Progress in Additively Manufactured Copper-Alloy GRCop-84, GRCop-42, and Bimetallic Combustion Chambers for Liquid Rocket Engines
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Paul R Gradl↗
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Characterization of typical platelet injector flow configurations
A study to investigate the hydraulic atomization characteristics of several novel injector designs for use in liquid propellant rocket engines is presented. The injectors were manufactured from a series of thin stainless steel platelets through which orifices were very accurately formed by a photoetching process. These individual platelets were stacked together and the orifices aligned so as to produce flow passages of prescribed geometry. After alignment, the platelets were bonded into a single, 'platelet injector', unit by a diffusion bonding process. Because of the complex nature of the flow associated with platelet injectors, it was necessary to use experimental techniques, exclusively, throughout the study. Large scale models of the injectors were constructed from aluminum plates and the appropriate fluids were modeled using a glycerol-water solution. Stop-action photographs of test configurations, using spark-shadowgraph or stroboscopic back-lighting, are shown.
Hickox, C. E.↗
Prepsolv (TM): The optimum alternative to 1,1,1-trichloroethane and methyl ethyl ketone for hand-wipe cleaning of aerospace materials
Engineers at Hercules Aerospace, a rocket motor manufacturer in Utah, have worked closely with chemists at Glidco Organics to study the feasibility of using terpenes for zero-residue wipe cleaning. The result of this work is a technological breakthrough, in which the barrier to ultra-low non-volatile residue formation has been broken. After 2 years of development and testing, SCM Glidco Organics has announced the availability of Glidsafe(registered trademark) Prepsolv(TM): a state-of-the-art ultra-low residue terpene wipe cleaning agent that does not require rinsing. Prepsolv(TM) can successfully be used in simple hand-wipe cleaning processes without fear of leaving surface residues. Industry testing has confirmed that Prepsolv(TM) is not only highly effective, but can even be less expensive to use than traditional cleaning solvents like methyl chloroform. This paper addresses the features and benefits of Prepsolv(TM), and presents performance and material compatibility data that characterizes this unique cleaning agent. Since its commercialization, Hercules Aerospace has chosen Prepsolv(TM) as the optimum cleaning agent to replace ozone-depleting solvents in their weapons factory in Magna, UT. Likewise, Boeing has approved Prepsolv(TM) for cleaning components in the manufacture of commercial aircraft at their facilities in Seattle, WA and Wichita, KS. Additional approvals are forthcoming for this uniquely safe and effective solvent.
Gallagher, R. Scott↗
Channel Wall Nozzle Manufacturing and Hot-Fire Testing Using a Laser Wire Direct Closeout Technique for Liquid Rocket Engines
No abstract available
Gradl, Paul↗
Channel Wall Nozzle Manufacturing and Hot-Fire Testing using a Laser Wire Direct Closeout Technique for Liquid Rocket Engines
No abstract available
Gradl, Paul↗
Reactive Additive Manufacturing for Fourth Industrial Revolution Exploration Systems (RAMFIRE)
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LP-DED↗
NASA’s Space Launch System: Progress Toward Launch
The Space Launch System (SLS), NASA’s cornerstone launch capability for a new generation of deep space exploration, has begun assembly at Kennedy Space Center (KSC) in preparation for launch in 2021. SLS will provide an unparalleled launch capability for human and robotic deep space exploration missions. Its proven propulsion system, upgrade path to more powerful vehicles, and high-volume payload fairings make it the foundation for ambitious and demanding as part of the Artemis program. Artemis is NASA’s 21st-century plan to put boots on the Moon and to perform sustainable, long-term science in deep space, with eyes toward sending explorers to Mars. The initial SLS vehicle to fly, Block 1 in the crew configuration – with the new Orion spacecraft – is scheduled to lift off from revitalized launch facilities at KSC in 2021 for an uncrewed test flight known as Artemis I. Manufacturing is complete on the vehicle and all elements have been delivered to the Exploration Ground Systems (EGS) Program, except the core stage. The program’s all-new development, the core stage is currently in the midst of a “Green Run” test campaign at Stennis Space Center (SSC). Eight progressively more challenging tests in the Green Run series will culminate in a hot-fire of four flight-proven liquid hydrogen/liquid oxygen (LH2/LOX) RS25 engines. Following the Green Run hotfiring, the core stage will ship to KSC. Already at KSC, aft sections of the fivesegment solid rocket boosters are being assembled. Previously delivered elements, including the upper stage, are undergoing final checkouts in preparation for stacking. An exciting 2021 will include such milestones as stacking SLS and Orion in KSC’s Vehicle Assembly Building (VAB), modal testing, roll out to Launch Pad 39B, Wet Dress Rehearsal (WDR), and launch. Teams across the country are preparing for launch by finalizing procedures, defining launch constraints and flight rules, training console operators, performing simulations, and more. With the SLS Block 1 vehicle for Artemis I nearing integration and launch, the second Block 1 vehicle in the crew configuration, which will carry astronauts on an Artemis II hybrid lunar flyby mission, has several elements manufactured. In fact, the solid rocket motor segments and RS-25 engines are complete. Those program elements are processing hardware for the third flight and working toward manufacturing the second SLS variant to fly, Block 1B, which will onramp a powerful new upper stage, the Exploration Upper Stage (EUS).
