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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 NTRS2019

Channel Wall Nozzle Manufacturing Technology Advancements for Liquid Rocket Engines

A regeneratively-cooled nozzle is a critical component for expansion of the hot gases to enable high temperature and performance liquid rocket engines systems. Channel wall nozzles are a design solution used across the propulsion industry as a simplified method to fabricate the nozzle structure with internal coolant passages. The scale and complexity of the channel wall nozzle (CWN) design is challenging to fabricate leading to extended lead times and higher costs. Some of these challenges include: 1) unique and high temperature materials, 2) Tight tolerances during manufacturing and assembly to contain high pressure propellants, 3) thin-walled features to maintain adequate wall temperatures, and 4) Unique manufacturing process operations and tooling. The United States (U.S.) National Aeronautics and Space Administration (NASA) along with U.S. specialty manufacturing vendors are maturing modern fabrication techniques to reduce complexity and decrease costs associated with channel wall nozzle manufacturing technology. Additive Manufacturing (AM) is one of the key technology advancements being evaluated for channel wall nozzles. Much of additive manufacturing for propulsion components has focused on powder bed fusion, but the scale is not yet feasible for application to large scale nozzles. NASA is evolving directed energy deposition (DED) techniques for nozzles including arc-based deposition, blown powder deposition, and Laser Wire Direct Closeout (LWDC). There are different approaches being considered for fabrication of the nozzle and each of these DED processes offer unique process steps for rapid fabrication. The arc-based and blown powder deposition techniques are being used for the forming of the CWN liner. A variety of materials are being demonstrated including Inconel 625, Haynes 230, JBK-75, and NASA HR-1. The blown powder DED process is also being demonstrated for forming an integral channel nozzle in a single operation in similar materials. The LWDC process is a method for closing out the channels within the liner and forming the structural jacket using a localized laser wire deposition technique. Identical materials mentioned above have been used for this process in addition to bimetallic closeout (C-18150–SS347, and C-18150–Inconel 625). NASA has completed process development, material characterization, and hot-fire testing on a variety of these channel wall nozzle fabrication techniques. This paper will present an overview of the various processes and materials being evaluated and the results from the hot-fire testing. Future development and technology focus areas will also be discussed relative to channel wall nozzle manufacturing.

Gradl, Paul R.↗
NASA NTRS2020

Technology Advancements for Channel Wall Nozzle Manufacturing In Liquid Rocket Engines

A regeneratively-cooled or dump-cooled nozzle is a critical component for expansion of hot gases to enable high temperature and performance in liquid rocket engines systems. Regeneratively-cooled channel wall nozzles are a design solution used across the propulsion industry as a simplified method to fabricate the nozzle structure with internal coolant passages. The scale and complexity of the channel wall nozzle (CWN) design can be challenging to fabricate which results in extended lead times and higher costs. Some of these challenges include: 1) Unique and high temperature materials, 2) Tight tolerances on large parts during manufacturing and assembly to contain high pressure propellants, 3) Thin-walled features to maintain adequate wall temperatures, and 4) Unique manufacturing process operations and complex tooling. The United States (U.S.) National Aeronautics and Space Administration (NASA) and U.S. specialty manufacturing vendors are maturing modern fabrication techniques to reduce complexity and decrease costs associated with channel wall nozzle manufacturing technology. Additive Manufacturing (AM) is one of the key technology advancements under evaluation for channel wall nozzles. Much of additive manufacturing for propulsion components has focused on laser powder bed fusion (L-PBF), but the scale is not yet feasible for application to large scale nozzles. NASA is evolving directed energy deposition (DED) techniques for nozzles including arc-based deposition, blown powder deposition, and Laser Wire Direct Closeout (LWDC). There are different approaches being considered for fabrication of the nozzle, and each of these DED processes offer unique process steps for rapid fabrication. The arc-based and blown powder deposition techniques are used for the forming of the CWN liner. A variety of materials are being demonstrated including Inconel 625, Haynes 230, JBK-75, and NASA HR-1. The blown powder DED process is also being demonstrated for forming an integral channel nozzle in a single operation in similar materials. The LWDC process is a method for closing out the channels within the liner and forming the structural jacket using a localized laser wire deposition technique. Identical materials mentioned above have been used for this process in addition to bimetallic closeout (C-18150–SS347, and C-18150–Inconel 625). NASA has completed process development, material characterization, and hot-fire testing on a variety of these channel wall nozzle fabrication technique. This publication presents an overview of the various channel wall nozzle manufacturing processes and materials under evaluation including results from the hot-fire testing. Future development and technology focus areas is also discussed relative to channel wall nozzle manufacturing.

