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Developing Fabrication Technologies to Provide On Demand Manufacturing for Exploration of the Moon and Mars

NASA's human exploration initiative poses great opportunity and risk for manned and robotic missions to the Moon, Mars, and beyond. Engineers and scientists at the Marshall Space Flight Center (MSFC) are developing technologies for in situ fabrication capabilities during lunar and Martian surface operations utilizing provisioned and locally refined materials. Current fabrication technologies must be advanced to support the special demands and applications of the space exploration initiative such as power, weight and volume constraints. In Situ Fabrication and Repair (ISFR) will advance state-of-the-art technologies in support of habitat structure development, tools, and mechanical part fabrication. The repair and replacement of space mission components, such as life support items or crew exercise equipment, fall within the ISFR scope. This paper will address current fabrication technologies relative to meeting ISFR targeted capabilities, near-term advancement goals, and systematic evaluation of various fabrication methods.

Hammond, Monica S.↗

NASA's Space Launch System: Moving Toward the Launch Pad

The National Aeronautics and Space Administration's (NASA's) Space Launch System (SLS) Program, managed at the Marshall Space Flight Center (MSFC), is making progress toward delivering a new capability for human space flight and scientific missions beyond Earth orbit. Designed with the goals of safety, affordability, and sustainability in mind, the SLS rocket will launch the Orion Multi-Purpose Crew Vehicle (MPCV), equipment, supplies, and major science missions for exploration and discovery. Supporting Orion's first autonomous flight to lunar orbit and back in 2017 and its first crewed flight in 2021, the SLS will evolve into the most powerful launch vehicle ever flown via an upgrade approach that will provide building blocks for future space exploration. NASA is working to deliver this new capability in an austere economic climate, a fact that has inspired the SLS team to find innovative solutions to the challenges of designing, developing, fielding, and operating the largest rocket in history. This paper will summarize the planned capabilities of the vehicle, the progress the SLS Program has made in the 2 years since the Agency formally announced its architecture in September 2011, the path it is following to reach the launch pad in 2017 and then to evolve the 70 metric ton (t) initial lift capability to 130-t lift capability after 2021. The paper will explain how, to meet the challenge of a flat funding curve, an architecture was chosen that combines the use and enhancement of legacy systems and technology with strategic new developments that will evolve the launch vehicle's capabilities. This approach reduces the time and cost of delivering the initial 70 t Block 1 vehicle, and reduces the number of parallel development investments required to deliver the evolved 130 t Block 2 vehicle. The paper will outline the milestones the program has already reached, from developmental milestones such as the manufacture of the first flight hardware, to life-cycle milestones such as the vehicle's Preliminary Design Review (PDR). The paper will also discuss the remaining challenges both in delivering the 70-t vehicle and in evolving its capabilities to the 130-t vehicle, and how NASA plans to accomplish these goals. As this paper will explain, SLS is making measurable progress toward becoming a global infrastructure asset for robotic and human scouts of all nations by harnessing business and technological innovations to deliver sustainable solutions for space exploration.

Creech, Stephen D.↗

A hypertext-based Internet-assessable database for the MSFC Technology Transfer Office

There exists a continuing need to disseminate technical information and facilities capabilities from NASA field centers in an effort to promote the successful transfer of technologies developed with public funds to the private sector. As technology transfer is a stated NASA mission, there exists a critical need for NASA centers to document technology capabilities and disseminate this information on as wide a basis as possible. Certainly local and regional dissemination is critical, but global dissemination of scientific and engineering facilities and capabilities gives NASA centers the ability to contribute to technology transfer on a much broader scale. Additionally, information should be disseminated in a complete and rapidly available form. To accomplish this information dissemination, the unique capabilities of the Internet are being exploited. The Internet allows widescale information distribution in a rapid fashion to aid in the accomplishment of technology transfer goals established by the NASA/MSFC Technology Transfer Office. Rapid information retrieval coupled with appropriate electronic feedback, allows the scientific and technical capabilities of Marshall Space Flight Center, often unique in the world, to be explored by a large number of potential benefactors of NASA (or NASA-derived) technologies. Electronic feedback, coupled with personal contact with the MSFC Technology Transfer Office personnel, allows rapid responses to technical requests from industry and academic personnel as well as private citizens. The remainder of this report gives a brief overview of the Mosaic software and a discussion of technology transfer office and laboratory facilities data that have been made available on the Internet to promote technology transfer.

