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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 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 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 NTRS2018

Electrostatic Levitation for Studies of Additive Manufacturing Materials for Extreme Environments

The electrostatic levitation (ESL) laboratory at NASA's Marshall Space Flight Center (MSFC) is a national resource for researchers developing advanced materials for new technologies. Researchers have used MSFC's ESL Laboratory to develop advanced high-temperature materials for aerospace applications, coatings and structural materials for rocket nozzles, improved medical and industrial optics, metallic glasses, ablatives for reentry vehicles, and materials with memory. Modeling of additive manufacturing materials for extreme environments is necessary for the control of their resulting materials properties. Unfortunately, there is very little materials properties data for many additive manufacturing materials, especially of the materials in the liquid state. The MSFC ESL lab is ideal for the study of additive manufacturing materials to be used in extreme environments. The lab can provide density, surface tension, and viscosity of molten materials, emissivity measurements, and even creep strength measurements.

SanSoucie, Michael↗
NASA NTRS2018

Overview of Heatshield for Extreme Entry Environment Technology (HEEET) Engineering Test Unit (ETU) Manufacturing and Integration

The Heatshield for Extreme Entry Environment Technology (HEEET) projects objective is to mature a 3-D Woven Thermal Protection System (TPS) to Technical Readiness Level (TRL) 6 to support future NASA missions to destinations such as Venus and Saturn. A key aspect of the project has been the development of the manufacturing and integration processes/procedures necessary to build a heat shield utilizing the HEEET 3D-woven material. This has culminated in the building of a 1meter diameter Engineering Test Unit (ETU) representative of what would be used for a Saturn probe. This presentation will provide an overview of the manufacturing and integration processes utilized to build the ETU, with a focus on the seam design. The seam design represented the most challenging aspect of the HEEET development, given the aerothermal and structural requirements it needs to meet.

Thermal Protection System↗
NASA NTRSDate not supplied

Extreme Environment Hot Fire Durability of Post-Processed Additively Manufactured GRCop-Alloy Combustion Chambers in LOX/Hydrogen and LOX/Methane

Extreme environment survivability of metal additive manufactured (AM) GRCop-alloy thrust chambers has been demonstrated in different bi-propellants at near stoichiometric and even oxygen rich combustion. GRCop-alloy chambers tested at NASA Marshall Space Flight Center (MSFC) have accumulated over 26,000 seconds of hot fire duration and over 500 starts. These chambers are produced using an AM process called laser powder bed fusion (L-PBF). A major feature of this process is high wall surface roughness which can be customized in post processing to leverage various performance advantages. Post-processing can include heat treatment, final machining, polishing, and welding and is key to hardware survivability in extreme environments. Surface finish enhancement techniques were applied to the hot wall and coolant channels to reduce the overall total heat load to the chamber walls. Performance optimization of various thrust class TCA’s is a strategic technology goal of NASA MSFC. Three different chamber geometries using cryogenic methane and de-ionized water as coolants were hot fire tested to obtain their life cycle, pressure drop, and heat load performances. Several 1.2K lbf LOX/H2 chambers, 1K lbf LOX/CH4 chambers, and 7K lbf LOX/CH4 chambers were tested. All post-processed configurations performed remarkably well when subjected to extreme hot fire test conditions. Streaking and blanching due to localized oxygen rich conditions were observed on some test articles in their as-built surface finish state. However, this is actually a function of the injector mixing and only serves to further establish the durability of L-PBF GRCop-alloy thrust chambers. Several different polishing techniques were applied to the hot wall and integrated coolant channels prior to hot fire testing and their performances assessed. Overall, AM produced GRCop chambers are extremely reliable, durable, and customizable to the desired performance metrics.

grcop↗
NASA NTRS2017

Diamond-Dispersed Fiber-Reinforced Composite for Superior Friction and Wear Properties in Extreme Environments and Method for Fabricating the Same

Systems, methods, and articles of manufacture related to composite materials are discussed herein. These materials can be based on a mixture of diamond particles with a matrix and fibers or fabrics. The matrix can be formed into the composite material through optional pressurization and via heat treatment. These materials display exceptionally low friction coefficient and superior wear resistance in extreme environments.

Street, Kenneth↗
NASA NTRS1976

Space Shuttle Main Propulsion System

The Space Shuttle Main Propulsion System provides the impulse to transfer the reusable Orbiter of the Space Shuttle Transportation system and its payload from earth to earth orbit. Both cryogenic and solid rocket propulsion systems are utilized. The selected systems are characterized by (1) reusability wherever possible to reduce program cost, (2) design pressures, and other important design parameters, for the liquid propellant engine significantly higher than past programs for increased performance, and (3) advanced materials and manufacturing processes to withstand the extreme environments. The approaches for solution of these varied problems are emphasized.

