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All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

A Multi-Sensor Unoccupied Aerial System Improves Characterization of Vegetation Composition and Canopy Properties in the Arctic Tundra

Changes in vegetation distribution, structure, and function can modify the canopy properties of terrestrial ecosystems, with potential consequences for regional and global climate feedbacks. In the Arctic, climate is warming twice as fast as compared to the global average (known as ‘Arctic amplification’), likely having stronger impacts on arctic tundra vegetation. In order to quantify these changes and assess their impacts on ecosystem structure and function, methods are needed to accurately characterize the canopy properties of tundra vegetation types. However, commonly used ground-based measurements are limited in spatial and temporal coverage, and differentiating low-lying tundra plant species is challenging with coarse-resolution satellite remote sensing. The collection and processing of multi-sensor data from unoccupied aerial systems (UASs) has the potential to fill the gap between ground-based and satellite observations. To address the critical need for such data in the Arctic, we developed a cost-effective multi-sensor UAS (the ‘Osprey’) using off-the-shelf instrumentation. The Osprey simultaneously produces high-resolution optical, thermal, and structural images, as well as collecting point-based hyperspectral measurements, over vegetation canopies. In this paper, we describe the setup and deployment of the Osprey system in the Arctic to a tundra study site located in the Seward Peninsula, Alaska. We present a case study demonstrating the processing and application of Osprey data products for characterizing the key biophysical properties of tundra vegetation canopies. In this study, plant functional types (PFTs) representative of arctic tundra ecosystems were mapped with an overall accuracy of 87.4%. The Osprey image products identified significant differences in canopy-scale greenness, canopy height, and surface temperature among PFTs, with deciduous low to tall shrubs having the lowest canopy temperatures while non-vascular lichens had the warmest. The analysis of our hyperspectral data showed that variation in the fractional cover of deciduous low to tall shrubs was effectively characterized by Osprey reflectance measurements across the range of visible to near-infrared wavelengths. Therefore, the development and deployment of the Osprey UAS, as a state-of-the-art methodology, has the potential to be widely used for characterizing tundra vegetation composition and canopy properties to improve our understanding of ecosystem dynamics in the Arctic, and to address scale issues between ground-based and airborne/satellite observations.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2013

Electron microscopy: Phase transition singled out

One of the fundamental challenges within nanotechnology is to understand and control how nanoscale properties are initiated, evolve, and eventually terminate as a system moves from an individual nanostructure towards the meso- and macro-scale ensembles that are used in most applications. The ability to directly observe individual nanostructures and characterize their structure and composition has long been within the purview of transmission electron microscopy (TEM). The almost ubiquitous application of spherical aberration correction in TEM and in scanning-TEM (STEM) that has occurred over the last 10 years, now means it is possible to routinely characterize such nanostructures with both atomic resolution and sensitivity [1,2]. The development of temporal resolution in the TEM and the ability to study fast dynamics, on the other hand, has only recently come to the forefront of instrumentation development and is currently defined by two different approaches in the use of photoemission sources: the single shot s-ns dynamic TEM (DTEM) [3] and the stroboscopic ps-fs 4-D EM [4]. In the case of the DTEM, the goal is to observe the longer timescale irreversible structural changes that occur during nucleation and growth phenomena (here the single shot approach means there are enough electrons in a single pulsed beam to form a complete image). The 4-D EM focuses on a stroboscopic approach with the goal of studying very rapid reversible effects that occur during phase transitions (here an image is composed of thousands of pump-probe events each occurring with exactly the same time signature, with an individual pulse containing only a few electrons).

