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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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At least 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Large-scale Additive Manufacturing for Exploration

Additive Manufacturing (AM) is emerging as a mainstream manufacturing technology, and demand for large part manufacturing is getting stronger. Direct Metal Deposition (DMD) is a DED technology based on laser and powder metal application using a closed-loop-feedback control system. This webinar focuses on additive manufacturing of NASA’s RS-25 engine nozzle liner using DMD technology. This liner (10ft in height and 8ft in diameter) is beyond the print capability of existing 3D printing processes. To print this part, significant advancements were made to the DMD technology by deploying two process heads in the machine and expanding the machine work envelop to allow manufacturing of such large parts in a safe and efficient environment. A successful demonstration of the AM of the RS25 engine nozzle liner marks a new era in 3D printing and elevates the current 3D printing technology to a new level for affordable manufacturing of large metal parts.

Additive Manufacturing↗
NASA NTRSDate not supplied

Weldability Investigation of Crack Resistant Aluminum Filler Metals Developed for Large Scale Additive Manufacturing and Industrial Welding Applications

In this study the NASA MSFC welding and manufacturing team investigated a new-age aluminum filler wire designed for welding and additive manufacturing (AM) of high strength aluminum alloys. High strength aluminum alloys are known to exhibit hot cracking and hot tearing issues during fusion welding operations. The goal of this investigation was to determine whether this new-age family of alloys can suppress the hot cracking and hot tearing issues exhibited during welding of high strength aluminum alloys and to do an initial characterization of the mechanical performance of welds created using these filler wires. This study focuses on fusion welding of aluminum alloy 6061 and compares the weldability characteristics of five aluminum filler metals and two forms of 6061 base material. The MSFC team utilized manual gas tungsten arc welding (GTAW) to conduct all welding operations and carried out metallographic analysis accompanied with mechanical testing to evaluate the performance of the welds created during this study. During the study it was observed that the new-age filler wires facilitated grain refinement in the weld fusion zone and were capable of creating crack free welds in aluminum alloy 6061 while exhibiting properties that met or exceeded conventional off the shelf aluminum filler metals.

Welding↗
NASA NTRS2015

Essentials for Team Based Rehearsals and the Differences Between Earth Orbiting and Deep Space Missions

The mission readiness environment is where spacecraft and ground systems converge to form the entire as built flight system for the final phase of operationally-themed testing. For most space missions, this phase starts between nine to twelve months prior to the planned launch. In the mission readiness environment, the goal is to perform sufficient testing to exercise the flight teams and systems through all mission phases in order to demonstrate that all elements are ready to support. As part of the maturation process, a mission rehearsal program is introduced to focus on team processes within the final flight system, in a more realistic operational environment. The overall goal for a mission rehearsal program is to: 1) ensure all flight system elements are able to meet mission objectives as a cohesive team; 2) reduce the risk in space based operations due to deficiencies in people, processes, procedures, or systems; and 3) instill confidence in the teams that will execute these first time flight activities. A good rehearsal program ensures critical events are exercised, discovers team or flight system nuances whose impact were previously unknown, and provides a real-time environment in which to interact with the various teams and systems. For flight team members, the rehearsal program provides experience and training in the event of planned (or unplanned) flight contingencies. To preserve the essence for team based rehearsals, this paper will explore the important elements necessary for a successful rehearsal program, document differences driven by Earth Orbiting (Aqua, Aura, Suomi-National Polar-orbiting Partnership (NPP)) and Deep Space missions (New Horizons, Mars Atmosphere and Volatile EvolutioN (MAVEN)) and discuss common challenges to both mission types. In addition, large scale program considerations and enhancements or additional steps for developing a rehearsal program will also be considered. For NASA missions, the mission rehearsal phase is a key milestone for predicting and ensuring on-orbit success.

Gomez-Rosa, Carlos↗
NASA NTRS2004

High-Fidelity Full System Simulations

High-fidelity full system simulations have the potential for revolutionizing the way complex systems, such as propulsion systems for aerospace vehicles, are designed, developed, manufactured, and operated. Significant time and cost savings will result from simulations that will resolve deleterious component interactions early in the design process. In addition, innovative new system configurations will result from the use of new tools that enable designers to challenge traditional rules and practices. The major challenges to developing and implementing high-fidelity systems simulations are in reducing the time and effort required to build, execute, and analyze data for the high complex simulations. In addition, large scale testing with unique instrumentation is required to validate the simulations. The solution to these problems reside in the application of advanced information technologies to assist the user to effectively manage, process, and synthesize the vast amount of data. The following presentation describes in more detail the benefits of high-fidelity full system simulations, the challenges to developing and implementing large scale simulations, and one approach that is being followed by the NASA Glenn Research Center to overcome these challenges. In addition, topics for discussion by the panel and audience are suggested.