Jackson, Jeff↗

Simulation models for autonomous rendezvous and capture

Autonomous rendezvous and capture (AR&C) is a critical space technology with significant application to a variety of missions. Martin Marietta Astronautics Group (MMAG) has been developing AR&C technical capability in support of several recent NASA contracts. The use of AR&C for the Mars Rover/Sample Return (MRSR) mission was studied through a contract with JSC. Incorporation of AR&C in the Space Transportation Vehicle (STV) lunar mission was studied through a contract with MSFC. The MMAG has also been developing AR&C simulation capability under independent research and development studies. Simulation development was driven by two goals: comprehensive software simulation of the autonomous rendezvous and capture mission from launch to final capture; and integration of the overall software and hardware simulation to support an AR&C flight demonstration. This presentation will highlight the AR&C software simulation tools and analyze results from their application to the STV lunar mission. Plans for an integrated software and hardware simulation will also be summarized.

Smith, Nick G.↗

Carbon- and Ceramic-Matrix Composite Nozzle Extensions for Liquid Rocket Engines

Carbon-carbon (C-C) composite and ceramic matrix composite (CMC) nozzle extensions are being considered and developed for use with a variety of cryogenic liquid rocket engine systems. Some of the potential applications include in-space, lunar lander, and launch vehicle upper stage propulsion systems. Composite material systems of interest include C-C and carbon/silicon-carbide (C-SiC) composites, as well as modified versions of such composites (coatings, mixed matrices, oxidation inhibitors, etc.). Nozzle extension materials and fabrication methods under development by industry support both National Aeronautics and Space Administration (NASA) and Department of Defense (DOD) requirements, as well as those of the broader Commercial Space industry. Marshall Space Flight Center (MSFC) efforts are aimed at both (a) assisting industry with the development of composite nozzle extensions for cryogenic liquid rocket engines, and (b) developing and demonstrating capabilities for characterizing, testing, and qualifying such nozzle extensions. Results of recent MSFC nozzle-extension characterization efforts and engine firing demonstrations will be presented.

carbon-carbon↗

Comparing NASA and ESA Cost Estimating Methods for Human Missions to Mars

To compare working methodologies between the cost engineering functions in NASA Marshall Space Flight Center (MSFC) and ESA European Space Research and Technology Centre (ESTEC), as well as to set-up cost engineering capabilities for future manned Mars projects and other studies which involve similar subsystem technologies in MSFC and ESTEC, a demonstration cost estimate exercise was organized. This exercise was a direct way of enhancing not only cooperation between agencies but also both agencies commitment to credible cost analyses. Cost engineers in MSFC and ESTEC independently prepared life-cycle cost estimates for a reference human Mars project and subsequently compared the results and estimate methods in detail. As a non-sensitive, public domain reference case for human Mars projects, the Mars Direct concept was chosen. In this paper the results of the exercise are shown; the differences and similarities in estimate methodologies, philosophies, and databases between MSFC and ESTEC, as well as the estimate results for the Mars Direct concept. The most significant differences are explained and possible estimate improvements identified. In addition, the Mars Direct plan and the extensive cost breakdown structure jointly set-up by MSFC and ESTEC for this concept are presented. It was found that NASA applied estimate models mainly based on historic Apollo and Space Shuttle cost data, taking into account the changes in technology since then. ESA used models mostly based on European satellite and launcher cost data, taking into account the higher equipment and testing standards for human space flight. Most of NASA's and ESA s estimates for the Mars Direct case are comparable, but there are some important, consistent differences in the estimates for: 1) Large Structures and Thermal Control subsystems; 2) System Level Management, Engineering, Product Assurance and Assembly, Integration and Test/Verification activities; 3) Mission Control; 4) Space Agency Program Level activities.

