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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS1997

The Systematic Interpretation of Cosmic Ray Data (The Transport Project)

The Transport project's primary goals were to: (1) Provide measurements of critical fragmentation cross sections; (2) Study the cross section systematics; (3) Improve the galactic cosmic ray propagation methodology; and (4) Use the new cross section measurements to improve the interpretation of cosmic ray data. To accomplish these goals a collaboration was formed consisting of researchers in the US at Louisiana State University (LSU), Lawrence Berkeley Laboratory (LBL), Goddard Space Flight Center (GSFC), the University of Minnesota (UM), New Mexico State University (NMSU), in France at the Centre d'Etudes de Saclay and in Italy at the Universita di Catania. The US institutions, lead by LSU, were responsible for measuring new cross sections using the LBL HISS facility, analysis of these measurements and their application to interpreting cosmic ray data. France developed a liquid hydrogen target that was used in the HISS experiment and participated in the data interpretation. Italy developed a Multifunctional Neutron Spectrometer (MUFFINS) for the HISS runs to measure the energy spectra, angular distributions and multiplicities of neutrons emitted during the high energy interactions. The Transport Project was originally proposed to NASA during Summer, 1988 and funding began January, 1989. Transport was renewed twice (1991, 1994) and finally concluded at LSU on September, 30, 1997. During the more than 8 years of effort we had two major experiment runs at LBL, obtained data on the interaction of twenty different beams with a liquid hydrogen target, completed the analysis of fifteen of these datasets obtaining 590 new cross section measurements, published nine journal articles as well as eighteen conference proceedings papers, and presented more than thirty conference talks.

Guzik, T. Gregory↗
NASA NTRS1982

Behavior of liquid hydrogen inside an ICF target

The configuration of liquid hydrogen inside spherical glass shell ICF target was studied both theoretically and experimentally. Because of the zero contact angle between the .D2 liquid and glass substrate and the limited wetting surface that is continuous, the liquid hydrogen completely covers the interior of the glass shell, resulting in the formation of a void at the center. For this reason, the present problem distinguishes itself from that for a sessile drop sitting on a flat surface. A theory was formulated to calculate the liquid hydrogen configuration by including the London-dispersion force between the liquid and the substrate molecules. The net result is an augmented Bashforth-Adams equation appropriate to a spherical substrate, which is considered to be the major contribution of the present work. Preliminary calculations indicate that this equation accurately models the liquid hydrogen behavior inside a spherical microshell.

Kim, K.↗
NASA NTRS2017

Nano Icy Moons Propellant Harvester

As one of just a few bodies identified in the solar system with a liquid ocean, Europa has become a top priority in the search for life outside of Earth. However, cost estimates for exploring Europa have been prohibitively expensive, with estimates of a NASA Flagship class orbiter and lander approaching $5 billion. ExoTerra's NIMPH offers an affordable solution that can not only land, but return a sample from the surface to Earth. NIMPH combines solar electric propulsion (SEP) technologies being developed for the asteroid redirect mission and microsatellite electronics to reduce the cost of a full sample return mission below $500 million. A key to achieving this order-of-magnitude cost reduction is minimizing the initial mass of the system. The cost of any mission is directly proportional to its mass. By keeping the mission within the constraints of an Atlas V 551 launch vehicle versus an SLS, we can significantly reduce launch costs. To achieve this we reduce the landed mass of the sample return lander, which is the largest multiplier of mission mass, and shrink propellant mass through high efficiency SEP and gravity assists. The NIMPH projects first step in reducing landed mass focuses on development of a micro-In Situ Resource Utilization (micro-ISRU) system. ISRU allows us to minimize landed mass of a sample return mission by converting local ice into propellants. The project reduces the ISRU system to a CubeSat-scale package that weighs just 1.74 kg and consumes just 242 W of power. We estimate that use of this ISRU vs. an identical micro-lander without ISRU reduces fuel mass by 45 kg. As the dry mass of the lander grows for larger missions, these savings scale exponentially. Taking full advantage of the micro-ISRU system requires the development of a micro-liquid oxygen-liquid hydrogen engine. The micro-liquid oxygen-liquid hydrogen engine is tailored for the mission by scaling it to match the scale of the micro-lander and the low gravity of the target moon. We also tailor the engine for a near stoichiometric mixture ratio of 7.5. Most high-performance liquid oxygen-liquid hydrogen engines inject extra liquid hydrogen to lower the average molecular weight of the exhaust, which improves specific impulse. However, this extra liquid hydroden requires additional power and processing time on the surface for the ISRU to create. This increases mission cost, and on missions within high radiation environments such as Europa, increases radiation shielding mass. The resulting engine weighs just 1.36 kg and produces 71.5 newton of thrust at 364 s specific impulse. Finally, the mission reduces landed mass by taking advantage of the SEP modules solar power to beam energy to the surface using a collimated laser. This allows us to replace an 45 kg MMRTG with a 2.5 kg resonant array. By using the combination of ISRU, a liquid oxygen-liquid hydrogen engine, and beamed power, we reduce the initial mass of the lander to just 51.5 kg. When combined with an SEP module to ferry the lander to Europa the initial mission mass is just 6397 kg - low enough to be placed on an Earth escape trajectory using an Atlas V 551 launch vehicle. By comparison, we estimate a duplicate lander using an MMRTG and semi-storable propellants such as liquid oxygen-methane would result in an order of magnitude increase in initial lander mass to 445 kg. Attempting to perform the trajectory with a 450 s liquid oxygen-liquid hydrogen engine would increase initial mass to approximately 135,000 kg. Using an Atlas V 1 U.S. Dollar per kg rate to Earth escape value of $27.7k per kg, just the launch savings are over $3.5 billion.

