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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 NTRS2017

NASA Collaborative Design Processes

This is Block 1, the first evolution of the world's most powerful and versatile rocket, the Space Launch System, built to return humans to the area around the moon. Eventually, larger and even more powerful and capable configurations will take astronauts and cargo to Mars. On the sides of the rocket are the twin solid rocket boosters that provide more than 75 percent during liftoff and burn for about two minutes, after which they are jettisoned, lightening the load for the rest of the space flight. Four RS-25 main engines provide thrust for the first stage of the rocket. These are the world's most reliable rocket engines. The core stage is the main body of the rocket and houses the fuel for the RS-25 engines, liquid hydrogen and liquid oxygen, and the avionics, or "brain" of the rocket. The core stage is all new and being manufactured at NASA's "rocket factory," Michoud Assembly Facility near New Orleans. The Launch Vehicle Stage Adapter, or LVSA, connects the core stage to the Interim Cryogenic Propulsion Stage. The Interim Cryogenic Propulsion Stage, or ICPS, uses one RL-10 rocket engine and will propel the Orion spacecraft on its deep-space journey after first-stage separation. Finally, the Orion human-rated spacecraft sits atop the massive Saturn V-sized launch vehicle. Managed out of Johnson Space Center in Houston, Orion is the first spacecraft in history capable of taking humans to multiple destinations within deep space. 2) Each element of the SLS utilizes collaborative design processes to achieve the incredible goal of sending human into deep space. Early phases are focused on feasibility and requirements development. Later phases are focused on detailed design, testing, and operations. There are 4 basic phases typically found in each phase of development.

Jones, Davey↗
NASA NTRSDate not supplied

Mechanisms of Interfacial Mixing in the Blown Powder Deposition of Inconel 625 to Copper Alloy for Liquid Rocket Engine Applications

There is an increasing need for functional materials to support high heat flux applications and optimize weight by using bimetallic additive manufacturing (AM). While one promising fabrication technology is the use of blown powder directed energy deposition (DED) AM, challenges remain with bi-metallic combinations. Prominent among these challenges is the need to understand mixing of materials at the bimetallic interface for forming stronger, more durable and reliable joints to extend the versatility of AM into critical applications. One application is the manufacturing of combustion chambers with copper-alloy liners and Superalloy structural jackets. In this application, material combinations are selected for effective heat dissipation, using copper, and retention of strength at high temperatures using Inconel 625. Currently, the dominant problem with this configuration is the highly variable strength of the interface and its correlation with deposition parameters. In this study, samples were fabricated at several vendors with Inconel 625 deposited onto wrought C-18150 (Cu-Cr-Zr) to form a bimetallic interface. Characterization of the interfaces were achieved through optical and electron microscopy, mechanical testing of mini tensile specimens, and electron dispersion spectroscopy to understand diffusion and bulk mixing behaviors at the joint. A theoretical framework was constructed in the context of solidification and mixing mechanisms to explain the resulting differences in the interface. This qualitative approach utilized a fluid dynamics perspective to sum the order of magnitudes of the various acting forces on the weld pool during deposition to predict convection trends based off known parameters. The predicted trends for each vendor are compared to obtain a better understanding of how mixing in the molten pool varied based on deposition parameters.

Additive Manufacturing↗
NASA NTRS1979

Status of Space Shuttle External Tank Solid Rocket Booster and Main Engine

The current status of three major propulsion elements for the Space Transportation System is reviewed: the Space Shuttle Main Engine, the External Tank, and the Solid Rocket Booster. Consideration is given to test and manufacturing experience in the last year, test and manufacturing plans for the coming year, and the current status of the hardware to support the first manned orbital flight.