Hunt, Charles D.↗

Overview of Plume-Surface Interaction Data from Subscale Inert Gas Testing at NASA MSFC Test Stand 300 Vacuum Facilities

Maturation and validation of predictive modeling capabilities for plume-surface interaction, and the effects caused by the impingement of rocket engine exhaust on surface regolith, require relevant, highly characterized ground test data. The multi-phase nature of this problem poses challenges to ground testing across physical scaling, test environments and techniques, and diagnostics. NASA has developed a Physics Focused Ground Test (PFGT) of plume-surface interaction to address this need. The PFGT is a subscale, inert-gas experiment at Mars- and Lunar-relevant ambient pressure conditions that will provide critical data for model validation of cratering, ejecta, and plume physics. In this test, the ambient pressure in a vacuum chamber will be varied, along with the height of a supersonic nozzle above a surface, and the mass flow rate through the nozzle. Testing will be performed on a range of regolith simulants of varying composition and will also include instrumented impingement plate tests in place of regolith simulant to characterize gas-only plume physics. Novel high-speed visual diagnostics will capture temporal data on crater formation and ejecta dynamics, and planar laser-induced fluorescence diagnostics will capture plume structure and behavior. This paper will present an overview of the data collected during this test – for both the cratering and ejecta testing and the gas-only plume physics testing. Emphasis will be placed on trends, effects, and interactions observed in the data across the test parameter space.

Chad J. Eberhart↗

Overview of Plume-Surface Interaction Data from Subscale Inert Gas Testing at NASA MSFC Test Stand 300 Vacuum Facilities

Maturation and validation of predictive modeling capabilities for plume-surface interactions and their effects requires relevant, highly characterized ground test data. The National Aeronautics and Space Administration has developed a test bed for these behaviors under its Game Changing Developments Plume Surface Interactions project, and has undertaken testing at the Marshall Space Flight Center to address critical data needs. This manuscript provides a high-level overview of the testing and its associated data.

Chad J Eberhart↗

A Combined Computational, Experimental, and Technology Development Approach to In-Space Laser Manufacturing Maturation at NASA Marshall Space Flight Center

In-space manufacturing (ISM) is emerging as a field vital to continued access and capabilities in the space environment. NASA Marshall Space Flight Center (MSFC) is advancing the frontier of in-space laser manufacturing (ISLM) techniques through work initially focused on maturing laser beam welding (LBW) and laser forming (LF) for use in space. Such techniques proffer the ability to assemble and join structures in space from sheet metal or other stock – extant satellites, in situ resource utilization of Lunar regolith, etc. – by forming to desired shapes and then joining via in-space welding (ISW). ISLM processes are useful for assembly, joining, modification, and repair of structures in free space and on the Lunar surface such as large observatories, antennas, trusses, blast/thermal/radiation shields, pressure vessels, and more. However, these techniques are not yet qualified & certified (Q&C) for regular application in space. It would be prohibitively expensive, laborious, and time-consuming to perform Q&C via traditional experimental approaches as data collection & experimentation in space is resource-intensive. As such, benchmark experiments and focused, properly instrumented technology demonstration efforts in space can collect sufficient data that – when combined with verified computational models in an integrated computational materials engineering (ICME) approach – can validate ICME tools capable of translating more readily obtained ground data to in-space, in situ, computationally informed Q&C of ISLM techniques. Several ISLM projects at MSFC are obtaining the data required to validate ICME tools through both ground and flight experiments. A parabolic flight experiment of LBW under vacuum is manifested for August 2024, including both microgravity and Lunar gravity profiles. This collaboration with the Ohio State University is investigating common aerospace alloys such as 316L stainless steel, 2219 aluminum alloy, and Ti64 titanium alloy. In situ data collection includes videography, thermography, and reference thermocouples to build a thermal model of the welds. This will elucidate the relevant physics when combined with post-flight microstructural examination and mechanical testing. MSFC is also progressing towards a suborbital flight experiment of LBW under vacuum, which could provide reams of data on ISW during sustained, high-quality reduced gravity. The effect of combined thermal (cryogenic and high-temperature) and vacuum exposure on both LBW (NASA-funded) and LF (DARPA-funded) is being investigated through ground experiments. In addition to the copious data collected during these ground experiments, ruggedization of LBW hardware will also be pursued. The datasets from these experiments will be used to validate computational models which will inform future ISLM efforts in an ICME framework. A variety of techniques across lengths scales, from CALPHAD-driven thermodynamics & kinetics to phase field modeling of solidification to kinetic Monte Carlo simulations of grain evolution at the mesoscale, will be employed to accelerate the infusion and eventual Q&C of LBW and LF for use in space. The development of data-driven surrogate models to bridge ground to flight experiments and thereby reduce the need for resource-intensive experiments in space will also be investigated. These ICME techniques, surrogate models, and datasets from ground testing can also be employed to advance manufacturing in terrestrial environments.