liquid↗
NASA NTRS2009

Microfluidic Extraction of Biomarkers using Water as Solvent

A proposed device, denoted a miniature microfluidic biomarker extractor (mu-EX), would extract trace amounts of chemicals of interest from samples, such as soils and rocks. Traditionally, such extractions are performed on a large scale with hazardous organic solvents; each solvent capable of dissolving only those molecules lying within narrow ranges of specific chemical and physical characteristics that notably include volatility, electric charge, and polarity. In contrast, in the mu-EX, extractions could be performed by use of small amounts (typically between 0.1 and 100 L) of water as a universal solvent. As a rule of thumb, in order to enable solvation and extraction of molecules, it is necessary to use solvents that have polarity sufficiently close to the polarity of the target molecules. The mu-EX would make selection of specific organic solvents unnecessary, because mu-EX would exploit a unique property of liquid water: the possibility of tuning its polarity to match the polarity of organic solvents appropriate for extraction of molecules of interest. The change of the permittivity of water would be achieved by exploiting interactions between the translational states of water molecules and an imposed electromagnetic field in the frequency range of 300 to 600 GHz. On a molecular level, these interactions would result in disruption of the three-dimensional hydrogen-bonding network among liquid-water molecules and subsequent solvation and hydrolysis of target molecules. The mu-EX is expected to be an efficient means of hydrolyzing chemical bonds in complex macromolecules as well and, thus, enabling analysis of the building blocks of these complex chemical systems. The mu-EX device would include a microfluidic channel, part of which would lie within a waveguide coupled to an electronically tuned source of broad-band electromagnetic radiation in the frequency range from 300 to 600 GHz (see figure). The part of the microfluidic channel lying in the waveguide would constitute an interaction volume. The dimensions of the interaction volume would be chosen in accordance with the anticipated amount of solid sample material needed to ensure extraction of sufficient amount of target molecules for detection and analysis. By means that were not specified at the time of reporting the information for this article, the solid sample material would be placed in the interaction volume. Then the electromagnetic field would be imposed within the waveguide and water would be pumped through the interaction volume to effect the extraction.

Amashukeli, Xenia↗
NASA NTRS1988

Measurement of C-12, O-16, and Fe-56 charge changing cross sections in helium at high energy, comparison with cross sections in hydrogen, and application to cosmic-ray propagation

We present measurements of the spallation cross sections of carbon, oxygen, and iron in helium and hydrogen, at beam energies from 540 to 1600 MeV/nucleon, performed by exposing liquid helium, CH2, and C targets. Charge changing cross sections are reported for fragments down to Ne for Fe + alpha and Fe + p reactions, and down to B for O + alpha, O + p, C + alpha, and C + p reactions. Alpha- to p-induced cross section ratios (sigma(sub alpha)/sigma(sub p)) are determined at the same energy per nucleon. From these measurements an empirical formula for the (sigma(sub alpha)/sigma(sub p)) ratios is derived and is found in good agreement with available isotopic cross sections data from radioactivity and radiochemical techniques. These results are applied to the propagation of heavy charged cosmic rays in an interstellar medium with a helium to hydrogen abundance ratio of 0.10. It is shown that the Sc-Mn/Fe ratio prediction is decreased relative to the B/C ratio when compared to propagation calculations in a pure hydrogen interstellar medium.