Lindstrom, R. E.↗
NASA NTRS2014

NASA's Space Launch System: Momentum Builds Toward First Launch

NASA's Space Launch System (SLS) is gaining momentum toward the first launch of a new exploration-class heavy lift launch vehicle for international exploration and science initiatives. The SLS comprises an architecture that begins with a vehicle capable of launching 70 metric tons (t) into low Earth orbit. It will launch the Orion Multi-Purpose Crew Vehicle (MPCV) on its first autonomous flight beyond the Moon and back in December 2017. Its first crewed flight follows in 2021. SLS can evolve to a130-t lift capability and serve as a baseline for numerous robotic and human missions ranging from a Mars sample return to delivering the first astronauts to explore another planet. The SLS Program formally transitioned from the formulation phase to implementation with the successful completion of the rigorous Key Decision Point C review in 2014. As a result, the Agency authorized the Program to move forward to Critical Design Review, scheduled for 2015. In the NASA project life cycle process, SLS has completed 50 percent of its major milestones toward first flight. Every SLS element manufactured development hardware for testing over the past year. Accomplishments during 2013/2014 included manufacture of core stage test articles, preparations for qualification testing the solid rocket boosters and the RS-25 main engines, and shipment of the first flight hardware in preparation for the Exploration Flight Test-1 (EFT-1) in 2014. SLS was conceived with the goals of safety, affordability, and sustainability, while also providing unprecedented capability for human exploration and scientific discovery beyond Earth orbit. In an environment of economic challenges, the SLS team continues to meet ambitious budget and schedule targets through the studied use of hardware, infrastructure, and workforce investments the United States made in the last half century, while selectively using new technologies for design, manufacturing, and testing, as well as streamlined management approaches that have increased decision velocity and reduced associated costs. This paper will summarize recent SLS Program accomplishments, as well as the challenges and opportunities ahead for the most powerful and capable launch vehicle in history.

May, Todd A.↗
NASA NTRS1993

Computational Fluid Dynamics (CFD) Analysis for the Reduction of Impeller Discharge Flow Distortion

The use of Computational Fluid Dynamics (CFD) in the design and analysis of high performance rocket engine pumps has increased in recent years. This increase has been aided by the activities of the Marshall Space Flight Center (MSFC) Pump Stage Technology Team (PSTT). The team's goals include assessing the accuracy and efficiency of several methodologies and then applying the appropriate methodology(s) to understand and improve the flow inside a pump. The PSTT's objectives, team membership, and past activities are discussed in Garcia1 and Garcia2. The PSTT is one of three teams that form the NASA/MSFC CFD Consortium for Applications in Propulsion Technology (McConnaughey3). The PSTT first applied CFD in the design of the baseline consortium impeller. This impeller was designed for the Space Transportation Main Engine's (STME) fuel turbopump. The STME fuel pump was designed with three impeller stages because a two-stage design was deemed to pose a high developmental risk. The PSTT used CFD to design an impeller whose performance allowed for a two-stage STME fuel pump design. The availability of this design would have lead to a reduction in parts, weight, and cost had the STME reached production. One sample of the baseline consortium impeller was manufactured and tested in a water rig. The test data showed that the impeller performance was as predicted and that a two-stage design for the STME fuel pump was possible with minimal risk. The test data also verified another CFD predicted characteristic of the design that was not desirable. The classical 'jet-wake' pattern at the impeller discharge was strengthened by two aspects of the design: by the high head coefficient necessary for the required pressure rise and by the relatively few impeller exit blades, 12, necessary to reduce manufacturing cost. This 'jet-wake pattern produces an unsteady loading on the diffuser vanes and has, in past rocket engine programs, lead to diffuser structural failure. In industrial applications, this problem is typically avoided by increasing the space between the impeller and the diffuser to allow the dissipation of this pattern and, hence, the reduction of diffuser vane unsteady loading. This approach leads to small performance losses and, more importantly in rocket engine applications, to significant increases in the pump's size and weight. This latter consideration typically makes this approach unacceptable in high performance rocket engines.

Garcia, R.↗
NASA NTRS2014

NASA's Space Launch System: Momentum Builds Towards First Launch

NASA's Space Launch System (SLS) is gaining momentum programmatically and technically toward the first launch of a new exploration-class heavy lift launch vehicle for international exploration and science initiatives. The SLS comprises an architecture that begins with a vehicle capable of launching 70 metric tons (t) into low Earth orbit. Its first mission will be the launch of the Orion Multi-Purpose Crew Vehicle (MPCV) on its first autonomous flight beyond the Moon and back. SLS will also launch the first Orion crewed flight in 2021. SLS can evolve to a 130-t lift capability and serve as a baseline for numerous robotic and human missions ranging from a Mars sample return to delivering the first astronauts to explore another planet. Managed by NASA's Marshall Space Flight Center, the SLS Program formally transitioned from the formulation phase to implementation with the successful completion of the rigorous Key Decision Point C review in 2014. At KDP-C, the Agency Planning Management Council determines the readiness of a program to go to the next life-cycle phase and makes technical, cost, and schedule commitments to its external stakeholders. As a result, the Agency authorized the Program to move forward to Critical Design Review, scheduled for 2015, and a launch readiness date of November 2018. Every SLS element is currently in testing or test preparations. The Program shipped its first flight hardware in 2014 in preparation for Orion's Exploration Flight Test-1 (EFT-1) launch on a Delta IV Heavy rocket in December, a significant first step toward human journeys into deep space. Accomplishments during 2014 included manufacture of Core Stage test articles and preparations for qualification testing the Solid Rocket Boosters and the RS-25 Core Stage engines. SLS was conceived with the goals of safety, affordability, and sustainability, while also providing unprecedented capability for human exploration and scientific discovery beyond Earth orbit. In an environment of economic challenges, the nationwide SLS team continues to meet ambitious budget and schedule targets through the studied use of hardware, infrastructure, and workforce investments the United States has already made in the last half century, while selectively using new technologies for design, manufacturing, and testing, as well as streamlined management approaches that have increased decision velocity and reduced associated costs. This paper will summarize recent SLS Program technical accomplishments, as well as the challenges and opportunities ahead for the most powerful and capable launch vehicle in history.