in-space welding↗

Flight control augmentation for AFT CG launch vehicles

The Space Shuttle was only the first step in achieving routine access to space. Recently, the NASA Marshall Space Flight Center (MSFC) has been studying a whole spectrum of new launch vehicles (L/V's) for space transportation. Some of these could transport components of the Space Station to orbit, and some could take us to Mars and beyond to boldly expand our frontiers of knowledge. In all our future launch vehicle (L/V) designs, decreasing the structural weight will always be of great concern. This is tantamount to increased payload capability, which in turn means reduced cost-per-pound to orbit. One very significant increase in payload capability has been defined. In a L/V recently studied at MSFC it has been shown that a sizable weight savings can be realized by a rearrangement of the internal propellant tanks. Studies have been conducted both at MSFC and at Martin Marietta Corporation, maker of the Space Shuttle External Tank (ET) which show that a very substantial weight can be saved by inverting the relative positions of the liquid hydrogen (LH2) and the liquid oxygen (LOX) propellant tanks in a particular L/V studied. As the vehicle sits on the launch pad, in the conventional configuration the heavier LOX tank is located on top of the lighter LH2. This requires a heavy structural member between the two tanks to prevent the lighter LH2 tank from being crushed. This configuration also requires large, long, and even drag producing LOX feed lines running the length of the vehicle on the exterior fuselage. If the relative position of the propellant tanks is inverted, both the heavy structural separation member and the long LOX feed lines could be deleted. While the structures community at MSFC was elated with this finding, the LOX tank aft configuration gave the vehicle an aft center-of-gravity (cg) location which surfaced controllability concerns. In the conventional configuration the L/V is controlled in the ascent trajectory by the gimballing of its rocket engines. Studies have been conducted at MSFC which showed that the resulting aft cg configured L/V would not be adequately controllable with the engine gimballing alone.

Barret, Chris↗

Extending the International Space Station Life and Operability

The International Space Station (ISS) is in an operational configuration with final assembly complete. To fully utilize ISS and extend the operational life, it became necessary to upgrade and extend the onboard systems with the Obsolescence Driven Avionics Redesign (ODAR) project. ODAR enabled a joint project between the Johnson Space Center (JSC) and Marshall Space Flight Center (MSFC) focused on upgrading the onboard payload and Ku-Band systems, expanding the voice and video capabilities, and including more modern protocols allowing unprecedented access for payload investigators to their on-orbit payloads. The MSFC Huntsville Operations Support Center (HOSC) was tasked with developing a high-rate enhanced Functionally Distributed Processor (eFDP) to handle 300Mbps Return Link data, double the legacy rate, and incorporate a Line Outage Recorder (LOR). The eFDP also provides a 25Mbps uplink transmission rate with a Space Link Extension (SLE) interface. HOSC also updated the Payload Data Services System (PDSS) to incorporate the latest Consultative Committee for Space Data Systems (CCSDS) protocols, most notably the use of the Internet Protocol (IP) Encapsulation, in addition to the legacy capabilities. The Central Command Processor was also updated to interact with the new onboard and ground capabilities of Mission Control Center -- Houston (MCC-H) for the uplink functionality. The architecture, implementation, and lessons learned, including integration and incorporation of Commercial Off The Shelf (COTS) hardware and software into the operational mission of the ISS, is described herein. The applicability of this new technology provides new benefits to ISS payload users and ensures better utilization of the ISS by the science community

