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

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NASA NTRSDate not supplied

Photonic Source for Binary Source Simulations

More than half of the sun-like stars are in binary systems or have companions that hinder the search for planets around them using traditional technologies. There are only 69 FGK dwarfs within ten pc that can harbor true earth analogs. Direct imaging can detect and study the habitability of those targets measuring the chemical composition of the atmosphere, and astrometry can measure the planet's mass. We use Multi-Star Wavefront Control (MSWC), a technique that removes stellar leakage from both stellar components to enable direct imaging of binary systems. Currently, there is a technology demonstration experiment of MSWC for the Roman coronagraph instrument at the High Contrast Imaging Testbeds operated at JPL. One of the challenges for this experiment is to produce a binary source where both stars are incoherent with each other at close physical separation. On the other hand, to measure masses, it is possible to obtain relative astrometry measurements between the binary. The TOLIMAN concept proposes to use a diffractive pupil to calibrate the distortion and detector effects to reach 1uas astrometric accuracy. JPL currently has a laboratory to demonstrate this technology, which faces the same challenge as the MSWC project of producing two incoherent nearby sources. We developed Photonic Chips with multiple waveguides in Silicon Nitride for both projects to create incoherent single sources as close as 15um. In this paper, we present the concept application, the chips design, and the first results.

photonic chips↗
DOE OSTI2022

Self-Sensing, Stretchable, Active Circuit Arrays: Liquid Metal Paste as a Combination Interconnect and Strain Sensor

Stretchable electrical interconnects and substrate materials are increasingly used to create flexible and con-formable electronic systems for soft robotics, smart textiles, and wearable devices. Wires fabricated using composite or liquid conductive inks encapsulated in silicone enable high strain and are mechanically robust. The resistance of these inter-connects increases with strain, which can present challenges for power delivery and signaling among electronic components. However, this effect can be used directly to estimate strain within a stretchable circuit without the need for additional sensor components. In this work, we present an approach for fabricating fully-stretchable, multi-layer active circuit arrays in silicone using liquid metal paste interconnects, in which power and data wires are re-purposed as strain sensors to estimate substrate deformation. As a proof-of-principle, we demonstrate a 3×3 active circuit array that self-senses relative voltage supply at each node to estimate deformation and consumes less than 10 mA per node. Each node is digitally addressable and performs both analog measurement and digital conversion. All interconnects are fabricated using liquid metal paste, and power, data, and sensing are performed over a shared, four-wire interface in this multi-layer stretchable printed circuit board.

99 GENERAL AND MISCELLANEOUS↗
NASA NTRS2016

Two-Step Multi-Physics Analysis of an Annular Linear Induction Pump for Fission Power Systems

One of the key technologies associated with fission power systems (FPS) is the annular linear induction pump (ALIP). ALIPs are used to circulate liquid-metal fluid for transporting thermal energy from the nuclear reactor to the power conversion device. ALIPs designed and built to date for FPS project applications have not performed up to expectations. A unique, two-step approach was taken toward the multi-physics examination of an ALIP using ANSYS Maxwell 3D and Fluent. This multi-physics approach was developed so that engineers could investigate design variations that might improve pump performance. Of interest was to determine if simple geometric modifications could be made to the ALIP components with the goal of increasing the Lorentz forces acting on the liquid-metal fluid, which in turn would increase pumping capacity. The multi-physics model first calculates the Lorentz forces acting on the liquid metal fluid in the ALIP annulus. These forces are then used in a computational fluid dynamics simulation as (a) internal boundary conditions and (b) source functions in the momentum equations within the Navier-Stokes equations. The end result of the two-step analysis is a predicted pump pressure rise that can be compared with experimental data.

Fission Power Systems↗
NASA NTRS2016

Two-Step Multi-Physics Analysis of an Annular Linear Induction Pump for Fission Power Systems

One of the key technologies associated with fission power systems (FPS) is the annular linear induction pump (ALIP). ALIPs are used to circulate liquid-metal fluid for transporting thermal energy from the nuclear reactor to the power conversion device. ALIPs designed and built to date for FPS project applications have not performed up to expectations. A unique, two-step approach was taken toward the multi-physics examination of an ALIP using ANSYS Maxwell 3D and Fluent. This multi-physics approach was developed so that engineers could investigate design variations that might improve pump performance. Of interest was to determine if simple geometric modifications could be made to the ALIP components with the goal of increasing the Lorentz forces acting on the liquid-metal fluid, which in turn would increase pumping capacity. The multi-physics model first calculates the Lorentz forces acting on the liquid metal fluid in the ALIP annulus. These forces are then used in a computational fluid dynamics simulation as (a) internal boundary conditions and (b) source functions in the momentum equations within the Navier-Stokes equations. The end result of the two-step analysis is a predicted pump pressure rise that can be compared with experimental data.