Wood, C. C.↗
NASA NTRSDate not supplied

Development and Manufacture of A Proof-of-Concept Magnetically-Geared Actuator for Use in Extremely Cold Lunar Environments

A magnetically-geared actuator is being developed for extremely cold space environments to avoid the wiring and significant efficiency penalty associated with heating grease-lubricated actuators as well as the stringent life and loading constraints imposed by dry film lubricated mechanical gears. This paper describes the lessons learned while designing, manufacturing, and assembling a proof-of-concept prototype similar to the preliminary design of the actuator.

lunar surface↗
NASA NTRS2023

Development and Manufacture of A Proof-of-Concept Magnetically-Geared Actuator for Use in Extremely Cold Lunar Environments

A magnetically-geared actuator is being developed for extremely cold space environments to avoid the wiring and significant efficiency penalty associated with heating grease-lubricated actuators as well as the stringent life and loading constraints imposed by dry film lubricated mechanical gears. This paper describes the lessons learned while designing, manufacturing, and assembling a proof-of-concept prototype similar to the preliminary design of the actuator.

lunar surface↗
NASA NTRSDate not supplied

NASA LSII Lunar Simulant Project

Introduction: America has entered a new era of exploration. NASA’s Artemis program will lead humanity forward to the Moon and prepare us for the next giant leap, the exploration of Mars [1]. To champion technologies needed to live on and explore the Moon, NASA’s Space Technology Mission Directorate (STMD) established the Lunar Surface Innovation Initiative (LSII)[2].LSII's technology development portfolio includes: Utilizing the Moon’s resources; Establishing sustainable surface power; Building machinery and electronics that work in extreme environments, like super-chilly permanently shadowed craters; Mitigating lunar dust; Carrying out surface excavation, manufacturing and construction duties; and Extreme access which includes navigating and exploring the surface/subsurface. To support the development and testing of these technologies, LSII created the lunar simulant project, to create and/or acquire low-, medium-and high-fidelity lunar simulants to match the needs of STMD projects at all levels of technology readiness levels (TRL), as well as other NASA programs. There is not one bulk lunar simulant that will satisfy the needs of all projects. NASA's Approach to Simulants: Just as LSII's activities are being implemented through a combination of unique NASA work and public-private partnerships, NASA will work with commercial simulant providers to acquire simulants that meet NASA's needs. If warranted, NASA will develop simulants using government agencies, as was done with the NASA/USGS Lunar Highlands Type (NU-LHT)series of lunar simulants [3].NASA is also collaborating with the Johns Hopkins University Applied Physics Laboratory(JHUAPL) Lunar Surface Innovation Consortium (LSIC) in the development and characterization of lunar simulants [4]. Within NASA, a small team (< 10 people) is coordinating simulant activities across the agency, with team members located at several NASA centers. The overall objective of the project is to procure lunar simulants in sufficient amounts for earth-based testing of subsystems and systems in a variety of environments (i.e., laboratory, high-bay, thermal-vacuum chambers), required for Artemis missions to the Moon, as well as other missions carrying NASA lunar payloads, such as the Commercial Lunar Payload Services (CLPS)program [5]. Lunar Highlands Simulant: NASA's Artemis Program is targeting the lunar south pole region for initial human missions and the Artemis Base Camp. Hence, the LSII lunar simulant project is currently focusing on the mineralogy and properties of lunar highlands regolith [6 and 7]. Plagioclase-rich rocks (e.g., anorthosite, norite) are the dominant constituent in highlands simulants, with Shawmere, Stillwater, and White Mountain anorthosites being used in commercially available simulants. However, because these feedstocks are terrestrial in nature, they include hydrated minerals, carbon-bearing minerals, and other chemical signatures that are not present on the Moon, and these minor mineral assemblages need to be taken into account when trying to understand test procedures and results. Glass Component: While much attention has been placed on the rock/mineral component of lunar simulants, glass is just as important when creating simulants. The glass component in lunar regoliths is often greater than 50% by volume [8]. This component includes impact melt glass, dark matrix breccias, and agglutinates. However, this component is difficult, time-consuming and expensive to make. Most lunar simulants, past and current, have relied on basaltic cinder as a feedstock for glass. Getting better glass components at a lower cost, particularly agglutinates and glass with an anorthositic composition is a near-term objective that the NASA simulant project is trying to address . Characterization: It is extremely important for lunar simulants to be characterized by several analytical methods. Gruener et al. [9] and JHUAPL LSIC [10] conducted initial assessments of some of the commercially available simulants in 2019 and early 2020, before the global pandemic. Further analyses are needed to better quantify important parameters such as, modal mineralogy and glass content, particle shape, and particle size distribution. These quantified results can then be used in determining figures of merit (FOM) that show how well simulants compare to lunar regolith [11 and 12].