Cecil, Andrew J.↗

Study of FES/CAST/HGS

The microgravity materials processing program has been instrumental in providing the crystal growth community with an experimental environment to better understand the phenomena associated with the growing of crystals. In many applications one may pursue the growth of large single crystals which cannot be grown on earth due to convective driven flows. A microgravity environment is characterized by neither convection of buoyancy. Consequently superior crystals are able to be grown in space. On the other hand, since neither convection nor buoyancy dominates the fluid flow in a microgravity environment, then lesser dominating phenomena can affect crystal growth, such as surface driven flows or diffusion limited solidification. In the case of experiments that are to be flown in space using the Fluid Experiments System (FES), diffusion limited growth should be the dominating phenomenon. The use of holographic and Schlieren optical techniques for studying the concentration gradients in solidification processes has been used by several investigators over the years. The Holographic Ground System (HGS) facility at MSFC has been a primary resource in researching this capability. Consequently scientific personnel have been able to utilize these techniques in both ground based research and in space experiments. An important event in the scientific utilization of the HGS facilities was the TGS (triglycine sulfate) Crystal Growth and the Casting and Solidification Technology (CAST) experiments that were flown on the International Microgravity Lab (IML) mission in March of this year. The preparation and processing of these space observations are the primary experiments reported in this work. This project provides some ground-based studies to optimize on the holographic techniques used to acquire information about the crystal growth processes flown on IML. Since the ground-based studies will be compared with the space-based experimental results, it is necessary to conduct sufficient ground based studies to best determine how the experiment in space worked. The current capabilities in computer based systems for image processing and numerical computation have certainly assisted in those efforts. As anticipated, this study has certainly shown that these advanced computing capabilities are helpful in the data analysis of such experiments.

Workman, Gary L.↗

Design and Preliminary Testing of a High Performance Antiproton Trap (HiPAT)

Antimatter represents the pinnacle of energy density, offering the potential to enhance current fusion/fission concepts enabling various classes of deep space missions. Current production rates are sufficient to support proof-of-concept evaluation of many key technologies associated with antimatter-derived propulsion. Storage has been identified as a key enabling technology for all antimatter-related operations, and as such is the current focus of this NASA-MSFC effort to design and fabricate a portable device capable of holding up to 10(exp 12) particles. Hardware has been assembled and initial tests are underway to evaluate the trap behavior using electron gun generated, positive hydrogen ions. Ions have been stored for tens of minutes, limited by observed interaction with background gas. Additionally, radio frequency manipulation is being tested to increase lifetime by stabilizing the stored particles, potentially reducing their interaction with background gas, easing requirements on ultimate trap vacuum and precision mechanical alignment.