John Honeycutt↗
Manufacturing Process Developments for Regeneratively-Cooled Channel Wall Rocket Nozzles
Regeneratively cooled channel wall nozzles incorporate a series of integral coolant channels to contain the coolant to maintain adequate wall temperatures and expand hot gas providing engine thrust and specific impulse. NASA has been evaluating manufacturing techniques targeting large scale channel wall nozzles to support affordability of current and future liquid rocket engine nozzles and thrust chamber assemblies. The development of these large scale manufacturing techniques focus on the liner formation, channel slotting with advanced abrasive water-jet milling techniques and closeout of the coolant channels to replace or augment other cost reduction techniques being evaluated for nozzles. NASA is developing a series of channel closeout techniques including large scale additive manufacturing laser deposition and explosively bonded closeouts. A series of subscale nozzles were completed evaluating these processes. Fabrication of mechanical test and metallography samples, in addition to subscale hardware has focused on Inconel 625, 300 series stainless, aluminum alloys as well as other candidate materials. Evaluations of these techniques are demonstrating potential for significant cost reductions for large scale nozzles and chambers. Hot fire testing is planned using these techniques in the future.
Gradl, Paul↗
Coal-Fired Rocket Engine
Brief report describes concept for coal-burning hybrid rocket engine. Proposed engine carries larger payload, burns more cleanly, and safer to manufacture and handle than conventional solid-propellant rockets. Thrust changeable in flight, and stops and starts on demand.
Anderson, Floyd A.↗
Robust Low Cost Liquid Rocket Combustion Chamber by Advanced Vacuum Plasma Process
Next-generation, regeneratively cooled rocket engines will require materials that can withstand high temperatures while retaining high thermal conductivity. Fabrication techniques must be cost efficient so that engine components can be manufactured within the constraints of shrinking budgets. Three technologies have been combined to produce an advanced liquid rocket engine combustion chamber at NASA-Marshall Space Flight Center (MSFC) using relatively low-cost, vacuum-plasma-spray (VPS) techniques. Copper alloy NARloy-Z was replaced with a new high performance Cu-8Cr-4Nb alloy developed by NASA-Glenn Research Center (GRC), which possesses excellent high-temperature strength, creep resistance, and low cycle fatigue behavior combined with exceptional thermal stability. Functional gradient technology, developed building composite cartridges for space furnaces was incorporated to add oxidation resistant and thermal barrier coatings as an integral part of the hot wall of the liner during the VPS process. NiCrAlY, utilized to produce durable protective coating for the space shuttle high pressure fuel turbopump (BPFTP) turbine blades, was used as the functional gradient material coating (FGM). The FGM not only serves as a protection from oxidation or blanching, the main cause of engine failure, but also serves as a thermal barrier because of its lower thermal conductivity, reducing the temperature of the combustion liner 200 F, from 1000 F to 800 F producing longer life. The objective of this program was to develop and demonstrate the technology to fabricate high-performance, robust, inexpensive combustion chambers for advanced propulsion systems (such as Lockheed-Martin's VentureStar and NASA's Reusable Launch Vehicle, RLV) using the low-cost VPS process. VPS formed combustion chamber test articles have been formed with the FGM hot wall built in and hot fire tested, demonstrating for the first time a coating that will remain intact through the hot firing test, and with no apparent wear. Material physical properties and the hot firing tests are reviewed.