Ferrando, P.↗
NASA NTRSDate not supplied

Advancement of Novel Additively Manufactured Alloys for Space Applications

NASA has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts have focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into development and flight applications. While many common aerospace alloys have been and continue to be a focus of ongoing development, the need for custom-alloy developments for high performance applications enabled by AM processes has been realized. The applications being targeted are liquid rocket engines with high heat fluxes, high pressure, and that utilize propellants such as hydrogen, which can degrade the alloy. NASA has recently focused on the development and advancement of novel alloy advancement using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, and JBK-75. These alloys have been evaluated using the laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. The results from these processes have demonstrated that AM can enable rapid development of new alloy systems that can yield higher performances. These alloys have undergone the fundamental metallurgical evaluations, heat treatment study, and microstructure characterization and mechanical testing campaign. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL). This presentation will provide a background and overview of these AM-enabled novel alloys, AM processing development including metallurgical and mechanical property studies. It will also cover the latest advancement in the parallel component development and testing and future developments. The goal of these alloy development is to allow for technology infusion into NASA and commercial spaceflight missions as well as to establish and sustain the needed commercial AM supply chain.

Additive Manufacturing↗
NASA NTRSDate not supplied

Advancement of Metal Additive Manufacturing Processes and Alloys for Rocket Propulsion Applications

NASA has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the 2000’s. Several efforts have focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into development and flight applications. While many common aerospace alloys have been and continue to be a focus of ongoing development, the need for custom-alloy developments for high performance applications enabled by various AM processes has been realized. The applications being targeted are liquid rocket engines with high heat fluxes, high pressure, and that utilize propellants such as hydrogen, which can degrade the alloy. NASA has recently focused on the development and advancement of novel alloy advancement using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, and JBK-75. These alloys have been evaluated using powder bed fusion (PBF), directed energy deposition (DED), and solid-state AM processes. The results from these processes have demonstrated that AM can enable rapid development of new alloy systems that can yield higher performances across various metal AM processes. These alloys have undergone the fundamental metallurgical evaluations, heat treatment study, and microstructure characterization and mechanical testing campaign. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL). This presentation will provide a background and overview of various AM-enabled novel alloys, a comparison across the AM processes, and development including metallurgical and mechanical property studies. It will also cover the latest advancement in the parallel component development and testing and future developments. The goal of these alloy development and use of various AM processes is to allow for technology infusion into NASA and commercial spaceflight missions as well as to establish and sustain the needed commercial AM supply chain.

Additive Manufacturing↗
NASA NTRSDate not supplied

Metal Additive Manufacturing Developments for Propulsion Applications

NASA has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the 2000’s. Several efforts have focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into development and flight applications. While many common aerospace alloys have been and continue to be a focus of ongoing development, the need for custom-alloy developments for high performance applications enabled by various AM processes has been realized. The applications being targeted are liquid rocket engines with high heat fluxes, high pressure, and that utilize propellants such as hydrogen, which can degrade the alloy. NASA has recently focused on the development and advancement of novel alloy advancement using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, and JBK-75. These alloys have been evaluated using powder bed fusion (PBF), directed energy deposition (DED), and solid-state AM processes. The results from these processes have demonstrated that AM can enable rapid development of new alloy systems that can yield higher performances across various metal AM processes. These alloys have undergone the fundamental metallurgical evaluations, heat treatment study, and microstructure characterization and mechanical testing campaign. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL). This presentation will provide a background and overview of various AM-enabled novel alloys, a comparison across the AM processes, and development including metallurgical and mechanical property studies. It will also cover the latest advancement in the parallel component development and testing and future developments. The goal of these alloy development and use of various AM processes is to allow for technology infusion into NASA and commercial spaceflight missions as well as to establish and sustain the needed commercial AM supply chain.