Additive manufacturing↗
NASA NTRS1994

Modeling near wall effects in second moment closures by elliptic relaxation

The elliptic relaxation model of Durbin (1993) for modeling near-wall turbulence using second moment closures (SMC) is compared to DNS data for a channel flow at Re(sub t) = 395. The agreement for second order statistics and even the terms in their balance equation is quite satisfactory, confirming that very little viscous effects (via Kolmogoroff scales) need to be added to the high Reynolds versions of SMC for near-wall-turbulence. The essential near-wall feature is thus the kinematic blocking effect that a solid wall exerts on the turbulence through the fluctuating pressure, which is best modeled by an elliptic operator. Above the transition layer, the effect of the original elliptic operator decays rapidly, and it is suggested that the log-layer is better reproduced by adding a non-homogeneous reduction of the return to isotropy, the gradient of the turbulent length scale being used as a measure of the inhomogeneity of the log-layer. The elliptic operator was quite easily applied to the non-linear Craft & Launder pressure-strain model yielding an improved distinction between the spanwise and wall normal stresses, although at higher Reynolds number (Re) and away from the wall, the streamwise component is severely underpredicted, as well as the transition in the mean velocity from the log to the wake profiles. In this area a significant change of behavior was observed in the DNS pressure-strain term, entirely ignored in the models.

Laurence, D.↗
NASA NTRS2014

Using Authentic Data to Facilitate Comparative Planetology & Student-led Classroom Investigations

This session will engage participants in a hands‐on activity that uses stunning NASA imagery from space to help participants gain an understanding of how scientists use Earth to gain a better understanding of other planetary bodies in the solar system. Participants will make observations, develop identification criteria, and use evidence to justify inferences made about processes sculpting the surface of different planetary worlds. Participants will also "build" a comparative planetology feature wall that will facilitate a comparative view of major geologic processes and features across the inner solar system. This session will highlight additional comparative planetology activities and demonstrate how the use of authentic data and imagery can help facilitate student‐led research in the classroom, helping teachers address the Next Generation Science Standards.

Graff, Paige↗
NASA NTRS1988

Empty test section streamlining of the transonic self-streamlining wind tunnel fitted with new walls

The original flexible top and bottom walls of the Transonic Self-Streamlining Wind Tunnel (TSWT), at the University of Southampton, have been replaced with new walls featuring a larger number of static pressure tappings and detailed mechanical improvements. This report describes the streamling method, results, and conclusions of a series of tests aimed at defining sets of aerodynamically straight wall contours for the new flexible walls. This procedure is a necessary prelude to model testing. The quality of data obtained compares favorably with the aerodynamically straight data obtained with the old walls. No operational difficulties were experienced with the new walls.