Holmes, Richard↗
Microstructural Characterization of Laser Powder Bed Fusion (L-PBF) Additively Manufactured Inconel 718 for Aerospace Application
Alloy 718 (Inconel 718) is used for aerospace applications because of its excellent corrosion resistance and mechanical properties. This alloy is particularly applicable in manufacturing components subjected to high temperatures in rocket engines, aero-engines, and gas turbines. Properties for this alloy when processing on systems from similar and different Laser Powder Bed Fusion (L-PBF) machines provide subtle differences due to process parameters, feedstock, and machine configurations. A series of sixteen L-PBF AM Inconel 718 geometric feature build plates have been evaluated for microstructure using optical microscopy. This study presents the details of the microstructure analysis concerning geometry and different machine platforms. Microstructural investigations of these samples included average grain width measurement for all the X-Y and Y-Z build layers and are accompanied by process parameters and powder characterization. The present work concludes with a discussion on the importance of captured differences among builds to understand the practical limitations among AM platforms.
Additive Manufacturing↗
Material Characterization of Additively Manufactured Components for Rocket Propulsion
To advance Additive Manufacturing (AM) technologies for production of rocket propulsion components the NASA Glenn Research Center (GRC) is applying state of the art characterization techniques to interrogate microstructure and mechanical properties of AM materials and components at various steps in their processing. The materials being investigated for upper stage rocket engines include titanium, copper, and nickel alloys. Additive manufacturing processes include laser powder bed, electron beam powder bed, and electron beam wire fed processes. Various post build thermal treatments, including Hot Isostatic Pressure (HIP), have been studied to understand their influence on microstructure, mechanical properties, and build density. Micro-computed tomography, electron microscopy, and mechanical testing in relevant temperature environments has been performed to develop relationships between build quality, microstructure, and mechanical performance at temperature. A summary of GRCs Additive Manufacturing roles and experimental findings will be presented.
Additive Manufacturing↗
Materials Characterization of Additively Manufactured Components for Rocket Propulsion
To advance Additive Manufacturing (AM) technologies for production of rocket propulsion components the NASA Glenn Research Center (GRC) is applying state of the art characterization techniques to interrogate microstructure and mechanical properties of AM materials and components at various steps in their processing. The materials being investigated for upper stage rocket engines include titanium, copper, and nickel alloys. Additive manufacturing processes include laser powder bed, electron beam powder bed, and electron beam wire fed processes. Various post build thermal treatments, including Hot Isostatic Pressure (HIP), have been studied to understand their influence on microstructure, mechanical properties, and build density. Micro-computed tomography, electron microscopy, and mechanical testing in relevant temperature environments has been performed to develop relationships between build quality, microstructure, and mechanical performance at temperature. A summary of GRC's Additive Manufacturing roles and experimental findings will be presented.
Additive Manufacturing↗
Advancement of Metal Additive Manufacturing Processes and Alloys for Rocket Propulsion Applications
NASA has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the 2000’s. Several efforts have focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into development and flight applications. While many common aerospace alloys have been and continue to be a focus of ongoing development, the need for custom-alloy developments for high performance applications enabled by various AM processes has been realized. The applications being targeted are liquid rocket engines with high heat fluxes, high pressure, and that utilize propellants such as hydrogen, which can degrade the alloy. NASA has recently focused on the development and advancement of novel alloy advancement using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, and JBK-75. These alloys have been evaluated using powder bed fusion (PBF), directed energy deposition (DED), and solid-state AM processes. The results from these processes have demonstrated that AM can enable rapid development of new alloy systems that can yield higher performances across various metal AM processes. These alloys have undergone the fundamental metallurgical evaluations, heat treatment study, and microstructure characterization and mechanical testing campaign. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL). This presentation will provide a background and overview of various AM-enabled novel alloys, a comparison across the AM processes, and development including metallurgical and mechanical property studies. It will also cover the latest advancement in the parallel component development and testing and future developments. The goal of these alloy development and use of various AM processes is to allow for technology infusion into NASA and commercial spaceflight missions as well as to establish and sustain the needed commercial AM supply chain.