36 MATERIALS SCIENCE↗
DOE OSTI2025

Status Report on Design of In-situ Thermomechanical Testing at LANSCE

Nuclear fuel encounters severe thermomechanical environments in which its mechanical response is determined by its microstructure, temperature and stress level histories. Simulating the response of such microstructures is crucial for predicting both performance and transient fuel mechanical responses and experimental verification of such predictions is therefore of great interest. While most of the deformation in a nuclear fuel rod occurs in the cladding, deformation of the fuel itself is still of interest with deformation mechanisms at operating temperature and above including creep, swelling, cracking as well as pellet-clad interaction. Characterization of these properties and understanding of the underlying deformation phenomena at operating or excursion temperatures is therefore of great importance for development and ultimately licensing of improved and novel nuclear fuel forms. Diffraction techniques offer unique insight on the atomistic (e.g. crystal structure) and microstructure (e.g. phase transformations, texture, defects) length scales and have a long history of providing unique data to inform relevant deformation models that enable the required predictive capabilities. For example, dislocations lead to diffraction peak broadening that can be characterized to estimate the dislocation density and study the role of dislocations on the deformation while measuring lattice strains allows to studie load sharing in two phase materials. In this report the requirements for a sample environment for high temperature deformation of nuclear fuels are defined. The HIPPO neutron time-of-flight diffractometer at LANSCE will host this sample environment and is also described. This instrument covers diffraction angles from 140° to 40° and is also equipped with an event-mode neutron imaging detector system, enabling energy-resolved neutron imaging in parallel with the diffraction that could measure sample temperature from Doppler broadening of neutron absorption resonances or measure pore densities from changes in the attenuation. Designs of devices to characterize thermomechanical properties of nuclear fuel without diffraction are also considered to guide the design. While this report is focused on applications for nuclear fuels, the device can also characterize cladding, moderator or structural materials and therefore contribute to other fields of research and development for advanced reactors. The temperatures planned to be reached are above 2000℃, thus enabling characterization of LWR reactor fuels under accident scenarios but also reaching temperatures of fuels developed for nuclear thermal propulsion and providing opportunities to characterize those. In conjunction with the energy-resolved neutron imaging detector, this setup would allow to measure neutron cross-sections at high temperatures, filling a gap towards development of reactors operating at high temperatures.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2013

HTGR Economic / Business Analysis and Trade Studies Market Analysis for HTGR Technologies and Applications

This report provides supplemental information to the assessment of target markets provided in Appendix A of the 2012 Next Generation Nuclear Plant (NGNP) Industry Alliance (NIA) business plan [NIA 2012] for deployment of High Temperature Gas-Cooled Reactors (HTGRs) in the 2025 – 2050 time frame. This report largely reiterates the [NIA 2012] assessment for potential deployment of 400 to 800 HTGR modules (100 to 200 HTGR plants with 4 reactor modules) in the 600-MWt class in North America by 2050 for electricity generation, co-generation of steam and electricity, oil sands operations, hydrogen production, and synthetic fuels production (e.g., coal to liquids). As the result of increased natural gas supply from hydraulic fracturing, the current and historically low prices of natural gas remain a significant barrier to deployment of HTGRs and other nuclear reactor concepts in the U.S. However, based on U.S. Department of Energy (DOE) Energy Information Agency (EIA) data, U.S. natural gas prices are expected to increase by the 2030 – 2040 timeframe when a significant number of HTGR modules could be deployed. An evaluation of more recent EIA 2013 data confirms the assumptions in [NIA 2012] of future natural gas prices in the range of approximately $7/MMBtu to $10/MMBtu during the 2030 – 2040 timeframe. Natural gas prices in this range will make HTGR energy prices competitive with natural gas, even in the absence of carbon-emissions penalties. Exhibit ES-1 presents the North American projections in each market segment including a characterization of the market penetration logic. Adjustments made to the 2012 data (and reflected in Exhibit ES-1) include normalization to the slightly larger 625MWt reactor module, segregation between steam cycle and more advanced (higher outlet temperature) modules, and characterization of U.S. synthetic fuel process applications as a separate market segment.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2016

2D and 3D characterization of pore defects in die cast AM60

The widespread application of die castings can be hampered due to the potential of large scale porosity to act as nucleation sites for fracture and fatigue. It is therefore important to develop robust approaches to the characterization of porosity providing parameters that can be linked to the material's mechanical properties. We have tackled this problem in a study of the AM60 die cast Mg alloy, using samples extracted from a prototype shock tower. A quantitative characterization of porosity has been undertaken, analyzing porosity in both 2D (using classical metallographic methods) and in 3D (using X-ray computed tomography (XCT)). Metallographic characterization results show that shrinkage pores and small gas pores can be distinguished based on their distinct geometrical features. Shrinkage pores are irregular with multiple arms, resulting in a form factor less than 0.4. In contrast, gas pores are generally more circular in shape yielding form factors larger than 0.6. XCT provides deeper insight into the shape of pores, although this understanding is limited by the resolution obtainable by laboratory based XCT. It also shows how 2D sectioning can produce artefacts as single complex pores are sectioned into multiple small pores. - Highlights: • Mg (e.g. AM60) die castings may contain large scale porosity that act as nucleation sites for fracture and fatigue • Quantitative characterization of porosity metallography (2D) and X-ray tomography (3D) is used • Shrinkage pores and small gas pores can be distinguished based on their distinct geometrical features. • Shrinkage pores are irregular giving a form factor < 0.4; gas pores are rounder with form factors > 0.6 • XCT enables pore visualization, although limited by the resolution obtainable by laboratory based XCT.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Tracer-Guided Characterization of Dominant Pore Networks and Implications for Permeability and Wettability in Shale