Fission Power Systems↗
DOE OSTI2024

Multi-resonant switched capacitor power converter architecture

A switched-capacitor (SC) network in an SC converter is controlled to operate at varying resonant modes to achieve high conversion ratio efficiency, at a low circuit component count. These power converters are suited to numerous application areas including improving energy efficiency of data centers. A family of resonant switched capacitor (SC) converters with multiple operating phases are presented “Multi-Resonant SC Converters”. Described in detail are an 8-to-1 Multi-Resonant-Doubler (MRD) converter and a 6-to-1 Cascaded Series-Parallel (CaSP). The topology of these converters make them amenable to combining like units in parallel toward reaching higher power levels.

Ye, Zichao↗
NASA NTRS2008

Applications of TRMM-based Multi-Satellite Precipitation Estimation for Global Runoff Simulation: Prototyping a Global Flood Monitoring System

Advances in flood monitoring/forecasting have been constrained by the difficulty in estimating rainfall continuously over space (catchment-, national-, continental-, or even global-scale areas) and flood-relevant time scale. With the recent availability of satellite rainfall estimates at fine time and space resolution, this paper describes a prototype research framework for global flood monitoring by combining real-time satellite observations with a database of global terrestrial characteristics through a hydrologically relevant modeling scheme. Four major components included in the framework are (1) real-time precipitation input from NASA TRMM-based Multi-satellite Precipitation Analysis (TMPA); (2) a central geospatial database to preprocess the land surface characteristics: water divides, slopes, soils, land use, flow directions, flow accumulation, drainage network etc.; (3) a modified distributed hydrological model to convert rainfall to runoff and route the flow through the stream network in order to predict the timing and severity of the flood wave, and (4) an open-access web interface to quickly disseminate flood alerts for potential decision-making. Retrospective simulations for 1998-2006 demonstrate that the Global Flood Monitor (GFM) system performs consistently at both station and catchment levels. The GFM website (experimental version) has been running at near real-time in an effort to offer a cost-effective solution to the ultimate challenge of building natural disaster early warning systems for the data-sparse regions of the world. The interactive GFM website shows close-up maps of the flood risks overlaid on topography/population or integrated with the Google-Earth visualization tool. One additional capability, which extends forecast lead-time by assimilating QPF into the GFM, also will be implemented in the future.

Hong, Yang↗
NASA NTRS2019

Advanced CMCs, Additive Manufacturing, and Joining/Integration Technologies

An overview of ceramic matrix composite (CMC) and additive manufacturing capabilities at GRC is provided. The additive manufacturing methods include laminated object manufacturing (LOM), binder jetting, 3-D printing, extrusion, direct writing and multi-materials additive manufacturing. Examples are given of GRC's extensive experience in the development and implementation of CMCs in various aerospace systems. Additive manufacturing offers significant advantages in fabricating preforms, ceramics, and CMCs. They will have to be selectively applied to "traditional" components but can also enable new applications. Additive manufacturing of lightweight and multifunctional polymer composites can provide wide ranging properties. Multi-material printing approaches could provide new opportunities to explore and expand the design envelope. Joining and Integration technologies, gaskets and sealants, as well as repair and refurbishment are also keys for Hypersonic applications.

Grady, Joseph E.↗
NASA NTRS1996

On-Orbit Calibration of a Multi-Spectral Satellite Satellite Sensor Using a High Altitude Airborne Imaging Spectrometer

Earth-looking satellites must be calibrated in order to quantitatively measure and monitor components of land, water and atmosphere of the Earth system. The inevitable change in performance due to the stress of satellite launch requires that the calibration of a satellite sensor be established and validated on-orbit. A new approach to on-orbit satellite sensor calibration has been developed using the flight of a high altitude calibrated airborne imaging spectrometer below a multi-spectral satellite sensor.

sensor calibration calibration Earth-looking satel↗
DOE OSTI2021

Performance Evaluation of Comparative Vacuum Monitoring and Piezoelectric Sensors for Structural Health Monitoring of Rotorcraft Components