Lewis, M. C.↗
NASA NTRS2019

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

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

Gradl, Paul R.↗
NASA NTRS1984

Methods to recover the narrow Dicke sub-Doppler feature in evacuated wall-coated cells without restrictions on cell size

The hyperfine resonance observed in evacuated wall-coated cells with dimensions lambda/2 (lambda is the hyperfine resonance wavelength) consists of a narrow Dicke sub-Doppler linewidth feature, the spike, superimposed on a broad pedestal. The hydrogen maser provides a classic example of this lineshape. As cell size is increased, an effect unique to evacuated wall-coated cells occurs. Certain combinations of microwave field distribution and cell size result in a lineshape having a pedestal with a small spike feature or only the broad pedestal with no spike. Such conditions are not appropriate for atomic frequency standard applications. The cause of the evacuated wall-coated cell lineshape is reviewed and methods to recover the narrow spike feature without restrictions on cell size is discussed. One example is a cell with dimensions having equal volumes of exposure to opposite phases of the microwave magnetic field.

Robinson, H. G.↗
NASA NTRS1989

Hardware and operating features of the adaptive wall test section for the 0.3-meter transonic cryogenic tunnel

A 13- by 13-inch adaptive wall test section was installed in the Langley 0.3-Meter Transonic Cryogenic Tunnel circuit. This test section has four solid walls and is configured for two-dimensional airfoil testing. The top and bottom walls are flexible and movable, whereas the sidwalls are rigid and fixed. The test section has a turntable to support airfoil models, a survey mechanism to probe the model wake, and provisions for a sidewall boundary-layer-control system. Details of the adaptive wall test section, the tunnel circuit modifications, the supporting instrumentation, the monitoring and control hardware, and the wall adaptation strategy are discussed. Sample results of shakedown tests with the test section empty and with an airfoil installed are also included.

Mineck, Raymond E.↗
NASA NTRS2004

Multidimensional Unstructured-Grid Liquid Rocket Engine Nozzle Performance and Heat Transfer Analysis

The objective of this study is to conduct a unified computational analysis for computing design parameters such as axial thrust, convective and radiative wall heat fluxes for regeneratively cooled liquid rocket engine nozzles, so as to develop a computational strategy for computing those parameters through parametric investigations. The computational methodology is based on a multidimensional, finite-volume, turbulent, chemically reacting, radiating, unstructured-grid, and pressure-based formulation, with grid refinement capabilities. Systematic parametric studies on effects of wall boundary conditions, combustion chemistry, radiation coupling, computational cell shape, and grid refinement were performed and assessed. Under the computational framework of this study, it is found that the computed axial thrust performance, flow features, and wall heat fluxes compared well with those of available data and calculations, using a strategy of structured-grid dominated mesh, finite-rate chemistry, and cooled wall boundary condition.

Wang, Ten-See↗
NASA NTRS1978

Interior morphology of fresh Martian craters - The effects of target characteristics

The interior morphology of 183 fresh Martian craters observed on Viking imagery was studied. Freshness was determined by rim sharpness and continuity according to the scheme used to classify lunar and Mercurian craters. Results indicate that central-peak and wall degradation features are more common than previously thought. Central peaks are observed in craters as small as 2 km in diameter and in nearly all fresh craters with diameters greater than 10 km. Scallops or terraces are found to occur in all craters with diameters greater than 20 km, and wall slumping seems common in craters from 5 to 10 km in diameter. The ratio of crater diameter to crater floor diameter is significantly larger than for lunar craters. Central peaks and pits are more frequent in craters formed in cratered terrain than in those formed on plains; wall failure occurs at smaller diameters in plains craters. It is suggested that these peculiarities of crater interior morphologies may be due to a subsurface volatile layer. The influence of target variations on the interior morphologies observed in fresh craters was studied. Preliminary results indicate well-defined effects due to target differences.