Additive Manufacturing↗
NASA NTRS1993

Semiempirical fragmentation models on galactic cosmic ray transport calculations with hydrogen target

Nuclear fragmentation cross sections of Silberberg and Tsao that are more accurate for a hydrogen target were implemented in the data base to replace those of Rudstam for a galactic cosmic ray transport code (HZETRN). Sample calculations were made for the transported galactic cosmic ray flux through a liquid hydrogen shield at solar minimum condition to determine the effect of such a change. The transported flux based on the Silberberg-Tsao semiempirical formalism contains fewer high-LET (linear energy transfer) components but more low-LET components than the results based on Rudstam's formalism: and this disparity deepens as the shield thickness increases. A comparison of the results obtained from using both energy-dependent and energy-independent cross sections of Silberberg and Tsao indicates that the energy-independent assumption results in an underestimation of high-LET flux above 100 keV/micron by approximately 40 percent for a 15-g/cm(sup 2) thickness of liquid hydrogen. Similar results were obtained in a previous study when both energy-dependent and energy-independent cross sections of Rudstam were considered. Nonetheless, the present study found that an energy-independent calculation would be best accomplished by using Rudstam's cross sections as done in the past for various engineering applications.

Shinn, Judy L.↗
NASA NTRS2022

Artemis I Countdown 101

Before the Artemis I mission launches on its way around the Moon, the launch team at Kennedy Space Center and supporting teams across the country will begin the launch countdown about two days before liftoff. The launch countdown contains "L Minus” and "T Minus" times. "L minus" indicates how far away we are from liftoff in hours and minutes and does not include built-in holds. “T minus” time is a sequence of events that are built into the launch countdown where counting and holds are inserted. The 730,000 gallons of propellants that will be loaded into the rocket are liquid oxygen (LO2) and liquid hydrogen (LH2). Pauses in the countdown, or "holds," are built into the countdown to allow the launch team to target a precise launch window, and to provide a cushion of time for certain tasks and procedures without impacting the overall schedule. For the Artemis I countdown, planned built-in holds vary in length and occur at the following times: L-8 hours, 40 minutes, and L-40 minutes.

Madison Elizabeth Tuttle↗
NASA NTRS1994

Uniform hydrogen fuel layers for inertial fusion targets by microgravity

A critical concern in the fabrication of targets for inertial confinement fusion (ICF) is ensuring that the hydrogenic (D(sub 2) or DT) fuel layer maintains spherical symmetry. Solid layered targets have structural integrity, but lack the needed surface smoothness. Liquid targets are inherently smooth, but suffer from gravitationally induced sagging. One method to reduce the effective gravitational field environment is freefall insertion into the target chamber. Another method to counterbalance field gravitational force is to use an applied magnetic field combined with a gradient field to induce a magnetic dipole force on the liquid fuel layer. Based on time dependent calculations of the dynamics of the liquid fuel layer in microgravity environments, we show that it may be possible to produce a liquid layered ICF target that satisfies both smoothness and symmetry requirements.

Parks, P. B.↗
NASA NTRS1982

Variable reluctance proximity sensors for cryogenic valve position indication

A test was conducted to determine the performance of a variable reluctance proximity sensor system when installed in a space shuttle external tank vent/relief valve. The sensors were used as position indicators. The valve and sensors were cycled through a series of thermal transients; while the valve was being opened and closed pneumatically, the sensor's performance was being monitored. During these thermal transients, the vent valve was cooled ten times by liquid nitrogen and two times by liquid hydrogen. It was concluded that the sensors were acceptable replacements for the existing mechanical switches. However, the sensors need a mechanical override for the target similar to what is presently used with the mechanical switches. This override could insure contact between sensor and target and eliminate any problems of actuation gap growth caused by thermal gradients.

Cloyd, R. A.↗
NASA NTRS2008

John F. Kennedy Space Center's Technology Development and Application 2006-2007 Report