May, Todd↗
NASA NTRS1972

Study of blade clearance effects on centrifugal pumps

A program of analysis, design, fabrication, and testing has been conducted to develop and experimentally verify analytical models to predict the effects of impeller blade clearance on centrifugal pumps. The effect of tip clearance on pump efficiency, and the relationship between the head coefficient and torque loss with tip clearance was established. Analysis were performed to determine the cost variation in design, manufacture, and test that would occur between unshrouded and shrouded impellers. An impeller, representative of typical rocket engine impellers, was modified by removing its front shroud to permit variation of its blade clearances. It was tested in water with special instrumentation to provide measurements of blade surface pressures during operation. Pump performance data were obtained from tests at various impeller tip clearances. Blade pressure data were obtained at the nominal tip clearance. Comparisons of predicted and measured data are given.

Hoshide, R. K.↗
NASA NTRS2013

NASA Tech Briefs, October 2013

Topics include: A Short-Range Distance Sensor with Exceptional Linearity; Miniature Trace Gas Detector Based on Microfabricated Optical Resonators; Commercial Non-Dispersive Infrared Spectroscopy Sensors for Sub-Ambient Carbon Dioxide Detection; Fast, Large-Area, Wide-Bandgap UV Photodetector for Cherenkov Light Detection; Mission Data System Java Edition Version 7; Adaptive Distributed Environment for Procedure Training (ADEPT); LEGEND, a LEO-to-GEO Environment Debris Model; Electronics/Computers; Millimeter-Wave Localizers for Aircraft-to-Aircraft Approach Navigation; Impedance Discontinuity Reduction Between High-Speed Differential Connectors and PCB Interfaces; SpaceCube Version 1.5; High-Pressure Lightweight Thrusters; Non-Magnetic, Tough, Corrosion- and Wear-Resistant Knives From Bulk Metallic Glasses and Composites; Ambient Dried Aerogels; Applications for Gradient Metal Alloys Fabricated Using Additive Manufacturing; Passivation of Flexible YBCO Superconducting Current Lead With Amorphous SiO2 Layer; Propellant-Flow-Actuated Rocket Engine Igniter; Lightweight Liquid Helium Dewar for High-Altitude Balloon Payloads; Method to Increase Performance of Foil Bearings Through Passive Thermal Management; Unibody Composite Pressurized Structure; JWST Integrated Science Instrument Module Alignment Optimization Tool; Radar Range Sidelobe Reduction Using Adaptive Pulse Compression Technique; Digitally Calibrated TR Modules Enabling Real-Time Beamforming SweepSAR Architectures; Electro-Optic Time-to-Space Converter for Optical Detector Jitter Mitigation; Partially Transparent Petaled Mask/Occulter for Visible-Range Spectrum; Educational NASA Computational and Scientific Studies (enCOMPASS); Coarse-Grain Bandwidth Estimation Scheme for Large-Scale Network; Detection of Moving Targets Using Soliton Resonance Effect; High-Efficiency Nested Hall Thrusters for Robotic Solar System Exploration; High-Voltage Clock Driver for Photon-Counting CCD Characterization; Development of the Code RITRACKS; and Enabling Microliquid Chromatography by Microbead Packing of Microchannels.

Source record↗
NASA NTRS2019

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

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

Gradl, Paul R.↗
NASA NTRSDate not supplied

Analysis of Additively Manufactured Inconel 718 Combustion Behavior in Promoted Oxygen Environments

Promoted combustion testing is a vital tool for engineers to establish the combustion and flammability characteristics of materials (metallic or otherwise) in oxygen enriched environments. Historically, much of the established data for metallic promoted combustion has been with regards to cast and wrought forms. However, with the emergence of additive manufacturing as a preferred method of fabrication, the need exists to evaluate how metals in that form behave. This paper will serve as a review of the work that has been done and an analysis of the nickel-based superalloy Inconel 718, a material popular for aerospace applications such as liquid fueled rocket components and turbine engines. Promoted combustion testing (per the ASTM G124 standard) was conducted on samples of both wrought and selective laser melted fabrication, to provide comparison of flammability response between materials produced by each manufacturing method. Additionally, post-build treatments were applied to test samples to identify any effects on performance provided by hot isostatic pressing, oxygen-getting wrap during HIP, stress relieving, and solutionizing/aging heat treatments. This study will utilize optical and scanning electron microscopy, energy dispersive spectroscopy, x-ray diffraction, and metallography to identify the differences in behavior of additively manufactured and wrought Inconel 718.