Lytle, John K.↗
NASA NTRS2016

Manufacturing Process Developments for Regeneratively-Cooled Channel Wall Rocket Nozzles

Regeneratively cooled channel wall nozzles incorporate a series of integral coolant channels to contain the coolant to maintain adequate wall temperatures and expand hot gas providing engine thrust and specific impulse. NASA has been evaluating manufacturing techniques targeting large scale channel wall nozzles to support affordability of current and future liquid rocket engine nozzles and thrust chamber assemblies. The development of these large scale manufacturing techniques focus on the liner formation, channel slotting with advanced abrasive water-jet milling techniques and closeout of the coolant channels to replace or augment other cost reduction techniques being evaluated for nozzles. NASA is developing a series of channel closeout techniques including large scale additive manufacturing laser deposition and explosively bonded closeouts. A series of subscale nozzles were completed evaluating these processes. Fabrication of mechanical test and metallography samples, in addition to subscale hardware has focused on Inconel 625, 300 series stainless, aluminum alloys as well as other candidate materials. Evaluations of these techniques are demonstrating potential for significant cost reductions for large scale nozzles and chambers. Hot fire testing is planned using these techniques in the future.

Gradl, Paul↗
NASA NTRS2013

Faxing Structures to the Moon: Freeform Additive Construction System (FACS)

Using the highly articulated All-Terrain Hex-Limbed Extra-Terrestrial Explorer (ATHLETE) robotic mobility system as a precision positioning tool, a variety of print head technologies can be used to 3D print large-scale in-situ structures on planetary surfaces such as the moon or Mars. In effect, in the same way CAD models can be printed in a 3D printer, large-scale structures such as walls, vaults, domes, berms, paving, trench walls, and other insitu derived elements can be FAXed to the planetary surface and built in advance of the arrival of crews, supplementing equipment and materials brought from earth. This paper discusses the ATHLETE system as a mobility / positioning platform, and presents several options for large-scale additive print head technologies, including tunable microwave "sinterator" approaches and in-situ concrete deposition. The paper also discusses potential applications, such as sintered-in-place habitat shells, radiation shielding, road paving, modular bricks, and prefabricated construction components.

Apollo Lunar Module↗
NASA NTRSDate not supplied

Development of Large-Scale Thrust Chambers using Laser Powder Directed Energy Deposition

Historical manufacturing methods for liquid propulsion combustion chambers have relied on series of tube-walls or slotted channel walls (subsequently brazed or plated) for regenerative cooling paths. Large-scale additive manufacturing techniques offer strong potential to minimize manufacturing lead times and cost for developing liquid propulsion chambers, while maintaining performance metrics of traditionally manufactured hardware. The benefits expand beyond traditional combustion chambers to lesser considered nuclear thermal propulsion chambers where radiation energizes the singular incoming propellant stream instead of an exothermic chemical reaction. While each subset of liquid propulsion chambers reaps similar benefit, the geometric challenges in each design can vary substantially. This manuscript discusses the challenges of large contraction ratio propulsion chambers, bimetallic liners and closeout jackets, and material selection when considering laser powder directed energy deposition. LP-DED presently offers build volumes unattainable by L-PBF systems, required for large diameter thrust chambers. LP-DED typically has faster deposition time and is capable of overhang angles without support material (due to the ability to tilt the build plate and minimize the actual build angle). These benefits come at the cost of feature resolution. Designers and manufacturers should consider the effects of thick-wall features printed parallel to the primary surface versus perpendicular due to distortion. Thick-wall and thin-wall features printed in the same plane can substantially increase build time. Where large-scale L-PBF overlaps in size, there may be limited benefit in the quantity of powder required for the build due to the low capture rate of LP-DED and a case-by-case examination is required.

LP-DED↗
NASA NTRSDate not supplied

TPSAS-NF1676L-32708-DND

Proposed Effort under Advanced Air Transport Technology (AATT): - Select advanced Al alloy with formability and additive manufacturability, high combined strength and toughness - Fabricate single-piece Integrally Stiffened Cylinders (~10 ft. dia. x 10 ft. long) with longitudinal stiffeners - Demonstrate joining technology for assembly of two cylinders into 20-ft. long fuselage structure - Optimize structural design incorporating tailored, selective reinforcement for durability and damage tolerance - Build-up window, door and circumferential ring frames with large-scale additive manufacturing - Structural test to validate manufacturing demonstration, structural models and analysis

Taminger, Karen M↗
NASA NTRS1976

Preliminary feasibility study of pallet-only mode for magnetospheric and plasmas in space payloads, volume 4

Results of studies performed on the magnetospheric and plasma portion of the AMPS are presented. Magnetospheric and plasma in space experiments and instruments are described along with packaging (palletization) concepts. The described magnetospheric and plasma experiments were considered as separate entities. Instrumentation ospheric and plasma experiments were considered as separate entities. Instrumentation requirements and operations were formulated to provide sufficient data for unambiguous interpretation of results without relying upon other experiments of the series. Where ground observations are specified, an assumption was made that large-scale additions or modifications to existing facilities were not required.