The costs associated with the increasing maintenance and surveillance needs of aging structures are rising at an unexpected rate. Multi-site fatigue damage, hidden cracks in hard-to-reach locations, disbonded joints, erosion, impact, and corrosion are among the major flaws encountered in today’s extensive fleet of aging aircraft and space vehicles. Aircraft maintenance and repairs represent about a quarter of a commercial fleet’s operating costs. The application of Structural Health Monitoring (SHM) systems using distributed sensor networks can reduce these costs by facilitating rapid and global assessments of structural integrity. The use of in-situ sensors for real-time health monitoring can overcome inspection impediments stemming from accessibility limitations, complex geometries, and the location and depth of hidden damage. Reliable, structural health monitoring systems can automatically process data, assess structural condition, and signal the need for human intervention. The ease of monitoring an entire on-board network of distributed sensors means that structural health assessments can occur more often, allowing operators to be even more vigilant with respect to flaw onset. SHM systems also allow for condition-based maintenance practices to be substituted for the current time-based or cycle-based maintenance approach thus optimizing maintenance labor. The Federal Aviation Administration has conducted a series of SHM validation and certification programs intended to comprehensively support the evolution and adoption of SHM practices into routine aircraft maintenance practices. This report presents one of those programs involving a Sandia Labs-aviation industry effort to move SHM into routine use for aircraft maintenance. The Airworthiness Assurance NDI Validation Center (AANC) at Sandia Labs, in conjunction with Sikorsky, Structural Monitoring Systems Ltd., Anodyne Electronics Manufacturing Corp., Acellent Technologies Inc., and the Federal Aviation Administration (FAA) carried out a trial validation and certification program to evaluate Comparative Vacuum Monitoring (CVM) and Piezoelectric Transducers (PZT) as a structural health monitoring solution to specific rotorcraft applications. Validation tasks were designed to address the SHM equipment, the health monitoring task, the resolution required, the sensor interrogation procedures, the conditions under which the monitoring will occur, the potential inspector population, adoption of CVM and PZT systems into rotorcraft maintenance programs and the document revisions necessary to allow for their routine use as an alternate means of performing periodic structural inspections. This program addressed formal SHM technology validation and certification issues so that the full spectrum of concerns, including design, deployment, performance and certification were appropriately considered. Sandia Labs designed, implemented, and analyzed the results from a focused and statistically relevant experimental effort to quantify the reliability of a CVM system applied to Sikorsky S-92 fuselage frame application and a PZT system applied to an S-92 main gearbox mount beam application. The applications included both local and global damage detection assessments. All factors that affect SHM sensitivity were included in this program: flaw size, shape, orientation and location relative to the sensors, as well as operational and environmental variables. Statistical methods were applied to performance data to derive Probability of Detection (POD) values for SHM sensors in a manner that agrees with current nondestructive inspection (NDI) validation requirements and is acceptable to both the aviation industry and regulatory bodies. The validation work completed in this program demonstrated the ability of both CVM and PZT SHM systems to detect cracks in rotorcraft components. It proved the ability to use final system response parameters to provide a Green Light/Red Light (“GO” – “NO GO”) decision on the presence of damage. In additional to quantifying the performance of each SHM system for the trial applications on the S-92 platform, this study also identified specific methods that can be used to optimize damage detection, guidance on deployment scenarios that can affect performance and considerations that must be made to properly apply CVM and PZT sensors. These results support the main goal of safely integrating SHM sensors into rotorcraft maintenance programs. Additional benefits from deploying rotorcraft Health and Usage Monitoring Systems (HUMS) may be realized when structural assessment data, collected by an SHM system, is also used to detect structural damage to compliment the operational environment monitoring. The use of in-situ sensors for health monitoring of rotorcraft structures can be a viable option for both flaw detection and maintenance planning activities. This formal SHM validation will allow aircraft manufacturers and airlines to confidently make informed decisions about the proper utilization of CVM and PZT technology. It will also streamline future regulatory actions and formal certification measures needed to assure the safe application of SHM solutions.