Pore network characterization is an important aspect in unconventional reservoir evaluation. While application of the technique of scanning electron microscope (SEM) brings substantial advances in pore characterization in shale, understanding the connected pore network that dominates flow in shale samples is limited by using SEM alone because of small fields of view and lack of views of connectivity in 3D. In this research, a technique integrating tracer imbibition, micro-computed tomography (CT) imaging, and SEM imaging was developed to provide a solution for multiscale imaging in shale. Tracer imbibition indicates pore connectivity; micro-CT imaging after tracer imbibition thus provides an overview of the connected pore network at the millimeter scale. With guidance from micro-CT images after tracer imbibition, a more accurate and detailed characterization of pore systems and related mineralogy can be conducted using higher-resolution SEM. The method was applied to five samples from Wolfcamp and Eagle Ford Formations. Results reveal the effectiveness of the integrated method by showing different patterns of distribution of the dominant pore network and different controlling mineralogy. Dominant porosity, estimated from grayscale analyses, displays a good correlation with permeability. This result indicates that dominant porosity is more relevant to permeability than is total porosity. Results from imbibition tests are also compared with that from contact angle measurement, and important implications on wettability can be obtained. The integrated method thus has the capacity to link the dominant pore network and wettability with microscale to submicroscale mineralogy, which can help better understand the pore systems and fluid flow in shale. Plain Language Summary Pore network characterization and wettability are two important aspects in unconventional reservoir evaluation and are crucial to understanding the nature of shale oil or gas storage and production. Here, a new technique integrating tracer imbibition, micro-computed tomography imaging, and scanning electron microscope imaging was developed for a more representative and effective pore characterization in shale. This integrated technique can provide a direct visualization of the dominant pore network in a millimeter-scale sample and, at the same time, can provide a guided pore network characterization under nanoscale resolution. This method thus can generate results that are more representative and more accurate in a more efficient way compared with the traditional scanning electron microscope method. The new technique can also reveal the local wettability in microscale. High-resolution analysis on the tracer imbibition or fluid displacement and mineralogy can shed light on the local wettability and the controlling mineralogy in shale.

58 GEOSCIENCES↗
DOE OSTI2016

Molecular mobility in glassy dispersions

Dielectric spectroscopy was used to characterize the structural relaxation in pharmaceutical dispersions containing nifedipine (NIF) and either poly(vinyl) pyrrolidone (PVP) or hydroxypropyl methylcellulose acetate succinate (HPMCAS). The shape of the dielectric response (permittivity versus log time) curve was observed to be independent of temperature. Thus, for the pure NIF as well as the dispersions, the validity of the time-temperature superposition principle was established. Furthermore, though the shape of the full dielectric response varied with polymer concentration, the regime related to the α- or structural relaxation was found to superimpose for the dispersions, though not with the response of the NIF itself. Hence, there is a limited time-temperature-concentration superposition for these systems as well. Therefore, in this polymer concentration range, calculation of long relaxation times in these glass-forming systems becomes possible. We found that strong drug-polymer hydrogen bonding interactions improved the physical stability (i.e., delayed crystallization) by reducing the molecular mobility. The strength of hydrogen bonding, structural relaxation time, and crystallization followed the order: NIF$-$PV P>NIF$-$HPMCAS>NIF. With an increase in polymer concentration, the relaxation times were longer indicating a decrease in molecular mobility. The temperature dependence of relaxation time, in other words fragility, was independent of polymer concentration. This is the first application of the superposition principle to characterize structural relaxation in glassy pharmaceutical dispersions.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1996

Smart Materials and Structures Applications at the NASA Langley Research Center

This overview of the presentation covers Langley's smart materials infrastructure, materials research, applications, and summary. Langley's infrastructure consists of fabrication and characterization of smart structures. Materials researched include ceramics, polymers, and polymer-ceramic composites. Applications include interior aircraft noise suppression, aircraft engine noise reduction, active flutter damping of aircraft wings for better performance, active shape control of polymeric reflectors, and aircraft wing distortion to eliminate control surfaces.

