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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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Study of the Effects of Materials Selection for the Closeout Structure on the Service Life of a Liquid Rocket Engine Thrust Chamber

The external structure of rocket engines thrust chambers for aerospace applications should be designed in order to provide adequate stiffness to the thrust chamber; however, it affects in a significant way the engine service life since it acts as a structural bound for the internal structure which is subjected to very high temperature values. The adoption of thin closeout structures allows to have lighter structures and to significantly increase the service life of the thrust chamber. The aim of the present work is to perform numerical investigations on the influence of the closeout geometry and materials on the number of cycles to failure of the thrust chamber. Furthermore, a study on the impact of creep phenomenon on the service life is illustrated. In particular, the present paper is focused on the thermomechanical study of the closeout structure, in terms of material choice, thickness, joining process with the inner liner, etc. Transient thermal and static structural nonlinear analyses are conducted by means of a commercial finite element code (ANSYS), in order to evaluate the number of cycles to failure for the investigated configurations. Viscoplastic models are adopted in order to simulate the highly nonlinear and rate-dependent phenomena occurring in the inner liner structure.

36 MATERIALS SCIENCE↗

Brazing of Martensitic Stainless Steel to Copper Using Electroplated Copper and Silver Coatings

Brazing of 3 mm thick sheets of low-carbon martensitic stainless steel and Cu-Cr-Zr-Ti alloy was attempted using electroplated coatings of Cu and Ag. Ni coating of 5 µm thick was provided on the MSS base metal to enhance the wettability. Brazing experiments were carried out at 985 °C for a holding of 15 min. Detailed microstructural studies, hardness, lap-shear, tensile, and pressure tests were carried out on the brazed joints. The reaction between the Cu and Ag coatings lead to the formation of in situ braze metal. The microstructure of the braze metal was found to consist of Cu-rich primary alpha (α{sub P}) and Ag-rich eutectic mixture (β + α{sub E}). In lap-shear tests, the brazed joints produced with an overlap of 9 and 6 mm were found to fail in copper base metal, while the joints produced with an overlap of 3 mm failed in the braze metal exhibiting a lap-shear strength of 147 MPa. In tensile tests, the butt brazed joints were found to fail in copper base metal as well with an average tensile strength of 213 MPa. The braze metal hardness was found to be higher than the hardness of the copper base metal. In pressure tests, the brazed panels were found to survive a pressure of 750 bar without undergoing any damage. These results show that electroplated coatings of Cu and Ag can be advantageously utilized for brazing of large, complex-shaped parts such as thrust chambers in space industry.

36 MATERIALS SCIENCE↗

Axial load management system

An axial load management system for a turbomachine including a rotating drivetrain, a thrust bearing assembly, a sensor, and a valve supply line. The rotating drivetrain includes a compressor section and an expander section fluidly coupled together by a closed flowpath. The thrust bearing assembly includes a thrust runner, a thrust bearing housing, and a gas thrust bearing extending between the thrust runner and the thrust bearing housing. Further, the gas thrust bearing supports the rotating drivetrain. The sensor is attached to at least one of the thrust bearing housing or the gas thrust bearing. The valve supply line is fluidly coupled to the closed flowpath. A valve positioned within the valve supply line selectively allows a working fluid to flow between the closed flowpath and a thrust chamber defined by a rotating surface and a fixed surface to modify an axial load on the rotating drivetrain.

42 ENGINEERING↗

Production Unit for Fusible Metal Powders

A pilot production unit for fusible metal powders is considered. The formation of liquid metal particles in a melt generator based on the chamber of a low-thrust rocket engine is described. The systems employed in the proposed unit are itemized, including supply systems for the fuel components and initial powder material; the system for flow-rate measurement; the system for collection of the solidifying metal particles; and the system for automated collection and preliminary analysis of the experimental data.