Source record↗
NASA NTRS1982

Simulation of the fluctuating field of a forced jet

The fluctuating field of a jet excited by transient mass injection is simulated numerically. The model is developed by expanding the state vector as a mean state plus a fluctuating state. Nonlinear terms are not neglected and the effect of nonlinearity is studied. The results show a significant spectral broadening in the flow field due to the nonlinearity. In addition, large scale structures are broken down into smaller scales.

Bayliss, A.↗
NASA NTRS1982

Simulation of the fluctuating field of a forced jet

The fluctuating field of a jet excited by transient mass injection is simulated numerically. The model is developed by expanding the state vector as a mean state plus a fluctuating state. Nonlinear terms are not neglected and the effect of nonlinearity is studied. The results show a significant spectral broadening in the flow field due to the nonlinearity. In addition, large scale structures are broken down into small scales. Previously announced in STAR as N82-34191

Bayliss, A.↗
NASA NTRS1985

On the interaction of a sound pulse with the shear layer of an axisymmetric jet. Part 3: Nonlinear effects

The fluctuating field of a jet excited by transient mass injection is simulated numerically. The model is developed by expanding the state vector as a mean state plus a fluctuating state. Nonlinear terms are not neglected, and the effect of nonlinearity was studied. A high order numerical method is used to compute the solution. The results show a significant spectral broadening in the flow field due to the nonlinearity. In addition, large scale structures are broken down into smaller scales.

Bayliss, A.↗
NASA NTRS1986

On the interaction of a sound pulse with the shear layer on an axisymmetric jet. III - Non-linear effects

The fluctuating field of a jet excited by transient mass injection is simulated numerically. The model is developed by expanding the state vector as a mean state plus a fluctuating state. Nonlinear terms are not neglected, and the effect of nonlinearity is studied. A high order numerical method is used to compute the solution. The results show a significant spectral broadening in the flow field due to the nonlinearity. In addition, large scale structures are broken down into smaller scales.

Bayliss, A.↗
NASA NTRS2016

Rapid Fabrication Techniques for Liquid Rocket Channel Wall Nozzles

The functions of a regeneratively-cooled nozzle are to (1) expand combustion gases to increase exhaust gas velocity while, (2) maintaining adequate wall temperatures to prevent structural failure, and (3) transfer heat from the hot gases to the coolant fluid to promote injector performance and stability. Regeneratively-cooled nozzles are grouped into two categories: tube-wall nozzles and channel wall nozzles. A channel wall nozzle is designed with an internal liner containing a series of integral coolant channels that are closed out with an external jacket. Manifolds are attached at each end of the nozzle to distribute coolant to and away from the channels. A variety of manufacturing techniques have been explored for channel wall nozzles, including state of the art laser-welded closeouts and pressure-assisted braze closeouts. This paper discusses techniques that NASA MSFC is evaluating for rapid fabrication of channel wall nozzles that address liner fabrication, slotting techniques and liner closeout techniques. Techniques being evaluated for liner fabrication include large-scale additive manufacturing of freeform-deposition structures to create the liner blanks. Abrasive water jet milling is being evaluated for cutting the complex coolant channel geometries. Techniques being considered for rapid closeout of the slotted liners include freeform deposition, explosive bonding and Cold Spray. Each of these techniques, development work and results are discussed in further detail in this paper.