Horner, Garnett↗
NASA NTRS2013

Application of CO2 Snow Jet Cleaning in Conjunction with Laboratory Based Total Reflection X-Ray Fluorescence

The Genesis mission was the first mission returning solar material to Earth since the Apollo program [1,2]. Unfortunately the return of the space craft on September 8, 2004 resulted in a crash landing, which shattered the samples into small fragments and exposed them to desert soil and other debris. Thus only small fragments of the original collectors are available, each having different degrees of surface contamination. Thorough surface cleaning is required to allow for subsequent analysis of solar wind material embedded within. An initial cleaning procedure was developed in coordination with Johnson Space Center which focused on removing larger sized particulates and a thin film organic contamination acquired during collection in space [3]. However, many of the samples have additional residues and more rigorous and/or innovative cleaning steps might be necessary. These cleaning steps must affect only the surface to avoid leaching and re-distribution of solar wind material from the bulk of the collectors. To aid in development and identification of the most appropriate cleaning procedures each sample has to be thoroughly inspected before and after each cleaning step. Laboratory based total reflection X-ray fluorescence (TXRF) spectrometry lends itself to this task as it is a non-destructive and surface sensitive analytical method permitting analysis of elements from aluminum onward present at and near the surface of a flat substrate [4]. The suitability of TXRF has been demonstrated for several Genesis solar wind samples before and after various cleaning methods including acid treatment, gas cluster ion beam, and CO2 snow jet [5 - 7]. The latter one is non-invasive and did show some promise on one sample [5]. To investigate the feasibility of CO2 snow jet cleaning further, several flown Genesis samples were selected to be characterized before and after CO2 snow application with sample 61052 being discussed below.

Schmeling, M.↗
DOE OSTI2011

Crystal Growth and Characterization of Epitaxial Layers of Laser and Nonlinear Optical Materials for Thin-Disk and Waveguide laser applications

This paper summarizes the main results we obtained in our laboratories in relation with crystalline layers obtained by liquid phase epitaxial growth of lanthanide doped KLu(WO{sub 4}){sub 2} and Nb:RbTiOPO{sub 4} grown on KLu(WO{sub 4}){sub 2} and RbTiOPO{sub 4} substrates, respectively. Macroscopic defect free epitaxial layers were grown and characterized in terms of their compositional homogeneity, structural stress in the layer/substrate interface and laser and waveguiding performances.

36 MATERIALS SCIENCE↗
NASA NTRSDate not supplied

TPS Certification by Analysis: Model-Driven Characterization of Properties and Failure in Woven Thermal Protection Systems

Woven, ablative thermal protection system (TPS) materials provide a robust option for aggressive (re)entries and thus have been baselined for the upcoming Mars Sample Return (MSR) mission's Earth Entry System (EES). The reliability requirements for MSR-EES necessitate understanding of material property variability, which could be significant given the complex structure and anisotropic nature of properties in TPS weaves, as well as the response to potential impact with micrometeoroids or orbital debris during the EES re-entry. The TPS Certification by Analysis effort within the Entry Systems Modeling project seeks to provide computational models and analyses that support the certification against such material-based risks. For the present talk, focus will be given to the characterization of baseline woven TPS material properties and mechanical failure limits, which entails (1) use of computational techniques (e.g., machine learning) to interpret computed tomography images of the weave to generate representative structural models and (2) application of multiscale material modeling approaches to characterize thermomechanical and failure properties.

thermal protection systems↗
NASA NTRSDate not supplied

TPS Certification by Analysis: Model-Driven Characterization of Properties and Failure in Woven Thermal Protection Systems

Woven, ablative thermal protection system (TPS) materials provide a robust option for aggressive (re)entries and thus have been baselined for the upcoming Mars Sample Return (MSR) mission’s Earth Entry System (EES). The reliability requirements for MSR-EES necessitate understanding of material property variability, which could be significant given the complex structure and anisotropic nature of properties in TPS weaves, as well as the response to potential impact with micrometeoroids or orbital debris during the EES re-entry. The TPS Certification by Analysis effort within the Entry Systems Modeling project seeks to provide computational models and analyses that support the certification against such material-based risks. For the present talk, focus will be given to the characterization of baseline woven TPS material properties and mechanical failure limits, which entails (1) use of computational techniques (e.g., machine learning) to interpret computed tomography images of the weave to generate representative structural models and (2) application of multiscale material modeling approaches to characterize thermomechanical and failure properties.