42 ENGINEERING↗

Method and apparatus to produce high specific impulse and moderate thrust from a fusion-powered rocket engine

A system and method for producing and controlling high thrust and desirable specific impulse from a continuous fusion reaction is disclosed. The resultant relatively small rocket engine will have lower cost to develop, test, and operate that the prior art, allowing spacecraft missions throughout the planetary system and beyond. The rocket engine method and system includes a reactor chamber and a heating system for heating a stable plasma to produce fusion reactions in the stable plasma. Magnets produce a magnetic field that confines the stable plasma. A fuel injection system and a propellant injection system are included. The propellant injection system injects cold propellant into a gas box at one end of the reactor chamber, where the propellant is ionized into a plasma. The propellant and fusion products are directed out of the reactor chamber through a magnetic nozzle and are detached from the magnetic field lines producing thrust.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Performance Characterization of a Natural Gas-Air Rotating Detonation Engine at Elevated Pressure

Performance of a rotating detonation engine was studied to understand the challenges of achieving and quantifying a net pressure gain at engine-relevant conditions. The combustor under study was designed for operation with natural gas and air at elevated chamber pressures and air preheat temperatures representative of land based power generation gas turbine engines. The thrust produced by the combustor was measured to characterize its performance while high-frequency pressure transducers and high speed imaging of broadband combustion chemiluminescence provided information about the wave structure and dynamics. The rotating detonation engine was tested with two injector configurations to explore the effect of injector design and combustor operating mode on device performance. Analysis using multiple metrics showed nearly identical performance between similar operating conditions that alternately produced a single detonation wave or two counter-propagating waves in the combustion chamber. Across the range of tested conditions, a maximum pressure gain of -42% was measured. Several tests were observed to produce up to 10% more thrust than an ideal, constant pressure combustor, though this comparison ignores injection losses. Comparison of measured pressure gain with idealized simulations showed that the net pressure gain of a rotating detonation engine is closely tied to the area ratio between the inlet and outlet of the combustor.

20 FOSSIL-FUELED POWER PLANTS↗

A Scintillating Xenon Bubble Chamber for Dark Matter Detection. Final Report

This report describes the progress in the search for particle dark matter achieved under DOE award DE-SC0012161, as well as the invention of a new dark matter and neutrino detection technique. Work supported by this award follows in three distinct thrusts: (1) the successful completion of the Generation-1 Direct Detection experiment PICO-60, which set the world-leading limit on the spin-dependent coupling of dark matter to protons and achieved a precise understanding of the response of bubble chambers to nuclear-recoil signals and electron-recoil backgrounds; (2) the construction of the Generation-2 Direct Detection experiment LZ, which will soon be the world's most sensitive dark matter detector; and (3) the demonstration of the first scintillating bubble chamber. The development of a scintillating liquid noble bubble chamber was the primary goal of the proposed work, with the aim of combining the excellent background rejection of a PICO-style bubble chamber with the event-by-event energy resolution of a liquid-noble detector such as LZ. This work produced the first ever observation of coincident scintillation and bubble nucleation by a nuclear recoil in a superheated fluid and also revealed an unexpected benefit to the use of noble liquids in a bubble chamber, namely the ability to increase the degree of superheat by an order of magnitude beyond that achievable in PICO-style detectors while maintaining PICO's world-leading background rejection. This discovery has led to new projects in the US and Canada, developing noble liquid bubble chambers both as detectors for low-mass dark matter and as detectors of coherent elastic neutrino-nucleus scattering (CEvNS) by neutrinos produced at nuclear reactors.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

Installation and Commissioning of the SBC-LAr10 Detector at Fermilab

This report describes the progress towards a scalable detector capable of quasi-background-free detection of sub-keV nuclear recoils under DOE award DE-SC0024254. Work supported by this award follows two distinct thrusts: (1) the first calibration of sensitivity to sub-keV nuclear recoils in a liquid-noble bubble chamber, based on data taken in a prototype liquid xenon bubble chamber run previously at Northwestern University, and (2) the successful assembly and installation of the 10-kg liquid argon bubble chamber SBC-LAr10 in the MINOS underground area at Fermilab. These accomplishments have paved the way for the precision calibration of SBC-LAr10 in the MINOS underground area at Fermilab in the coming year, which will use novel calibration techniques to measure the potential of the liquid noble bubble chamber technology for the detection of GeV-scale dark matter particles and the measurement of coherent elastic nuclear scattering by reactor anti-neutrinos (CEvNS).

