the GRX-810 alloy offers a two-fold increase in tensile strength, 1,000-fold better creep properties, and two-fold improvement in oxidation resistance. NASA successfully demonstrated the development and manufacturing of components using the GRX-810 alloy through laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Extensive efforts were made to model, evaluate metallurgical properties, develop heat treatment processes, characterize the microstructure, and determine mechanical properties. The GRX-810 alloy was specifically designed for aerospace applications, including liquid rocket engine injectors, preburners, turbines, and hot-section components, capable of withstanding temperatures up to 1,100 °C. The objective of this alloy development is to bridge the temperature gap between traditional Nickel-based superalloys and refractory alloys. This paper provides a comprehensive comparison of the GRX-810 alloy with other aerospace alloys, discussing its microstructure, mechanical properties, processing advancements, component development, and hot-fire testing results. The ultimate goal of this development was to elevate the Technology Readiness Level (TRL) of the GRX-810 alloy, enabling its integration into NASA and commercial aerospace applications.

GRX-810↗
NASA NTRS2019

Additive Manufacturing Development and Hot-Fire Testing of Liquid Rocket Channel Wall Nozzles Using Blown Powder Directed Energy Deposition Inconel 625 and JBK-75 Alloys

Additive manufacturing (AM) is being investigated at NASA and across much of the rocket propulsion industry as an alternate fabrication technique to create complex geometries for liquid engine components that offers schedule and cost saving opportunities. The geometries that can be created using AM offer a significant advantage over traditional techniques. Internal complexities, such as internal coolant channels for combustion chambers and nozzles that would typically require several operations to manufacture traditionally can be fabricated in one process. Additionally, the coolant channels are closed out as a part of the AM build process, eliminating the complexities of a traditional process like brazing or plating. The primary additive manufacturing technique that has been evaluated is powder bed fusion (PBF), or selective laser melting (SLM), but there is a scale limitation for this technique. There are several alternate additive manufacturing techniques that are being investigated for large-scale nozzles and chambers including directed energy deposition (DED) processes. A significant advantage of the DED processes is the ability to adapt to a robotic or gantry CNC system with a localized purge or purge chamber, allowing unlimited build volume. This paper will discuss the development and hot-fire testing of channel-cooled nozzles fabricated utilizing one form of DED called blown powder deposition. This initial development work using blown powder DED is being explored to form the entire channel wall nozzle with integral coolant channels within a single AM build. Much of this development is focused on the design and DED-fabrication of complex and thin-walled features and on characterization of the materials properties produced with this techniques in order to evolve this process. Subscale nozzles were fabricated using this DED technique and hot-fire tested in Liquid Oxygen/Hydrogen (LOX/GH2) and LOX/Kerosene (LOX/RP-1) environments accumulating significant development time and cycles. The initial materials that were evaluated during this testing were high-strength nickel-based Inconel 625 and JBK-75. Further process development is being completed to increase the scale of this technology for large-scale nozzles. This paper will summarize the general design considerations for DED, specific channel-cooled nozzle design, manufacturing process development, property development, initial hot-fire testing and future developments to mature this technology for regeneratively-cooled nozzles. An overview of future development at NASA will also be discussed.

Gradl, Paul R.↗
NASA NTRS1991

Development of life prediction capabilities for liquid propellant rocket engines. Post-fire diagnostic system for the SSME system architecture study

This system architecture task (1) analyzed the current process used to make an assessment of engine and component health after each test or flight firing of an SSME, (2) developed an approach and a specific set of objectives and requirements for automated diagnostics during post fire health assessment, and (3) listed and described the software applications required to implement this system. The diagnostic system described is a distributed system with a database management system to store diagnostic information and test data, a CAE package for visual data analysis and preparation of plots of hot-fire data, a set of procedural applications for routine anomaly detection, and an expert system for the advanced anomaly detection and evaluation.

Gage, Mark↗
NASA NTRS1989

Rocket-triggered lightning strikes and forest fire ignition

Background information on the rocket-triggered lightning project at Kennedy Space Center (KSC), a summary of the forecasting problem there, the facilities and equipment available for undertaking field experiments at KSC, previous research activity performed, a description of the atmospheric science field laboratory near Mosquito Lagoon on the KSC complex, methods of data acquisition, and present results are discussed. New sources of data for the 1989 field experiment include measuring the electric field in the lower few thousand feet of the atmosphere by suspending field measuring devices below a tethered balloon. Problems encountered during the 1989 field experiment are discussed. Future prospects for both triggered lightning and lightning-kindled forest fire research at KSC are listed.

Fenner, James H.↗
NASA NTRS1990

Engine Data Interpretation System (EDIS)

A prototype of an expert system was developed which applies qualitative or model-based reasoning to the task of post-test analysis and diagnosis of data resulting from a rocket engine firing. A combined component-based and process theory approach is adopted as the basis for system modeling. Such an approach provides a framework for explaining both normal and deviant system behavior in terms of individual component functionality. The diagnosis function is applied to digitized sensor time-histories generated during engine firings. The generic system is applicable to any liquid rocket engine but was adapted specifically in this work to the Space Shuttle Main Engine (SSME). The system is applied to idealized data resulting from turbomachinery malfunction in the SSME.