Martin, James↗

RS-34 Phoenix (Peacekeeper Post Boost Propulsion System) Utilization Study

The Advanced Concepts Office (ACO) at the NASA Marshall Space Flight Center (MSFC) in conjunction with Pratt & Whitney Rocketdyne conducted a study to evaluate potential in-space applications for the Rocketdyne produced RS-34 propulsion system. The existing RS-34 propulsion system is a remaining asset from the decommissioned United States Air Force Peacekeeper ICBM program; specifically the pressure-fed storable bipropellant Stage IV Post Boost Propulsion System, renamed Phoenix. MSFC gained experience with the RS-34 propulsion system on the successful Ares I-X flight test program flown in October 2009. RS-34 propulsion system components were harvested from stages supplied by the USAF and used on the Ares I-X Roll control system (RoCS). The heritage hardware proved extremely robust and reliable and sparked interest for further utilization on other potential in-space applications. Subsequently, MSFC is working closely with the USAF to obtain all the remaining RS-34 stages for re-use opportunities. Prior to pursuit of securing the hardware, MSFC commissioned the Advanced Concepts Office to understand the capability and potential applications for the RS-34 Phoenix stage as it benefits NASA, DoD, and commercial industry. Originally designed, the RS-34 Phoenix provided in-space six-degrees-of freedom operational maneuvering to deploy multiple payloads at various orbital locations. The RS-34 Phoenix Utilization Study sought to understand how the unique capabilities of the RS-34 Phoenix and its application to six candidate missions: 1) small satellite delivery (SSD), 2) orbital debris removal (ODR), 3) ISS re-supply, 4) SLS kick stage, 5) manned GEO servicing precursor mission, and an Earth-Moon L-2 Waypoint mission. The small satellite delivery and orbital debris removal missions were found to closely mimic the heritage RS-34 mission. It is believed that this technology will enable a small, low-cost multiple satellite delivery to multiple orbital locations with a single boost. For both the small satellite delivery and the orbital debris mission candidates, the RS-34 Phoenix requires the least amount of modification to the existing hardware. The results of the RS-34 Phoenix Utilization Study show that the system is technically sufficient to successfully support all of the missions analyzed

Esther, Elizabeth A.↗

RS-34 Phoenix (Peacekeeper Post Boost Propulsion System) Utilization Study

The Advanced Concepts Office (ACO) at the NASA Marshall Space Flight Center (MSFC) in conjunction with Pratt & Whitney Rocketdyne conducted a study to evaluate potential in-space applications for the Rocketdyne produced RS-34 propulsion system. The existing RS-34 propulsion system is a remaining asset from the de-commissioned United States Air Force Peacekeeper ICBM program, specifically the pressure-fed storable bipropellant Stage IV Post Boost Propulsion System, renamed Phoenix. MSFC gained experience with the RS-34 propulsion system on the successful Ares I-X flight test program flown in October 2009. RS-34 propulsion system components were harvested from stages supplied by the USAF and used on the Ares I-X Roll control system (RoCS). The heritage hardware proved extremely robust and reliable and sparked interest for further utilization on other potential in-space applications. MSFC is working closely with the USAF to obtain RS-34 stages for re-use opportunities. Prior to pursuit of securing the hardware, MSFC commissioned the Advanced Concepts Office to understand the capability and potential applications for the RS-34 Phoenix stage as it benefits NASA, DoD, and commercial industry. As originally designed, the RS-34 Phoenix provided in-space six-degrees-of freedom operational maneuvering to deploy multiple payloads at various orbital locations. The RS-34 Phoenix Utilization Study sought to understand how the unique capabilities of the RS-34 Phoenix and its application to six candidate missions: 1) small satellite delivery (SSD), 2) orbital debris removal (ODR), 3) ISS re-supply, 4) SLS kick stage, 5) manned GEO servicing precursor mission, and an Earth-Moon L-2 Waypoint mission. The small satellite delivery and orbital debris removal missions were found to closely mimic the heritage RS-34 mission. It is believed that this technology will enable a small, low-cost multiple satellite delivery to multiple orbital locations with a single boost. For both the small satellite delivery and the orbital debris mission candidates, the RS-34 Phoenix requires the least amount of modification to the existing hardware. The results of the RS-34 Phoenix Utilization Study show that the system is technically sufficient to successfully support all of the missions analyzed.