47 OTHER INSTRUMENTATION↗

System for multiple burns from a rocket motor

A system for multiple burns from a solid fuel rocket motor may extinguish rocket fuel after the rocket has been ignited. The motor may be extinguished via rapid decompression of the combustion chamber. The fuel may then be reignited by a suitable igniter, and the process of extinguishing and reigniting may be repeated, enabling multi-burn maneuvers. A decompressive extinguishing plug nozzle may extinguish solid rocket fuel after the rocket has been ignited and/or keep a rocket in a disarmed (zero thrust) state until the rocket is to be armed. The nozzle may include a plug that mostly impedes the opening of the nozzle and an outer cowl that is movable to rapidly decompress the combustion chamber. This rapid decompression extinguishes the solid rocket fuel. In some aspects, the fuel can be reignited and extinguished multiple times.

Dallmann, Nicholas↗

Performance Characterization of a Natural Gas–Air Rotating Detonation Engine

An experimental study of a rotating detonation engine (RDE) operating with natural gas and air at elevated chamber pressures and air preheat temperatures was conducted to quantify its performance at conditions representative of land-based power generation gas turbine engines. Here, the thrust produced by the combustor was measured to characterize its work output potential. High-frequency pressure transducers and broadband chemiluminescence measurements of the flame provided information about the wave structure and dynamics. Analysis of common performance metrics demonstrated the necessity of normalizing any RDE performance parameter by the driving system potential, typically the reactant manifold pressure. Application of a thermodynamic performance model to a generic RDE identified the area ratio between the RDE exhaust and injection throats as the primary parameter affecting delivered pressure gain. The model was further applied to draw comparison with experimental measurements of net pressure gain for identical flow conditions. Only one of the two tested injector configurations followed the predicted trends, suggesting that performance of the second was governed by physical processes other than the reactant thermodynamics. Although an absolute pressure gain was not demonstrated, it is promising that the natural gas–air RDE delivered up to 90% of the theoretical performance.

20 FOSSIL-FUELED POWER PLANTS↗

Automated Control for Nuclear Thermal Propulsion Start-Up using MOOSE-based Applications

This report presents a Griffin/Bison/RELAP-7 numerical model of a prototypical NTP system that features fuel assemblies arranged in rings, and which was designed to simulate rapid startup transients. The physics modeled include full-core neutronics, assembly-wise heat conduction, and conjugate heat transfer, with the balance of plant mainly imposed through boundary conditions. In addition, various forms of automated reactivity control were deployed by using the MOOSE to autonomously drive the model and simulate the reactor transitioning from assumed initial conditions to nominal power in a fraction of a minute. To generate the cross-sections of the neutronics model, and in an effort to simultaneously account for the tremendous axial temperature gradients in the reactor and to limit the number of state points required for cross-section generation, the average component temperatures and hydrogen densities in the cooling channels were correlated to the average fuel and moderator temperatures, and fixed axial profiles were derived for nominal conditions and then used during the transient. With this approximation, a tractable cross-section library tabulated with fuel/moderator temperatures and CD angles was generated using Serpent. The full-core SPH correction procedure and the CD decusping technology in Griffin, respectively, ensure preservation of the multiplication factor and reaction rates at state points, along with a reasonably accurate reactivity worth between tabulated CD angles, despite using a coarse mesh. Feedback from other physics was calculated by modeling one representative fuel assembly per ring, along with the corresponding fuel and moderator cooling channels. To limit power overshoots during startup, another layer of multiphysics coupling was added to the model in order to automatically control the drums. Two different technologies presented herein showed outstanding performance in this regard: (1) a novel hybrid PID controller based on both power and reactivity signals, and (2) a PGC that relies on kinetics parameters and reactivity coefficients to predict future behavior and adjust the desired signal accordingly. A challenging benchmark was devised, featuring a power demand curve that exponentially increases by a factor of 500 within 30 seconds, then levels out after that. Both control approaches create a simulated power curve that closely follows the power demand curve and limits power overshoots to 1% or less. While the former approach requires more tuning of the internal parameters, the latter requires additional knowledge of the reactivity feedback coefficients and rates of change of the corresponding variables, including fuel and moderator temperature, which could be difficult to dynamically measure for a real NTP system. Fortunately, some inaccuracy in these quantities will not drastically degrade the PGC performance. Subsequently, a more realistic startup sequence was considered, in which the mass flow rate and outlet pressures are ramped up to model bootstrap and thrust build-up phases prior to reaching steady-state conditions, demonstrating the ability of the hybrid PID and PGCs to handle such transients, with both types of controllers exhibiting very similar behavior. Nevertheless, a significant chamber temperature overshoot was observed, caused by the demanded power signal and assumed mass flow rate. This issue could be mitigated by deploying a reactor controller that follows the chamber temperature signal and actuates both the control valves and drums (rather than using a power signal based solely on the drums to control reactivity). Enhancement of the hydrogen fluid properties available in MOOSE, as well as a better understanding of prototypical initial conditions, are also needed to further enhance this startup model. Finally, a study was performed to model decay heat post-shutdown, and to prepare for extending this model to predict shutdown behavior and post-shutdown pulsed cooling requirements.