Additive Manufacturing↗
Propulsion Design With Freeform Fabrication (PDFF)
The nation is challenged to decrease the cost and schedule to develop new space transportation propulsion systems for commercial, scientific, and military purposes. Better design criteria and manufacturing techniques for small thrusters are needed to meet current applications in missile defense, space, and satellite propulsion. The requirements of these systems present size, performance, and environmental demands on these thrusters that have posed significant challenges to the current designers and manufacturers. Designers are limited by manufacturing processes, which are complex, costly, and time consuming, and ultimately limited in their capabilities. The PDFF innovation vastly extends the design opportunities of rocket engine components and systems by making use of the unique manufacturing freedom of solid freeform rapid prototype manufacturing technology combined with the benefits of ceramic materials. The unique features of PDFF are developing and implementing a design methodology that uses solid freeform fabrication (SFF) techniques to make propulsion components with significantly improved performance, thermal management, power density, and stability, while reducing development and production costs. PDFF extends the design process envelope beyond conventional constraints by leveraging the key feature of the SFF technique with the capability to form objects with nearly any geometric complexity without the need for elaborate machine setup. The marriage of SFF technology to propulsion components allows an evolution of design practice to harmonize material properties with functional design efficiency. Reduced density of materials when coupled with the capability to honeycomb structure used in the injector will have significant impact on overall mass reduction. Typical thrusters in use for attitude control have 60 90 percent of its mass in the valve and injector, which is typically made from titanium. The combination of material and structure envisioned for use in an SFF thruster design could reduce thruster weight by a factor of two or more. The thrust-to-weight ratios for such designs can achieve 1,000:1 or more, depending on chamber pressure. The potential exists for continued development in materials, size, speed, accuracy of SFF techniques, which can lead to speculative developments of PDFF processes such as fabrication of custom human interface devices like masks, chairs, and clothing, and advanced biomedical application to human organ reconstruction. Other potential applications are: higher fidelity lower cost test fixtures for probes and inspection, disposable thrusters, and ISRU (in situ resource utilization) for component production in space or on Lunar and Martian missions, and application for embedding MEMS (microelectromechanical systems) during construction process of form changing aerostructure/dynamic structures.
Barnes, Daudi↗
Development of high strength, high temperature ceramics
Improvement in the high-pressure turbopumps, both fuel and oxidizer, in the Space Shuttle main engine were considered. The operation of these pumps is limited by temperature restrictions of the metallic components used in these pumps. Ceramic materials that retain strength at high temperatures and appear to be promising candidates for use as turbine blades and impellers are discussed. These high strength materials are sensitive to many related processing parameters such as impurities, sintering aids, reaction aids, particle size, processing temperature, and post thermal treatment. The specific objectives of the study were to: (1) identify and define the processing parameters that affect the properties of Si3N4 ceramic materials, (2) design and assembly equipment required for processing high strength ceramics, (3) design and assemble test apparatus for evaluating the high temperature properties of Si3N4, and (4) conduct a research program of manufacturing and evaluating Si3N4 materials as applicable to rocket engine applications.
Hall, W. B.↗
Low Cost, Upper Stage-Class Propulsion
The low cost, upper stage-class propulsion (LCUSP) element will develop a high strength copper alloy additive manufacturing (AM) process as well as critical components for an upper stage-class propulsion system that will be demonstrated with testing. As manufacturing technologies have matured, it now appears possible to build all the major components and subsystems of an upper stage-class rocket engine for substantially less money and much faster than traditionally done. However, several enabling technologies must be developed before that can happen. This activity will address these technologies and demonstrate the concept by designing, manufacturing, and testing the critical components of a rocket engine. The processes developed and materials' property data will be transitioned to industry upon completion of the activity. Technologies to enable the concept are AM copper alloy process development, AM post-processing finishing to minimize surface roughness, AM material deposition on existing copper alloy substrate, and materials characterization.
Vickers, John↗
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↗