Topics covered include: Reversible Chemochromic Hydrogen Detectors; Determining Trajectory of Triboelectrically Charged Particles, Using Discrete Element Modeling; Using Indium Tin Oxide To Mitigate Dust on Viewing Ports; High-Performance Polyimide Powder Coatings; Controlled-Release Microcapsules for Smart Coatings for Corrosion Applications; Aerocoat 7 Replacement Coatings; Photocatalytic Coatings for Exploration and Spaceport Design; New Materials for the Repair of Polyimide Electrical Wire Insulation; Commodity-Free Calibration; Novel Ice Mitigation Methods; Crack Offset Measurement With the Projected Laser Target Device; New Materials for Structural Composites and Protective Coatings; Fire Chemistry Testing of Spray-On Foam Insulation (SOFI); Using Aerogel-Based Insulation Material To Prevent Foam Loss on the Liquid-Hydrogen Intertank; Particle Ejection and Levitation Technology (PELT); Electrostatic Characterization of Lunar Dust; Numerical Analysis of Rocket Exhaust Cratering; RESOLVE Projects: Lunar Water Resource Demonstration and Regolith Volatile Characterization; Tribocharging Lunar Soil for Electrostatic Beneficiation; Numerically Modeling the Erosion of Lunar Soil by Rocket Exhaust Plumes; Trajectory Model of Lunar Dust Particles; Using Lunar Module Shadows To Scale the Effects of Rocket Exhaust Plumes; Predicting the Acoustic Environment Induced by the Launch of the Ares I Vehicle; Measuring Ultrasonic Acoustic Velocity in a Thin Sheet of Graphite Epoxy Composite; Hail Size Distribution Mapping; Launch Pad 39 Hail Monitor Array System; Autonomous Flight Safety System - Phase III; The Photogrammetry Cube; Bird Vision System; Automating Range Surveillance Through Radio Interferometry and Field Strength Mapping Techniques; Next-Generation Telemetry Workstation; GPS Metric Tracking Unit; and Space-Based Range.

Source record↗
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↗
NASA NTRS1990

Estimates of galactic cosmic ray shielding requirements during solar minimum

Estimates of radiation risk from galactic cosmic rays are presented for manned interplanetary missions. The calculations use the Naval Research Laboratory cosmic ray spectrum model as input into the Langley Research Center galactic cosmic ray transport code. This transport code, which transports both heavy ions and nucleons, can be used with any number of layers of target material, consisting of up to five different arbitrary constituents per layer. Calculated galactic cosmic ray fluxes, dose and dose equivalents behind various thicknesses of aluminum, water and liquid hydrogen shielding are presented for the solar minimum period. Estimates of risk to the skin and the blood-forming organs (BFO) are made using 0-cm and 5-cm depth dose/dose equivalent values, respectively, for water. These results indicate that at least 3.5 g/sq cm (3.5 cm) of water, or 6.5 g/sq cm (2.4 cm) of aluminum, or 1.0 g/sq cm (14 cm) of liquid hydrogen shielding is required to reduce the annual exposure below the currently recommended BFO limit of 0.5 Sv. Because of large uncertainties in fragmentation parameters and the input cosmic ray spectrum, these exposure estimates may be uncertain by as much as a factor of 2 or more. The effects of these potential exposure uncertainties or shield thickness requirements are analyzed.

Townsend, Lawrence W.↗
NASA NTRSDate not supplied

Maturation of Additive Manufactured Aerospace Alloys and Development of Mechanical and Thermophysical Properties for Space 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 have focused on the understanding of AM processes through design optimization, component fabrication, material characterization, testing, standards development, and infusion into propulsion development for flight applications. NASA and partners have matured commonly used aerospace alloys from various alloy families (Nickel, Steel, Iron, Aluminum, and Titanium) and AM processes. An extensive effort has been ongoing between NASA, industry partners, and academia to complete detailed AM process and heat treatment characterization, in addition to generating temperature-dependent mechanical and thermophysical properties. This presentation highlights the characterization and property results using laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes among various alloys. In addition to commonly used alloys, 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 launch vehicles, liquid rocket engines, advanced propulsion systems, advanced power systems, and in-space propulsion with high heat fluxes, high pressure, and that utilize propellants such as hydrogen, which can degrade alloys. This presentation will also discuss 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, and C-103. The results from these processes have demonstrated that AM can enable rapid development and new AM optimized alloys can yield higher performance. These alloys have undergone modeling, fundamental metallurgical evaluations, heat treatment studies, and microstructure characterization and mechanical testing campaigns. This, combined with direct application-specific component fabrication and hot-fire testing, can enable the increase of the Technology Readiness Level (TRL) through high duty-cycle testing. This presentation provides a background and overview of these various common and AM-enabled alloys and processing developments including the initial effort related to metallurgical, mechanical, and thermophysical property studies. It also covers the latest advancement in the parallel component development, hot-fire testing, and future developments for these alloys.

Additive Manufacturing↗