33 ADVANCED PROPULSION SYSTEMS↗

Rocket Engine Test System for Development of Novel Propulsion Technologies

A 150 lb f thrust class, modular, bi-propellant, rocket engine/gas-generator and supporting test infrastructure has been developed in a cooperative effort between Sandia National Laboratories and the New Mexico Institute of Mining and Technology’s (NMIMT’s) Energetic Materials Research and Testing Center (EMRTC). This modular test engine design consists of a head end fuel-oxidizer injector, a spark ignition gaseous H 2 /O 2 torch igniter, combustion chamber and nozzle module. This robust design allows for rapid configuration changes as well as economical repair should hardware become damaged in testing. The engine interfaces with a permanently installed pressurizing system capable of delivering liquid nitrous oxide and a variety of liquid fuels for both rocket engine development and propellant performance evaluation. The regulated high pressure systems allow for delivery of liquefied gases above their saturation pressure as well as allowing for high pressure rocket engine/gas-generator operation. The facility test cell houses a 1 ton thrust capacity test stand leaving room for larger scale engine development.

36 MATERIALS SCIENCE↗

Study of the Design and Characteristics of a Modified Pulsed Plasma Thruster with Graphite and Tungsten Trigger Electrodes

The paper presents experimental results for a modified pulsed plasma thruster (PPT) with solid propellant, using a coaxial anode–cathode design. Graphite from pencil leads served as propellant, and a tungsten trigger electrode was tested to reduce carbonization effects. Experiments were performed in a vacuum chamber at 0.001 Pa, employing diagnostics such as discharge current/voltage recording, power measurement, ballistic pendulum, time-of-flight (TOF) method, and a Faraday cup. Current and voltage waveforms matched an oscillatory RLC circuit with variable plasma channel resistance. Key discharge parameters were measured, including current pulse duration/amplitude and plasma channel formation/decay dynamics. Impulse bit values, obtained with a ballistic pendulum, reached up to 8.5 μN·s. Increasing trigger capacitor capacitance reduced thrust due to unstable “pre-plasma” formation and partial pre-discharge energy loss. Using TOF and Faraday cup diagnostics, plasma front velocity, ion current amplitude, current density, and ion concentration were determined. Tungsten electrodes produced lower charged particle concentrations than graphite but offered better adhesion resistance, minimal carbonization, and stable long-term performance. The findings support optimizing trigger electrode materials and PPT operating modes to extend lifetime and stabilize thrust output.

Faraday cup↗

Experimental Study of the Invariance of Pressure Gain with Respect to the Dynamics of Multiple Competing Waves in a Rotating Detonation Combustor

Changes in the overall performance of a rotating detonation combustor with respect to changes in operation mode and wave dynamics arising by operation with fixed inlet/exit geometry but at different combustor, lengths are investigated experimentally. The air inlet, fuel injection, and exit constriction geometry are held constant while only the length of the detonation channel is varied from 71 to 137 mm (which corresponds to about 10 to 20 channel widths). Operation of H2/air over a range of air mass flow rates and equivalence ratios are considered for every chamber length. The number and speed of (primary) detonation and secondary waves are characterized through high-speed pressure measurements in the detonation channel and aft chemiluminescence videos. The number of waves is found to increase with length while detonation wave speed decreases significantly. Particular emphasis is given to characterize a phenomenon that is observed at operation with longer combustor lengths and higher mass flow rates. The phenomenon manifests as a super-cycle behavior with a period equal to many detonation wave rotational periods and is characterized by a periodic and structured ascending/descending sequence of the number, speed, and direction of both (primary) detonation and secondary waves. This phenomenon is likely a manifestation of the system failing in achieving operation with a higher number of detonation waves as length and/or mass flow rate are increased. The performance of the device is quantified in terms of measured thrust and pressure gain (through the use of the equivalent available pressure). Both metrics are essentially found to be invariant with respect to combustor length and most importantly, mode of operation. Surprisingly, even operation with complex wave dynamics arising from transitions between multiple competing wave systems does not appear to alter the overall global performance of the device but rather, it remains defined by the total (capture) air mass flow rate, equivalence ratio, and inlet/outlet areas.