Additively Manufactured↗
NASA NTRS2015

NASA's Space Launch System Program Update

Hardware and software for the world's most powerful launch vehicle for exploration is being welded, assembled, and tested today in high bays, clean rooms and test stands across the United States. NASA's Space Launch System (SLS) continued to make significant progress in 2014 with more planned for 2015, including firing tests of both main propulsion elements and the program Critical Design Review (CDR). Developed with the goals of safety, affordability, and sustainability, SLS will still deliver unmatched capability for human and robotic exploration. The initial Block 1 configuration will deliver more than 70 metric tons of payload to low Earth orbit (LEO). The evolved Block 2 design will deliver some 130 metric tons to LEO. Both designs offer enormous opportunity and flexibility for larger payloads, simplifying payload design as well as ground and on-orbit operations, shortening interplanetary transit times, and decreasing overall mission risk. Over the past year, every vehicle element has manufactured or tested hardware. An RS-25 liquid propellant engine was hotfire-tested at NASA's Stennis Space Center, Miss. for the first time since 2009 exercising and validating the new engine controller, the renovated A-1 test stand, and the test teams. Four RS-25s will power the SLS core stage. A qualification five-segment solid rocket motor incorporating several design, material, and process changes was scheduled to be test-fired in March at the prime contractor's facility in Utah. The booster also successfully completed its Critical Design Review (CDR) validating the planned design. All six major manufacturing tools for the core stage are in place at the Michoud Assembly Facility in Louisiana, and have been used to build numerous pieces of confidence, qualification, and even flight hardware, including barrel sections, domes and rings used to assemble the world's largest rocket stage. SLS Systems Engineering accomplished several key tasks including vehicle avionics software and hardware build and testing, scale model acoustic and base heating tests. Construction of the Interim Cryogenic Propulsion Stage (ICPS) began. Advanced development provided a look into the future of SLS. Shell buckling knockdown factor testing refined decades-old design margins that added thousands of pounds to rocket payloads. Adaptive manufacturing and structured light scanning development promised to cut the cost and time associated with manufacturing and testing. This paper will provide an overview of the progress made over the past year and provide a glimpse of 2015 milestones and beyond on the way to the first launch in 2018.

May, Todd↗
NASA NTRS2015

NASA's Space Launch System Program Update

Hardware and software for the world's most powerful launch vehicle for exploration is being welded, assembled, and tested today in high bays, clean rooms and test stands across the United States. NASA's Space Launch System (SLS) continued to make significant progress in 2014 with more planned for 2015, including firing tests of both main propulsion elements and the program Critical Design Review (CDR). Developed with the goals of safety, affordability, and sustainability, SLS will still deliver unmatched capability for human and robotic exploration. The initial Block 1 configuration will deliver more than 70 metric tons of payload to low Earth orbit (LEO). The evolved Block 2 design will deliver some 130 metric tons to LEO. Both designs offer enormous opportunity and flexibility for larger payloads, simplifying payload design as well as ground and on-orbit operations, shortening interplanetary transit times, and decreasing overall mission risk. Over the past year, every vehicle element has manufactured or tested hardware. An RS-25 liquid propellant engine was hotfire-tested at NASA's Stennis Space Center, Miss. for the first time since 2009 exercising and validating the new engine controller, the renovated A-1 test stand, and the test teams. Four RS-25s will power the SLS core stage. A qualification five-segment solid rocket motor incorporating several design, material, and process changes was scheduled to be test-fired in March at the prime contractor's facility in Utah. The booster also successfully completed its Critical Design Review (CDR) validating the planned design. All six major manufacturing tools for the core stage are in place at the Michoud Assembly Facility in Louisiana, and have been used to build numerous pieces of confidence, qualification, and even flight hardware, including barrel sections, domes and rings used to assemble the world's largest rocket stage. SLS Systems Engineering accomplished several key tasks including vehicle avionics software and hardware build and testing, scale model acoustic and base heating tests. Construction of the Interim Cryogenic Propulsion Stage (ICPS) began. Advanced development provided a look into the future of SLS. Shell buckling knockdown factor testing refined decades-old design margins that added thousands of pounds to rocket payloads. Adaptive manufacturing and structured light scanning development promised to cut the cost and time associated with manufacturing and testing. This paper will provide an overview of the progress made over the past year and provide a glimpse of 2015 milestones and beyond on the way to the first launch in 2018.