42 ENGINEERING↗
NASA NTRS2004

Facilitating the Specification Capture and Transformation Process in the Development of Multi-Agent Systems

To support the development of flexible and reusable MAS, we have built a framework designated MAS-CF. MAS-CF is a component framework that implements a layered architecture based on contextual composition. Interaction rules, controlled by architecture mechanisms, ensure very low coupling, making possible the sharing of distributed services in a transparent, dynamic and independent way. These properties propitiate large-scale reuse, since organizational abstractions can be reused and propagated to all instances created from a framework. The objective is to reduce complexity and development time of multi-agent systems through the reuse of generic organizational abstractions.

Filho, Aluzio Haendehen↗
NASA NTRS2011

Fission Surface Power Systems (FSPS) Project Final Report for the Exploration Technology Development Program (ETDP): Fission Surface Power, Transition Face to Face

The Fission Surface Power Systems Project became part of the ETDP on October 1, 2008. Its goal was to demonstrate fission power system technology readiness in an operationally relevant environment, while providing data on fission system characteristics pertinent to the use of a fission power system on planetary surfaces. During fiscal years 08 to 10, the FSPS project activities were dominated by hardware demonstrations of component technologies, to verify their readiness for inclusion in the fission surface power system. These Pathfinders demonstrated multi-kWe Stirling power conversion operating with heat delivered via liquid metal NaK, composite Ti/H2O heat pipe radiator panel operations at 400 K input water temperature, no-moving-part electromagnetic liquid metal pump operation with NaK at flight-like temperatures, and subscale performance of an electric resistance reactor simulator capable of reproducing characteristics of a nuclear reactor for the purpose of system-level testing, and a longer list of component technologies included in the attached report. Based on the successful conclusion of Pathfinder testing, work began in 2010 on design and development of the Technology Demonstration Unit (TDU), a full-scale 1/4 power system-level non-nuclear assembly of a reactor simulator, power conversion, heat rejection, instrumentation and controls, and power management and distribution. The TDU will be developed and fabricated during fiscal years 11 and 12, culminating in initial testing with water cooling replacing the heat rejection system in 2012, and complete testing of the full TDU by the end of 2014. Due to its importance for Mars exploration, potential applicability to missions preceding Mars missions, and readiness for an early system-level demonstration, the Enabling Technology Development and Demonstration program is currently planning to continue the project as the Fission Power Systems project, including emphasis on the TDU completion and testing.

Palac, Donald T.↗
NASA NTRS2010

The Waypoint Planning Tool: Real Time Flight Planning for Airborne Science

NASA Earth science research utilizes both spaceborne and airborne real time observations in the planning and operations of its field campaigns. The coordination of air and space components is critical to achieve the goals and objectives and ensure the success of an experiment. Spaceborne imagery provides regular and continual coverage of the Earth and it is a significant component in all NASA field experiments. Real time visible and infrared geostationary images from GOES satellites and multi-spectral data from the many elements of the NASA suite of instruments aboard the TRMM, Terra, Aqua, Aura, and other NASA satellites have become norm. Similarly, the NASA Airborne Science Program draws upon a rich pool of instrumented aircraft. The NASA McDonnell Douglas DC-8, Lockheed P3 Orion, DeHavilland Twin Otter, King Air B200, Gulfstream-III are all staples of a NASA's well-stocked, versatile hangar. A key component in many field campaigns is coordinating the aircraft with satellite overpasses, other airplanes and the constantly evolving, dynamic weather conditions. Given the variables involved, developing a good flight plan that meets the objectives of the field experiment can be a challenging and time consuming task. Planning a research aircraft mission within the context of meeting the science objectives is complex task because it is much more than flying from point A to B. Flight plans typically consist of flying a series of transects or involve dynamic path changes when "chasing" a hurricane or forest fire. These aircraft flight plans are typically designed by the mission scientists then verified and implemented by the navigator or pilot. Flight planning can be an arduous task requiring frequent sanity checks by the flight crew. This requires real time situational awareness of the weather conditions that affect the aircraft track. Scientists at the University of Alabama-Huntsville and the NASA Marshall Space Flight Center developed the Waypoint Planning Tool, an interactive software tool, that enables scientists to develop their own flight plans (also known as waypoints) with point-and-click mouse capabilities on a digital map draped with real time satellite imagery. The Waypoint Planning Tool has further advanced to include satellite orbit predictions and seamlessly interfaces with the Real Time Mission Monitor which tracks the aircraft s position when the planes are flying. This presentation will describe the capabilities and features of the Waypoint Planning Tool highlighting the real time aspect, interactive nature and the resultant benefits to the airborne science community.