Wood, C. A.↗
NASA NTRS2020

Design and Testing of an Ultra-Light Weight Perching System for Sloped or Vertical Rough Surfaces on Mars

In this paper, we present the design, characterization, and functional demonstration of a perching system that enables a flying vehicle to land on rough sloped or vertical surfaces. Steep slopes are of particular scientific interest since they are often associated with geologically interesting features including sites of active modification (e.g. landslides/avalanches, slope streaks), exposed bedrock and/or ice, and as-yet unmodified young features (e.g. walls of fresh craters or polar pits that are actively expanding). However the steep nature of these sites makes access with traditional field robots difficult: ground vehicles are unable to traverse the steep terrain and aerial vehicles are limited by their flight time and an ability to operate near terrain. We propose to address these limitation by enabling the UAV to reliably perch on steep terrain to perform in situ measurements and collect samples. Perching also enables a solar powered UAV to traverse large terrain features such as the Valles Marineris that could not be covered in a single flight by repeatedly perching and recharging its batteries. The proposed perching system that is being developed consists of a microspine gripper, a compliant gripper to vehicle interface, and a flying vehicle equipped with an autonomy sensor suite. The system also includes perception and control algorithms that identify perching targets and execute the required perching maneuver. To date, the majority of the effort has focused on developing and characterizing the microspine gripper. The initial prototype weighs 100 g, is capable of securely grasping a range of natural surfaces, and successful grasps support loads of over 10 N. Refinement of the gripper, integrating and testing it on a UAV, measuring aerodynamic distrubances from wall effects, and developing the required perception and control algorithms is ongoing. This paper describes the overall architecture of our proposed system, the design of the gripper, and its performance during initial testing.

Backus, Spencer↗
NASA NTRS2004

New Acoustic Arena Qualified at NASA Glenn's Aero-Acoustic Propulsion Laboratory

A new acoustic arena has been qualified in the Aero-Acoustic Propulsion Laboratory (AAPL) at the NASA Glenn Research Center. This arena is outfitted specifically for conducting fan noise research with the Advanced Noise Control Fan (ANCF) test rig. It features moveable walls with large acoustic wedges (2 by 2 by 1 ft) that create an acoustic environment usable at frequencies as low as 250 Hz. The arena currently uses two dedicated microphone arrays to acquire fan inlet and exhaust far-field acoustic data. It was used successfully in fiscal year 2003 to complete three ANCF tests. It also allowed Glenn to improve the operational efficiency of the four test rigs at AAPL and provided greater flexibility to schedule testing. There were a number of technical challenges to overcome in bringing the new arena to fruition. The foremost challenge was conflicting acoustic requirements of four different rigs. It was simply impossible to construct a static arena anywhere in the facility without intolerably compromising the acoustic test environment of at least one of the test rigs. This problem was overcome by making the wall sections of the new arena movable. Thus, the arena can be reconfigured to meet the operational requirements of any particular rig under test. Other design challenges that were encountered and overcome included structural loads of the large wedges, personnel access requirements, equipment maintenance requirements, and typical time and budget constraints. The new acoustic arena improves operations at the AAPL facility in several significant ways. First, it improves productivity by allowing multiple rigs to operate simultaneously. Second, it improves research data quality by providing a unique test area within the facility that is optimal for conducting fan noise research. Lastly, it reduces labor and equipment costs by eliminating the periodic need to transport the ANCF into and out of the primary AAPL acoustic arena. The investment to design, fabricate, and install the new compact arena in fiscal year 2002 has paid dividends in fiscal year 2003 and will for many years to come. It has provided a dedicated, high-quality acoustic arena to support low-speed fan testing for ANCF while minimizing scheduling impacts and improving operational productivity in the AAPL facility.

Wnuk, Stephen P.↗
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 NTRS1981

Design of an energy conservation building

The concepts in designing and predicting energy consumption in a low energy use building are summarized. The building will use less than 30,000 Btu/sq.ft./yr. of boarder energy. The building's primary energy conservation features include heavy concrete walls with external insulation, a highly insulated ceiling, and large amounts of glass for natural lighting. A solar collector air system is integrated into the south wall. Calculations for energy conservation features were performed using NASA's NECAP Energy Program.