Cost, Thomas L.↗
NASA NTRS2007

Finite Element Simulation of Solid Rocket Booster Separation Motors During Motor Firing

One of the toughest challenges facing Solid Rocket Booster (SRB) engineers is to ensure that any design changes made to the Shuttle-Derived Booster Separation Motors (BSM) for future space exploration vehicles is able to withstand the increasingly hostile motor firing environment without cracking its critical component - the graphite throat. This paper presents a critical analysis methodology and techniques for assessing effects of BSM design changes with great accuracy and precision. For current Space Shuttle operation, the motor firing occurs at SRB separation - approximately 125 seconds after Shuttle launch at an altitude of about 28 miles. The motor operation event lasts about two seconds, however, the surface temperature of the graphite throat increases approximately 3400 F in less than one second with a corresponding increase in surface pressure of approximately 2200 pounds per square inch (psi) in less than one-tenth of a second. To capture this process fully and accurately, a two-phase sequentially coupled thermal-mechanical finite element approach was developed. This method allows the time- and location-dependent pressure fields to interact with the spatial-temporal thermal fields throughout the operation. The material properties of graphite throat are orthotropic and temperature-dependent. The analysis involves preload and multiple body contacts.

Yu. Weiping↗
NASA NTRS2010

Oxygen Compatibility Assessment of Components and Systems

Fire hazards are inherent in oxygen systems and a storied history of fires in rocket engine propulsion components exists. To detect and mitigate these fire hazards requires careful, detailed, and thorough analyses applied during the design process. The oxygen compatibility assessment (OCA) process designed by NASA Johnson Space Center (JSC) White Sands Test Facility (WSTF) can be used to determine the presence of fire hazards in oxygen systems and the likelihood of a fire. This process may be used as both a design guide and during the approval process to ensure proper design features and material selection. The procedure for performing an OCA is a structured step-by-step process to determine the most severe operating conditions; assess the flammability of the system materials at the use conditions; evaluate the presence and efficacy of ignition mechanisms; assess the potential for a fire to breach the system; and determine the reaction effect (the potential loss of life, mission, and system functionality as the result of a fire). This process should be performed for each component in a system. The results of each component assessment, and the overall system assessment, should be recorded in a report that can be used in the short term to communicate hazards and their mitigation and to aid in system/component development and, in the long term, to solve anomalies that occur during engine testing and operation.

Stoltzfus, Joel↗
NASA NTRS2009

Measurement and Characterization of Space Shuttle Solid Rocket Motor Plume Acoustics

Lift-off acoustic environments generated by the future Ares I launch vehicle are assessed by the NASA Marshall Space Flight Center (MSFC) acoustics team using several prediction tools. This acoustic environment is directly caused by the Ares I First Stage booster, powered by the five-segment Reusable Solid Rocket Motor (RSRMV). The RSRMV is a larger-thrust derivative design from the currently used Space Shuttle solid rocket motor, the Reusable Solid Rocket Motor (RSRM). Lift-off acoustics is an integral part of the composite launch vibration environment affecting the Ares launch vehicle and must be assessed to help generate hardware qualification levels and ensure structural integrity of the vehicle during launch and lift-off. Available prediction tools that use free field noise source spectrums as a starting point for generation of lift-off acoustic environments are described in the monograph NASA SP-8072: "Acoustic Loads Generated by the Propulsion System." This monograph uses a reference database for free field noise source spectrums which consist of subscale rocket motor firings, oriented in horizontal static configurations. The phrase "subscale" is appropriate, since the thrust levels of rockets in the reference database are orders of magnitude lower than the current design thrust for the Ares launch family. Thus, extrapolation is needed to extend the various reference curves to match Ares-scale acoustic levels. This extrapolation process yields a subsequent amount of uncertainty added upon the acoustic environment predictions. As the Ares launch vehicle design schedule progresses, it is important to take every opportunity to lower prediction uncertainty and subsequently increase prediction accuracy. Never before in NASA s history has plume acoustics been measured for large scale solid rocket motors. Approximately twice a year, the RSRM prime vendor, ATK Launch Systems, static fires an assembled RSRM motor in a horizontal configuration at their test facility in Utah. The remaining RSRM static firings will take place on elevated terrain, with the nozzle exit plume being mostly undeflected and the landscape allowing placement of microphones within direct line of sight to the exhaust plume. These measurements will help assess the current extrapolation process by direct comparison between subscale and full scale solid rocket motor data.

Kenny, Jeremy↗
NASA NTRS1972

Effects of experimentally measured pressure oscillations on the vibration of a solid rocket motor

Results are presented of firing a Nike rocket against a backstop for the purpose of obtaining pressure fluctuations in the rocket case and determining their relationship to structural vibrations of the case. Special care was required to obtain these pressure fluctuations because of the much higher static pressure generated in the rocket. Very small pressure fluctuations within the rocket case can cause significant vibration levels. A previously observed high frequency was shown to decrease with time before completely disappearing at about 1 second of burning time. The vibration of the case itself is probably related to the longitudinal structural modes at frequencies below 500 Hz and is dependent on local structural conditions at frequencies above this value.