He, Yubin↗
NASA NTRS2023

Multi-Star Wavefront Control at the Occulting Mask Coronagraph Testbed: Monochromatic Laboratory Demonstration for the Roman Coronagraph Instrument

The Astro2020 decadal survey recommended the Habitable Worlds Observatory (HWO), NASA’s direct imaging flagship mission, with a goal to achieve a statistically robust mission yield of 25 or more potentially habitable exoplanets. One way to achieve is to increase the instrument effectiveness by introducing additional bright, nearby targets. A majority of Sun-like stars have a stellar companion that can introduce additional noise into the field of view of any high-contrast imaging instrument and enabling exoplanet discovery around binary stars represents a path to increased corona graphic instrument efficiency by increasing the available science target pool of bright nearby stars. This includes both of the Alpha Centauri A and B stars which would represent the top science target for direct imaging if companion leakage could be suppressed. Multi-Star Wavefront Control(MSWC) is a technique that removes stellar leakage from both stellar components, enabling direct imaging of exoplanets in many binary star systems which can potentially increase corona graphic instrument effectivenessWe present the latest testbed results obtained with MSWC as part of the technology development effort focusing on demonstrations conducted on the Occulting Mask Coronagraph (OMC) testbed at JPL during thevacuum test window last winter, with an additional vacuum test planned for this fall. The MSWC mask consists of a shaped pupil mask similar to the one used for the Wide-Field of View mode, but also includes a set of superimposed, regularly-spaced dots that serve as a diffraction grating. OMC has a layout similar to the RomanSpace Telescope coronagraph instrument and configured with a binary imaging mode with a MSWC mask using same design as the contributed mask for the Roman coronagraph. Our testbed results represent the first demonstrations of this technique using the recently installed full binary source. We present results demonstrating suppression in the Super-Nyquist regime for the 3rd diffraction order reaching 8.7e-9 contrast with the Roman pupil. In addition, we present results obtained with a physical binary source and running MSWC in a binary star regime demonstrating 9.6e-8 contrast for a geometry matching potential Alpha Centauri observations in a515 nm monochromatic wavelength (similar but bluer than for Band 1) using the 5th diffraction order. Planned demonstrations in the upcoming vacuum window this fall will focus on Band 3d and Band 4 using the full MSWC mode for an Alpha Centauri geometry.

Roman Coronagraph Instrument↗
NASA NTRS2002

Multi-wavelength Luminosity Functions of Galaxies

Multivariate or multi-wavelength luminosity functions will reveal the interplay between star formation, chemical evolution, and absorption and re-emission of dust within evolving galaxy populations. By using principal component analysis to reduce the dimensionality of the problem, we optimally extract the relevant photometric information from large galaxy catalogs. As a demonstration of the technique, we derive the multi-wavelength luminosity function for the galaxies in the released SDSS catalog, and compare the results with those obtained by traditional methods. This technique will be applicable to catalogs of galaxies from datasets obtained by 2MASS, and the SIRTF and GALEX missions.

Gardner, J. P.↗
NASA NTRS2017

High-Fidelity Multi-Rotor Unmanned Aircraft System Simulation Development for Trajectory Prediction Under Off-Nominal Flight Dynamics

The NASA Unmanned Aircraft System (UAS) Traffic Management (UTM) project is conducting research to enable civilian low-altitude airspace and UAS operations. A goal of this project is to develop probabilistic methods to quantify risk during failures and off nominal flight conditions. An important part of this effort is the reliable prediction of feasible trajectories during off-nominal events such as control failure, atmospheric upsets, or navigation anomalies that can cause large deviations from the intended flight path or extreme vehicle upsets beyond the normal flight envelope. Few examples of high-fidelity modeling and prediction of off-nominal behavior for small UAS (sUAS) vehicles exist, and modeling requirements for accurately predicting flight dynamics for out-of-envelope or failure conditions are essentially undefined. In addition, the broad range of sUAS aircraft configurations already being fielded presents a significant modeling challenge, as these vehicles are often very different from one another and are likely to possess dramatically different flight dynamics and resultant trajectories and may require different modeling approaches to capture off-nominal behavior. NASA has undertaken an extensive research effort to define sUAS flight dynamics modeling requirements and develop preliminary high fidelity six degree-of-freedom (6-DOF) simulations capable of more closely predicting off-nominal flight dynamics and trajectories. This research has included a literature review of existing sUAS modeling and simulation work as well as development of experimental testing methods to measure and model key components of propulsion, airframe and control characteristics. The ultimate objective of these efforts is to develop tools to support UTM risk analyses and for the real-time prediction of off-nominal trajectories for use in the UTM Risk Assessment Framework (URAF). This paper focuses on modeling and simulation efforts for a generic quad-rotor configuration typical of many commercial vehicles in use today. An overview of relevant off-nominal multi-rotor behaviors will be presented to define modeling goals and to identify the prediction capability lacking in simplified models of multi-rotor performance. A description of recent NASA wind tunnel testing of multi-rotor propulsion and airframe components will be presented illustrating important experimental and data acquisition methods, and a description of preliminary propulsion and airframe models will be presented. Lastly, examples of predicted off-nominal flight dynamics and trajectories from the simulation will be presented.