J E Gruener↗
NASA NTRS2019

Ablators for Human and Robotic Exploration of the Moon, Mars and Beyond

When Apollo was designed to carry astronauts safely back from the Moon, at return speeds exceeding 11 km/s, it required development of a new lightweight ablative material to protect the capsule and crew from the intense heat of entry. Soon after the Apollo program, successful Mars Viking Lander missions employed a different and much lighter ablator in more benign entry conditions. On the other hand, the Pioneer-Venus and Galileo Probe missions that followed required yet another ablative system, to manage the extreme heating at those destinations, which was like flying a ballistic missile nose tip into a thermonuclear explosion. NASA had to invent a new heat-shield concept based on the rocket nozzle and ballistic missile ablative materials. In the mid 1990's, as the Science focus returned to Mars, advances in manufacturing, testing and materials technology led to innovative lightweight ablators that enabled comet and asteroid sample return missions and facilitated large lander missions such as MSL and Mars 2020. NASA's current plans for robotic and human exploration of the Moon, Mars and beyond introduce different constraints and new expectations for ablators. Human missions to Moon and Mars, sample return missions from Mars, and exploration of Uranus and Neptune, the two planets we are yet to explore, will require ablators that can withstand extreme environments, with verifiable robustness, and with raw materials and manufacturing approaches that are sustainable in the longer term. This talk will review the history of ablators as well as current ablative TPS development that addresses the requirements for future missions to Moon, Mars and beyond.

Mars and Beyond↗
NASA NTRS1970

Testing of brazed and welded connections of stainless-steel tubing

Test procedures and results are given for three types of semipermanent sleeve-type connections for stainless-steel tubing. Subject to the limited resistances to corrosion and vibration, all three types are found to be suitable for extremes in reliability and environment, if given close control during manufacture.

Cahill, J. B.↗
NASA NTRS2021

Analysis of Arc Welding Process in Space

This work is motivated by NASA plans to conduct welding experiments on the ISS. It is expected that deployment of welding and additive manufacturing technologies in the space environment has the potential to revolutionise how orbiting platforms are designed, manufactured, and assembled. However, the structure, composition and quality of a weld is extremely dependent on the environment and can be difficult to control in space. Shielding gases would also be tough to manage as gases behave differently in zero gravity and airless environments. Additional points of concern are related to the spatter and sparks dynamics in space. Therefore, there is a need for a more basic understanding of welding processes by computational modelling. To provide such an insight we developed state of art models of the ARC torch, droplet detachment and transfer, and the melt pool build up using magnetohydrodynamics approximation and level set method for two-phase liquid metal/-gas flow modelling. Two finite element models were built using 2D axisymmetric geometry in COMSOL Multiphysics®: (i) stationary model of the ARC torch and (ii) dynamical model of droplet detachment and transfer. Both models demonstrate reasonable agreement with earlier experimental observations and high sensitivity to the temperature dependence of the thermophysical parameters on the system materials. The models were used to provide physical insight into ARC welding in various environments and geometries. It was shown, in particular, that there is a significant probability of gas bubbles trapping in the meltpool and a possibility of unbounded wondering of sparks in the welding chamber in zero gravity. In addition, we estimated metal evaporation rate that may be hazardous in the confined environment of the ISS. These issues raise concern of quality of the weld and safety for ISS applications.

ARC welding↗
NASA NTRSDate not supplied

Welding in Space: Past, Present, and Future

It has been over fifty years since the first welds were made in space by Soviet cosmonauts on Soyuz-6 in October of 1969. The United States performed bead-on-plate welding, brazing, and metal melting experiments onboard the Skylab orbital space station several years later in 1973. Finally, Soviet cosmonauts departed their Salyut-7 capsule and made the first (and last) welds in open space in 1984. Progress on further demonstrations of welding in space stagnated, and subsequent microgravity welding research work shifted to lower-cost earth-based experiments that include drop towers and parabolic flights. With the advent of the International Space Station, relevant microgravity research was undertaken in the field of metal solidification science, and limited studies of brazing and soldering were undertaken; however, no welds have ever been on the Space Station. Therefore, it has been almost 40 years since a weld was made in space. Much like terrestrial construction and manufacturing industries, welding, joining, and allied processes will be enabling technologies for In-space Assembly and Manufacturing (ISAM) in the nascent “Space Economy”, a sector that is expected to approach a value of 10^12 USD within the next decade. It is critical that the welding and joining research community, along with the welding industry, engages the space industry to advance the understanding of those critical manufacturing processes which must be evaluated and matured in the extreme environments of space. Such environments include variable gravity (microgravity in low earth orbit, 0.17 gravity on the lunar surface, and 0.38 gravity on the martian surface), reduced pressure (extreme vacuum in space and the lunar surface to a predominantly CO2 atmosphere on Mars), and extreme temperatures (between 40 and 400 K). Past experiments and analyses are reviewed to suggest requirements that the welding and joining community should target to make strides on closing the current space welding gaps. Efforts to continue welding in space are currently underway at NASA in conjunction with academia and industry. Those are explored along with future agency goals which are seen as opportunities to engage the welding community on this historic effort.

in-space assembly and manufacturing↗