Esther, Elizabeth A.↗

RS-34 (Peacekeeper Post Boost Propulsion System) Orbital Debris Application Concept Study

The Advanced Concepts Office (ACO) at the NASA Marshall Space Flight Center (MSFC) lead a study to evaluate the Rocketdyne produced RS-34 propulsion system as it applies to an orbital debris removal design reference mission. The existing RS-34 propulsion system is a remaining asset from the de-commissioned United States Air Force Peacekeeper ICBM program; specifically the pressure-fed storable bi-propellant Stage IV Post Boost Propulsion System. MSFC gained experience with the RS-34 propulsion system on the successful Ares I-X flight test program flown in the Ares I-X Roll control system (RoCS). The heritage hardware proved extremely robust and reliable and sparked interest for further utilization on other potential in-space applications. Subsequently, MSFC is working closely with the USAF to obtain all the remaining RS-34 stages for re-use opportunities. Prior to pursuit of securing the hardware, MSFC commissioned the Advanced Concepts Office to understand the capability and potential applications for the RS-34 Phoenix stage as it benefits NASA, DoD, and commercial industry. Originally designed, the RS-34 Phoenix provided in-space six-degrees-of freedom operational maneuvering to deploy multiple payloads at various orbital locations. The RS-34 Concept Study, preceded by a utilization study to understand how the unique capabilities of the RS-34 Phoenix and its application to six candidate missions, sought to further understand application for an orbital debris design reference mission as the orbital debris removal mission was found to closely mimic the heritage RS-34 mission. The RS-34 Orbital Debris Application Concept Study sought to identify multiple configurations varying the degree of modification to trade for dry mass optimization and propellant load for overall capability and evaluation of several candidate missions. The results of the RS-34 Phoenix Utilization Study show that the system is technically sufficient to successfully support all of the missions analyzed. The results and benefits of the RS-34 Orbital Debris Application Concept Study are presented in this paper.

Esther, Elizabeth A.↗

Additive Manufactured Ultra-Fine Lattice Structures for Propulsion Catalysts

Traditional mono-propulsion catalysts consist of coated ceramic or graphite foams that possess anisotropic mechanical and fluid properties limiting design, cost, availability, and operational use. Ultra-fine lattice structures are repeating unit cells with ligament thickness as small as 100 μm produced via Additive manufacture (AM). These lattice structures have the potential to replace coated foams used in a mono-propellant system catalysts. AM ultra-fine lattice structures are designed to mimic the operational intent of coated foams but with improved design flexibility, compressive strength, and flow behavior printed from into a single part directly from the preferred platinum metal alloy. The investigation objective was to conduct feasibility studies of AM ultra-fine lattice structures capable of replacing coated foams with superior functionality. NASA MSFC identified desired lattice characteristics and created designs while EOS developed optimized laser powder bed fusion AM parameters to manufacture Ti6Al4V and tungsten specimens. Optimized designs, computational tools, AM parameters, and post-process methods were developed. Specimens underwent x-ray micro-focus CT, metallographic inspection, compression testing, and flow testing. Results demonstrate that AM ultra-fine lattices improved geometric and performance repeatability with the potential for significantly increased availability while decreasing cost and lead time.

Omar R Mireles↗

Additive Manufactured Ultra-Fine Lattice Structures for Propulsion Catalysts

Traditional mono-propulsion catalysts consist of coated ceramic or graphite foams that possess anisotropic mechanical and fluid properties limiting design, cost, availability, and operational use. Ultra-fine lattice structures are repeating unit cells with ligament thickness as small as 100 μm produced via Additive manufacture (AM). These lattice structures have the potential to replace coated foams used in a mono-propellant system catalysts. AM ultrafine lattice structures are designed to mimic the operational intent of coated foams but with improved design flexibility, compressive strength, and flow behavior printed from into a single part directly from the preferred platinum metal alloy. The investigation objective was to conduct feasibility studies of AM ultra-fine lattice structures capable of replacing coated foams with superior functionality. NASA MSFC identified desired lattice characteristics and created designs while EOS developed optimized laser powder bed fusion AM parameters to manufacture Ti6Al4V and tungsten specimens. Optimized designs, computational tools, AM parameters, and post-process methods were developed. Specimens underwent x-ray microfocus CT, metallographic inspection, compression testing, and flow testing. Results demonstrate that AM ultra-fine lattices improved geometric and performance repeatability with the potential for significantly increased availability while decreasing cost and lead time.

Omar R Mireles↗