Foster, John V.↗
DOE OSTI2016

Multi-Column Experimental Test Bed Using CaSDB MOF for Xe/Kr Separation

Processing of spent nuclear fuel produces off-gas from which several volatile radioactive components must be separated for further treatment or storage. As part of the Off-gas Sigma Team, parallel research at INL and PNNL has produced several promising sorbents for the selective capture of xenon and krypton from these off-gas streams. In order to design full-scale treatment systems, sorbents that are promising on a laboratory scale must be proven under process conditions to be considered for pilot and then full-scale use. To that end, a bench-scale multi-column system with capability to test multiple sorbents was designed and constructed at INL. This report details bench-scale testing of CaSDB MOF, produced at PNNL, and compares the results to those reported last year using INL engineered sorbents. Two multi-column tests were performed with the CaSDB MOF installed in the first column, followed with HZ-PAN installed in the second column. The CaSDB MOF column was placed in a Stirling cryocooler while the cryostat was employed for the HZ-PAN column. Test temperatures of 253 K and 191 K were selected for the first column while the second column was held at 191 K for both tests. Calibrated volume sample bombs were utilized for gas stream analyses. At the conclusion of each test, samples were collected from each column and analyzed for gas composition. While CaSDB MOF does appear to have good capacity for Xe, the short time to initial breakthrough would make design of a continuous adsorption/desorption cycle difficult, requiring either very large columns or a large number of smaller columns. Because of the tenacity with which Xe and Kr adhere to the material once adsorbed, this CaSDB MOF may be more suitable for use as a long-term storage solution. Further testing is recommended to determine if CaSDB MOF is suitable for this purpose.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

THE MASSIVE PROTOSTELLAR CLUSTER NGC 6334I AT 220 au RESOLUTION: DISCOVERY OF FURTHER MULTIPLICITY, DIVERSITY, AND A HOT MULTI-CORE

We present Very Large Array and Atacama Large Millimeter/submillimeter Array imaging of the deeply embedded protostellar cluster NGC 6334I from 5 cm to 1.3 mm at angular resolutions as fine as 0.″17 (220 au). The dominant hot core MM1 is resolved into seven components at 1.3 mm, clustered within a radius of 1000 au. Four of the components have brightness temperatures >200 K, radii ∼300 au, minimum luminosities ∼10{sup 4} L {sub ⊙}, and must be centrally heated. We term this new phenomenon a “hot multi-core.” Two of these objects also exhibit compact free–free emission at longer wavelengths, consistent with a hypercompact H ii region (MM1B) and a jet (MM1D). The spatial kinematics of the water maser emission centered on MM1D are consistent with it being the origin of the high-velocity bipolar molecular outflow seen in CO. The close proximity of MM1B and MM1D (440 au) suggests a proto-binary or a transient bound system. Several components of MM1 exhibit steep millimeter spectral energy distributions indicative of either unusual dust spectral properties or time variability. In addition to resolving MM1 and the other hot core (MM2) into multiple components, we detect five new millimeter and two new centimeter sources. Water masers are detected for the first time toward MM4A, confirming its membership in the protocluster. With a 1.3 mm brightness temperature of 97 K coupled with a lack of thermal molecular line emission, MM4A appears to be a highly optically thick 240 L {sub ⊙} dust core, possibly tracing a transient stage of massive protostellar evolution. The nature of the strongest water maser source CM2 remains unclear due to its combination of non-thermal radio continuum and lack of dust emission.

79 ASTRONOMY AND ASTROPHYSICS↗
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↗