Justin B. Haskins↗
DOE OSTI2019

Distributed Wireless Antenna Sensors for Boiler Condition Monitoring

Monitoring the operational conditions of coal-fired boilers is an important task that could bring tremendous benefits, including in-situ process control, real-time health assessment of structural components, improved heat transfer efficiency, reduced downtime, etc. Moreover, in-situ distributed sensing of the boiler conditions would provide large scale in-situ measurement data that will help us gain fundamental understandings of the combustion and heat transfer processes as well as enable the developments of new simulation tools, which could eventually lead to better design and more efficient operation of the boilers. The objectives of this research were to (a) develop wireless passive antenna sensors without electronics; (b) demonstrate multi-modality sensing using a signal antenna sensor; and (c) fabricate the antenna sensor from high-temperature materials. In this project, we have demonstrated that an antenna sensor or sensor array without any electronics can be wirelessly interrogated from a distance. In addition, a low-cost compact wireless sensor interrogator was developed for dynamic interrogation of the passive antenna sensor. We validated that a dual-frequency antenna sensor is capable of simultaneous strain and temperature measurements or temperature and ash accumulation measurements; all parameters are relevant to boiler condition monitoring. By measuring the temperature and ash accumulation height simultaneously, the dielectric constant of the ash as well as its temperature dependency can also be characterized. This capability could lead to potential applications of the antenna sensor for combustion process monitoring based on the ash composition. We also investigated different techniques of fabricating the antenna sensor using high-temperature materials such as alumina substrate and platinum paste and characterized the thermal response of the antenna sensor. A linear relationship between the antenna resonant frequency and the temperature change was validated.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2015

Micro-structural characterization of low resistive metallic Ni germanide growth on annealing of Ni-Ge multilayer

Nickel-Germanides are an important class of metal semiconductor alloys because of their suitability in microelectronics applications. Here we report successful formation and detailed characterization of NiGe metallic alloy phase at the interfaces of a Ni-Ge multilayer on controlled annealing at relatively low temperature ∼ 250 °C. Using x-ray and polarized neutron reflectometry, we could estimate the width of the interfacial alloys formed with nanometer resolution and found the alloy stoichiometry to be equiatomic NiGe, a desirable low-resistance interconnect. We found significant drop in resistance (∼ 50%) on annealing the Ni-Ge multilayer suggesting metallic nature of alloy phase at the interfaces. Further we estimated the resistivity of the alloy phase to be ∼ 59μΩ cm.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Impact of light output on the timing resolution of organic glass scintillator bars in a dual-ended readout configuration

The effectiveness of detector system modeling and validation depends on the quality of characterization performed on the system. For nuclear nonproliferation applications, which require detectors to address complex and variable field conditions, access to accurate system models is essential. This study presents the timing characterization of organic glass scintillator bars used in an imaging system developed at the University of Michigan. 137 Cs and 60 Co gamma-ray sources were used to determine the coincidence time resolution as a function of measured light output for two Compton scatter events between two organic glass scintillator bars. Timing resolution for two events, each with light output ranging from 100 to 1100 keVee were characterized. The resulting data were fit to a parametric function that was validated to agree with experimental results within ±25 ps. Simulations were performed to establish appropriate calibration points for each organic scintillator, thereby ensuring accurate calibration of light output values during analysis. This work successfully characterized the light output dependence of the coincidence timing resolution of a pair of organic glass detectors for use in an imaging system. Depending on the amount of scintillation light output from the events, the full width at half maximum of the measured coincidence time resolution ranged from 653.2 ± 16.1 ps for low light yields, 100 keVee, to 121.0 ± 8.4 ps for higher yields at 1100 keVee. The insights obtained from the timing resolution behavior will allow for accurate simulation capabilities in future security and verification efforts using scatter-based imaging systems.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2018