33 ADVANCED PROPULSION SYSTEMS↗

EPCAPE-PT-LANL Measurements: Humidified Cavity Attenuated Phase Shift Spectroscopy

Coastal cities offer a unique environment for studying aerosol-cloud interactions and the effects of urban emissions on cloud properties. As part of the Eastern Pacific Cloud Aerosol Precipitation Experiment (EPCAPE), the Partitioning Thrust by Los Alamos National Laboratory (EPCAPE-PT-LANL) was conducted. Our campaign focused on measuring the optical and chemical properties of aerosols and their interactions within marine stratocumulus clouds in La Jolla, California. EPCAPE-PT-LANL enhances the primary goals of EPCAPE through innovative observations of vapor-phase transitions between aerosols and cloud droplets, the impact of black carbon on aerosol-cloud dynamics, and the effects of cloud processing on aerosol optical properties. Instrument: Humidified Cavity Attenuated Phase Shift Particulate Matter Single Scattering Albedo (H-CAPS-PMSSA, Aerodyne Inc) Data Notes: The scattering truncation correction was not applied to Bsca. The Bext needs no correction. Files: data_10sec_CAPS.csv, data_10min_CAPS.csv Header: - Bext_wet_CAPS_450nm[1/Mm]: Wet aerosol extinction coefficient measured at 450 nm by the CAPS, in inverse megameters (Mm⁻¹). - Bsca_wet_CAPS_450nm[1/Mm]: Wet aerosol scattering coefficient measured at 450 nm by the CAPS, in inverse megameters (Mm⁻¹). - Temp_wet_CAPS[K]: Temperature inside the wet CAPS measurement chamber, in Kelvin. - Bext_dry_CAPS_450nm[1/Mm]: Dry aerosol extinction coefficient measured at 450 nm by the CAPS, in inverse megameters (Mm⁻¹). - Bsca_dry_CAPS_450nm[1/Mm]: Dry aerosol scattering coefficient measured at 450 nm by the CAPS, in inverse megameters (Mm⁻¹). - Temp_dry_CAPS[K]: Temperature inside the dry CAPS measurement chamber, in Kelvin. - Wet_RH_preCAPS[%]: Relative humidity before entering the wet CAPS, in percent. - Wet_RH_postCAPS[%]: Relative humidity after exiting the wet CAPS, in percent. - Humidifier_RH_CAPS[%]: Relative humidity inside the humidifier used with the CAPS, in percent. - dualCAPS_inlet_RH[%]: Relative humidity at the inlet of the dual (wet/dry) CAPS setup, in percent. - Wet_Temp_preCAPS[C]: Temperature before entering the wet CAPS, in degrees Celsius. - Wet_Temp_postCAPS[C]: Temperature after exiting the wet CAPS, in degrees Celsius. - Humidifier_Temp[C]: Temperature inside the humidifier used with the CAPS, in degrees Celsius. - dualCAPS_inlet_Temp[C]: Temperature at the inlet of the dual (wet/dry) CAPS setup, in degrees Celsius. - Zero_dry_CAPS: 1 is a calibration check for the dry CAPS to ensure zero reading under filter air conditions. - Zero_wet_CAPS: 1 is a calibration check for the wet CAPS to ensure zero reading under filter air conditions. - CVI_Flag[bool]: A boolean flag indicating whether the Counterflow Virtual Impactor (CVI) was active (true) or inactive (false) during the measurement.

54 ENVIRONMENTAL SCIENCES↗