May, Todd↗
NASA NTRS1992

Ceramic matrix composite applications in advanced liquid fuel rocket engine turbomachinery

Fiber-reinforced ceramic matrix composites have been identified with properties suitable for near term applications. Conceptual design studies indicate the feasibility of applying C/SiC, and subelements were manufactured that verify selected fabrication features and key material properties. Tests and inspection of these subelements confirmed their capabilities.

Brockmeyer, Jerry W.↗
NASA NTRS1997

Ablative Material Testing at Lewis Rocket Lab

The increasing demand for a low-cost, reliable way to launch commercial payloads to low- Earth orbit has led to the need for inexpensive, expendable propulsion systems for new launch vehicles. This, in turn, has renewed interest in less complex, uncooled rocket engines that have combustion chambers and exhaust nozzles fabricated from ablative materials. A number of aerospace propulsion system manufacturers have utilized NASA Lewis Research Center's test facilities with a high degree of success to evaluate candidate materials for application to new propulsion devices.

Source record↗
NASA NTRS2018

Enhanced Liquid Oxygen-Propylene Rocket Engine

Provided herein are various improvements to rocket engine components and rocket engine operational techniques. In one example, a rocket engine propellant injection apparatus is provided that includes a manifold formed into a single body by an additive manufacturing process and comprising a fuel cavity and an oxidizer cavity. The manifold also includes one or more propellant feed stubs, the one or more propellant feed stubs protruding from the manifold and formed into the single body of the manifold by the additive manufacturing process, with at least a first stub configured to carry fuel to the fuel cavity and at least a second stub configured to carry oxidizer to the oxidizer cavity. The manifold also includes a plurality of injection features formed by apertures in a face of the manifold, ones of the plurality of injection features configured to inject the fuel and the oxidizer for combustion.

Bostwick, Christopher↗
NASA NTRS1998

The Strutjet Rocket Based Combined Cycle Engine

The multi stage chemical rocket has been established over many years as the propulsion System for space transportation vehicles, while, at the same time, there is increasing concern about its continued affordability and rather involved reusability. Two broad approaches to addressing this overall launch cost problem consist in one, the further development of the rocket motor, and two, the use of airbreathing propulsion to the maximum extent possible as a complement to the limited use of a conventional rocket. In both cases, a single-stage-to-orbit (SSTO) vehicle is considered a desirable goal. However, neither the "all-rocket" nor the "all-airbreathing" approach seems realizable and workable in practice without appreciable advances in materials and manufacturing. An affordable system must be reusable with minimal refurbishing on-ground, and large mean time between overhauls, and thus with high margins in design. It has been suggested that one may use different engine cycles, some rocket and others airbreathing, in a combination over a flight trajectory, but this approach does not lead to a converged solution with thrust-to-mass, specific impulse, and other performance and operational characteristics that can be obtained in the different engines. The reason is this type of engine is simply a combination of different engines with no commonality of gas flowpath or components, and therefore tends to have the deficiencies of each of the combined engines. A further development in this approach is a truly combined cycle that incorporates a series of cycles for different modes of propulsion along a flight path with multiple use of a set of components and an essentially single gas flowpath through the engine. This integrated approach is based on realizing the benefits of both a rocket engine and airbreathing engine in various combinations by a systematic functional integration of components in an engine class usually referred to as a rocket-based combined cycle (RBCC) engine. RBCC engines exhibit a high potential for lowering the operating cost of launching payloads into orbit. Two sources of cost reductions can be identified. First, RBCC powered vehicles require only 20% takeoff thrust compared to conventional rockets, thereby lowering the thrust requirements and the replacement cost of the engines. Second, due to the higher structural and thermal margins achievable with RBCC engines coupled with a higher degree of subsystem redundance lower maintenance and operating cost are obtainable.

Siebenhaar, A.↗
NASA NTRS2015

Additively Manufactured Main Fuel Valve Housing

Selective Laser Melting (SLM) was utilized to fabricate a liquid hydrogen valve housing typical of those found in rocket engines and main propulsion systems. The SLM process allowed for a valve geometry that would be difficult, if not impossible to fabricate by traditional means. Several valve bodies were built by different SLM suppliers and assembled with valve internals. The assemblies were then tested with liquid nitrogen and operated as desired. One unit was also burst tested and sectioned for materials analysis. The design, test results, and planned testing are presented herein.

Eddleman, David↗