Development of Biocomposites from Agro Wastes for Low Dielectric Applications

The present work is attempting to synthesize and characterizations of a novel carbazole core containing cardanol based benzoxazine monomer from carbazole core containing aromatic diamine, cardanol and paraformaldehyde. In addition, carbazole core containing cardanol based benzoxazine polymer and various weight percentages of amine functionalized rice husk ash incorporated carbazole core containing cardanol based polybenzoxazine composites were prepared. The prepared polymer and its composites were characterized by FTIR, XRD, DSC, TGA and dielectric studies. The various studies confirm that the composites show increased Tg, higher char yield and better thermal stability compared to carbazole core containing cardanol based benzoxazine polymer. In addition to that the composites show significant decrease in the dielectric constant values than the neat cardanol based polybenzoxazine. The surface morphology and the distribution of rice husk ash in carbazole core containing cardanol based polybenzoxazine composites are confirmed by SEM and TEM analysis. Hence, the present study has attempted to prepared eco-friendly value added carbazole core containing cardanol based polybenzoxazine products for low dielectric constant applications by making use of biowaste for both matrix and reinforcement preparation to form biowaste based composites. Graphical Abstract: Schematic representation for the preparation of carbazole core containing cardanol based benzoxazine monomer, polybenzoxazine and biobased polybenzoxazine composites .

77 NANOSCIENCE AND NANOTECHNOLOGY↗
NASA NTRSDate not supplied

Advancement of Extreme Environment Additively Manufactured Alloys for Next Generation Space Propulsion Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into propulsion development and flight applications. NASA matured commonly used aerospace alloys from various alloy families (Nickel, Copper, Stainless and Steel, Aluminum, and Titanium-based) through detailed AM process and heat treatment characterization, in addition to mechanical and thermophysical testing. While these alloys are actively used in many propulsion applications, there is a need for ongoing AM optimized alloys using integrated computational materials engineering (ICME) and process development for high performance applications. The applications targeted are liquid rocket engines; advanced propulsion systems; and in-space propulsion with high heat fluxes, high pressure, and/or that use propellants that can degrade alloys (e.g., hydrogen). This paper highlights the characterization and physical properties of the more common AM alloys using laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Additionally, this paper discusses some of the ongoing novel alloy development and maturation using AM for use in these harsh environments, such as GRCop42, GRCop-84, NASA HR-1, GRX-810, and C-103. The results from these processes demonstrated that AM could enable rapid development and ongoing efforts for optimized alloys using ICME, yielding higher performances. These alloys have undergone modeling, fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing campaigns. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL) through high duty-cycle testing. A background and overview of these novel AM-enabled alloys and AM processing developments including metallurgical and mechanical property studies is presented here. The latest advancement in the parallel component development and hot-fire testing and future developments for these alloys is also discussed.

Additive Manufacturing↗
NASA NTRSDate not supplied

Advancement of Extreme Environment Additively Manufactured Alloys for Next Generation Space Propulsion Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into propulsion development and flight applications. NASA matured commonly used aerospace alloys from various alloy families (Nickel, Copper, Stainless and Steel, Aluminum, and Titanium-based) through detailed AM process and heat treatment characterization, in addition to mechanical and thermophysical testing. While these alloys are actively used in many propulsion applications, there is a need for ongoing AM optimized alloys using integrated computational materials engineering (ICME) and process development for high performance applications. The applications targeted are liquid rocket engines; advanced propulsion systems; and in-space propulsion with high heat fluxes, high pressure, and/or that use propellants that can degrade alloys (e.g., hydrogen). This paper highlights the characterization and physical properties of the more common AM alloys using laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Additionally, this paper discusses some of the ongoing novel alloy development and maturation using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, GRX-810, and C-103. The results from these processes demonstrated that AM could enable rapid development and ongoing efforts for optimized alloys using ICME, yielding higher performances. These alloys have undergone modeling, fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing campaigns. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL) through high duty-cycle testing. A background and overview of these novel AM-enabled alloys and AM processing developments including metallurgical and mechanical property studies is presented here. The latest advancement in the parallel component development and hot-fire testing and future developments for these alloys is also discussed.

Additive Manufacturing↗