Jensen, R. N.↗
NASA NTRS1977

Geology of the Valles Marineris - First Analysis of Imaging from the Viking 1 Orbiter Primary Mission

The Valles Marineris on the planet Mars constitute an enormous group of steep-walled equatorial canyons extending over an area more than 4000 km long and up to 700 km wide. An overview of Valles Marineris is provided, taking into account canyon system subdivisions, imaging and topographic data, Noctis Labyrinthus, western troughs, central troughs, east central troughs, and eastern canyons. Aspects of canyon wall and canyon floor morphology are discussed, giving attention to erosional features, layered rocks in canyon walls, tectonic features, plains, landslide deposits, hilly terrain, fractured floor, and floor plateaus and ridges. Upland pits and closed depressions in the canyons are considered along with regional tectonics and regional erosional styles.

Blasius, K. R.↗
NASA NTRS2016

Global Variations in Regolith Properties on Asteroid Vesta from Dawn's Low-Altitude Mapping Orbit

We investigate the depth, variability, and history of regolith on asteroid Vesta using data from the Dawn spacecraft. High-resolution (15-20 m pixel(sup -1)) Framing Cameraimages are used to assess the presence of morphologic indicators of a shallow regolith,including the presence of blocks in crater ejecta, spur-and-gully-type features in crater walls,and the retention of small (less than 300 m) impact craters. Such features reveal that the broad,regional heterogeneities observed on Vesta in terms of albedo and surface composition extend to the physical properties of the upper approx. 1 km of the surface. Regions of thin regolithare found within the Rheasilvia basin and at equatorial latitudes from approx. 0-90 deg. E and approx.260-360 deg. E. Craters in these areas that appear to excavate material from beneath the regolithhave more diogenitic (Rheasilvia, 090 deg. E) and cumulate eucrite (260-360 deg. E) compositions.A region of especially thick regolith, where depths generally exceed 1 km, is found from approx.100-240 deg. E and corresponds to heavily cratered, low-albedo surface with a basaltic eucritecomposition enriched in carbonaceous chondrite material. The presence of a thick regolithin this area supports the idea that this is an ancient terrain that has accumulated a larger component of exogenic debris. We find evidence for the gardening of crater ejecta towardmore howarditic compositions, consistent with regolith mixing being the dominant form of "weathering" on Vesta.

asteroid↗
NASA NTRSDate not supplied

Size Effects on Laser Powder Bed Fusion and Laser Powder Directed Energy Deposition GRCop-42 Alloy

Additive manufacturing (AM) plays a significant role in the fabrication of regeneratively cooled rocket engine combustion chambers, where internal channels are used to transport high pressure propellants to keep the engine from overheating. Cooling channels are designed with thin walls between the cooling and combustion sides, experiencing high thermal and mechanical stresses from large temperature gradients and internal pressures. Hence, selecting materials suited for this environment and maintaining a high-quality processing for this critical application is of utmost importance. GRCop-alloys (Cu-Cr-Nb) were developed as an ideal material for combustion chambers due to its high conductivity and high strength at temperature, being employed as a structural member for the hotwall with excellent heat transfer capabilities. GRCop-42 (Cu, 4 at% Cr, 2 at% Nb) has significantly matured using the Laser Powder Bed Fusion (L-PBF) process through microstructure, mechanical and thermophysical properties and evaluations using hot-fire testing. Additionally, Laser Powder Directed Energy Deposition (LP-DED) has demonstrated successful deposition and geometry samples using GRCop-42. While the maturation in properties has focused on bulk material properties from standard test specimens, these cannot be extrapolated to be used in thin walls, as different features (i.e., microstructure, porosity, and surface texture) have a greater effect on thin walls, especially on AM structures built using L-PBF and LP-DED. This presentation provides an overview of the effects introduced by reducing the thickness on the fabrication, microstructure, surface metrology and subsequent mechanical properties of GRCop-42 using L-PBF and LP-DED as well as future work planned for this research.

Gabriel Demeneghi↗