Schoenster, J. A.↗
NASA NTRS1988

The scaling of the threshold conditions for solid propellant erosive burning

Rocket test firings were performed to measure the transition length threshold conditions while systematically varying various rocket motor parameters. These include the crossflow velocity, the chamber pressure, the propellant nonerosive burning rate, the propellant surface roughness, and the motor port diameter. The erosive burning trends with varying propellant burning rate, motor chamber pressure, and mass flow rate are consistent with published results.

Strand, L. D.↗
NASA NTRS1947

Report on Rocket Power Plants Based on T-Substance

In the search for an energy source independent of air for the propulsion of underwater craft, attention was early concentrated on T-substance. It was possible to convince the OKM [NACA comment: Navy High Command] very quickly of the importance of this material. In 1934, the first experiments were undertaken. A difficulty was at once presented by the limited concentration that had been attained. At first only 60 percent T-substance could be supplied; this amount was later increased to as much as 85 percent. Decomposition and combustion experiments conducted on the grounds of the CPVA in Kiel-Dietrichsdorf led to the first practical information as to the technical feasibility of the use of T-substance. New perspectives soon developed because a method of concentrated energy production had been found here, which was capable of many applications. The idea of using this energy for the propulsion of missiles either in guns or as rockets suggested itself and appropriate proposals, which quickly led to the construction of the first experimental devices, were made to the official quarters concerned. In January 1937, the first flight of a DVL aircraft with T-substance auxiliary propulsion took place at Alimbsmuhle in the presence of Colonel Udet, who piloted the third flight. In June 1937, the first T-substance rockets were fired (Altenwalde). Then in rapid succession take-off auxiliary, main propulsion, and other rocket drives were brought out in experimental versions. Hydrogen peroxide is a well known chemical, which is widely used in the textile industry. Its chemical and physical properties as well as the processes of manufacture and use are familiar and have been described in voluminous books and papers, Nevertheless, much developmental work was required to open the way for T-substance as a usable oxygen carrier. In fact the utilization of hydrogen peroxide as the oxygen carrier for energy production had hitherto been the subject only of isolated suggestions, which have never been developed beyond the stage of theoretical discussion.

Walter, Hellmuth↗
NASA NTRS1973

Effect of thruster pulse length on thruster-exhaust damage of S13G white thermal control coatings

Rocket exhaust products which strike thermal control surfaces cause changes in solar absorptance (Alpha Sub s) and thermal emittance (Epsilon) of these surfaces. A study was made of the effect of rocket pulse duration on exhaust damage to S13G white coatings. Two pulse lengths were used - 14 msec and 50 msec. An MMH/N204 bipropellant 5-lb thrust rocket was fired into a simulated space environment with a vacuum of 0.00001 torr, a liquid helium temperature enclosure, and solar radiation. The changes in solar absorptance and thermal emittance of S13G white coatings due to rocket exhaust were made in-situ for total firing times of 58 seconds with 14 msec pulses and 223.7 sec with 50 msec pulses. The solar absorptance of S13G increased 25 percent due to 223.7 sec of exposure to 50 msec pulses and the thermal emittance was unaffected. The ratio of Alpha Sub s/Epsilon therefore increased by 25 percent. The short 14 msec pulse exhaust exposure caused between 40 and 70 percent increase in solar absorptance and a decrease of between 13 and 18 percent in thermal emittance. The corresponding increase in Alpha Sub s/Epsilon ratio was between 80 and 100 percent. Ultraviolet radiation was present in the short pulse test and may have contributed to the large damage of that test.

Sommers, R. D.↗
NASA NTRS1990

Array Of Rockets For Multicrewmember Evacuation

Emergency egress system undergoing development for aircraft and aerospace vehicles uses fixed array of tractor rockets to eject crewmembers. Crewmembers hook up to tractor rockets and fire them unaided. Positioned as unit in ready-to-use orientation during flight operations. On ground, swung out of way. Rocket array also mounts under exit hatch, serving as egress ramp.

Allen, Margaret A.↗
NASA NTRS1990

Rocket-triggered lightning strikes and forest fire ignition

The following are presented: (1) background information on the rocket-triggered lightning project an Kennedy Space Center (KSC); (2) a summary of the forecasting problem; (3) the facilities and equipment available for undertaking field experiments at KSC; (4) previous research activity performed; (5) a description of the atmospheric science field laboratory near Mosquito Lagoon on the KSC complex; (6) methods of data acquisition; and (7) present results. New sources of data for the 1990 field experiment include measuring the electric field in the lower few thousand feet of the atmosphere by suspending field measuring devices below a tethered balloon, and measuring the electric field intensity in clouds and in the atmosphere with aircraft. The latter program began in July of 1990. Also, future prospects for both triggered lightning and forest fire research at KSC are listed.

Fenner, James↗