Gradl, Paul R.↗
NASA NTRS2018

NASA's Centennial Challenge for 3D-Printed Habitat: Phase II Outcomes and Phase III Competition Overview

The 3D-Printed Habitat Challenge is part of NASA's Centennial Challenges Program. NASA's Centennial Challenges seek to accelerate innovation in aerospace technology development through public competitions. The 3D-Printed Habitat Challenge, launched in 2015, is part of the Centennial Challenges portfolio and focuses on habitat design and development of large-scale additive construction systems capable of fabricating structures from in situ materials and/or mission recyclables. The challenge is a partnership between NASA, Caterpillar (primary sponsor), Bechtel, Brick and Mortar Ventures, and Bradley University. Phase I of the challenge was an architectural concept competition in which participants generated conceptual renderings of habitats on Mars which could be constructed using locally available resources. Phase II asked teams to develop the printing systems and material formulations needed to translate these designs into reality. Work under the phase II competition, which concluded in August 2017 with a head to head competition at Caterpillar's Edward Demonstration Facility in Peoria, Illinois, is discussed, including the key technology development outcomes resulting from this portion of the competition. The phase III competition consists of both virtual and construction subcompetitions. Virtual construction asks teams to render high fidelity architectural models of a habitat and all the accompanying information required for construction of the pressure retaining and load bearing portions of the structure. In construction phase III, teams are asked to scale up their printing systems to produce a 1/3 scale habitat on-site at Caterpillar. The levels of the phase III construction competition (which include printing of a foundation and printing and hydrostatic testing of a habitat element) are discussed. Phase III construction also has an increased focus on autonomy, as these systems are envisioned for robotic precursor missions which would buildup infrastructure prior to the arrival of crew. Results of the phase III competition through July 2017 (which includes virtual construction level 1) are discussed. This Centennial Challenge enables an assessment of the scaleability and efficacy of various processes, material systems, and designs for planetary construction. There are also near-term terrestrial applications, from disaster response to affordable housing and infrastructure refurbishment, for these technologies.

Prater, T. J.↗
NASA NTRSDate not supplied

Hot-Fire Testing Results of Additively Manufactured NASA HR-1 towards Large Scale Implementation of Channel Wall Nozzles

Additive manufacturing (AM) has provided new design and manufacturing opportunities to reduce cost and schedules, consolidate parts, and optimize performance. One technique being evaluated is Laser Powder Directed Energy Deposition (LP-DED), which provides a significant increase in scale compared to Laser Powder Bed Fusion (L-PBF). NASA along with industry partners have been developing the LP-DED process to demonstrate internal channel geometry and development components for use in liquid rocket engine channel cooled nozzles. One material that has been the focus of this development is NASA HR-1, an Iron-Nickel based superalloy optimized for use in high pressure hydrogen environments. Material properties and process characterization has been completed on the high density thin-wall material in addition to advancements of the supply chain. NASA has also completed fabrication of several subscale and full scale channel wall nozzles in LP-DED NASA HR-1 and completed hot-fire testing. This includes refinement of the process to produce thin-walls and various channel geometries to meet the requirements for channel wall nozzle applications. This paper will provide an overview of the LP-DED process development, material characterization and properties, component manufacturing, and hot-fire testing. Hot-fire testing was completed for a lander-class 7K-lbf thrust chamber using Liquid Oxygen (LOX)/Methane. The design overview and results from hot-fire testing will be presented in addition to hardware development for future testing on 2K-lbf and 35k-lbf thrust chambers and large-scale manufacturing technology demonstrators.

Paul Gradl↗
NASA NTRS2017

Large-Scale Traveling Weather Systems in Mars Southern Extratropics

Between late fall and early spring, Mars' middle- and high-latitude atmosphere supports strong mean equator-to-pole temperature contrasts and an accompanying mean westerly polar vortex. Observations from both the MGS Thermal Emission Spectrometer (TES) and the MRO Mars Climate Sounder (MCS) indicate that a mean baroclinicity-barotropicity supports intense, large-scale eastward traveling weather systems (i.e., transient synoptic-period waves). Such extratropical weather disturbances are critical components of the global circulation as they serve as agents in the transport of heat and momentum, and generalized scalar/tracer quantities (e.g., atmospheric dust, water-vapor and ice clouds). The character of such traveling extratropical synoptic disturbances in Mars' southern hemisphere during late winter through early spring is investigated using a moderately high-resolution Mars global climate model (Mars GCM). This Mars GCM imposes interactively-lifted and radiatively-active dust based on a threshold value of the surface stress. The model exhibits a reasonable "dust cycle" (i.e., globally averaged, a dustier atmosphere during southern spring and summer occurs). Compared to the northern-hemisphere counterparts, the southern synoptic-period weather disturbances and accompanying frontal waves have smaller meridional and zonal scales, and are far less intense. Influences of the zonally asymmetric (i.e., east-west varying) topography on southern large-scale weather are investigated, in addition to large-scale up-slope/down-slope flows and the diurnal cycle. A southern storm zone in late winter and early spring presents in the western hemisphere via orographic influences from the Tharsis highlands, and the Argyre and Hellas impact basins. Geographically localized transient-wave activity diagnostics are constructed that illuminate dynamical differences amongst the simulations and these are presented.

Hollingsworth, Jeffery L.↗