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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 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
NASA NTRS1989

Capabilities of wind tunnels with two-adaptive walls to minimize boundary interference in 3-D model testing

An initial wind tunnel test was made to validate a new wall adaptation method for 3-D models in test sections with two adaptive walls. First part of the adaptation strategy is an on-line assessment of wall interference at the model position. The wall induced blockage was very small at all test conditions. Lift interference occurred at higher angles of attack with the walls set aerodynamically straight. The adaptation of the top and bottom tunnel walls is aimed at achieving a correctable flow condition. The blockage was virtually zero throughout the wing planform after the wall adjustment. The lift curve measured with the walls adapted agreed very well with interference free data for Mach 0.7, regardless of the vertical position of the wing in the test section. The 2-D wall adaptation can significantly improve the correctability of 3-D model data. Nevertheless, residual spanwise variations of wall interference are inevitable.

Rebstock, Rainer↗
NASA NTRS1989

Corrections to the thin wall approximation in general relativity

The question is considered whether the thin wall formalism of Israel applies to the gravitating domain walls of a lambda phi(exp 4) theory. The coupled Einstein-scalar equations that describe the thick gravitating wall are expanded in powers of the thickness of the wall. The solutions of the zeroth order equations reproduce the results of the usual Israel thin wall approximation for domain walls. The solutions of the first order equations provide corrections to the expressions for the stress-energy of the wall and to the Israel thin wall equations. The modified thin wall equations are then used to treat the motion of spherical and planar domain walls.

Garfinkle, David↗
NASA NTRS1994

A wall interference assessment/correction system

A Wall Signature method originally developed by Hackett has been selected to be adapted for the Ames 12-ft Wind Tunnel WIAC system in the project. This method uses limited measurements of the static pressure at the wall, in conjunction with the solid wall boundary condition, to determine the strength and distribution of singularities representing the test article. The singularities are used in turn for estimating wall interference at the model location. The development and implementation of a working prototype will be completed, delivered and documented with a software manual. The WIAC code will be validated by conducting numerically simulated experiments rather than actual wind tunnel experiments. The simulations will be used to generate both free-air and confined wind-tunnel flow fields for each of the test articles over a range of test configurations. Specifically, the pressure signature at the test section wall will be computed for the tunnel case to provide the simulated 'measured' data. These data will serve as the input for the WIAC method--Wall Signature method. The performance of the WIAC method then may be evaluated by comparing the corrected parameters with those for the free-air simulation. The following two additional tasks are included: (1) On-line wall interference calculation: The developed wall signature method (modified Hackett's method) for Ames 12-ft Tunnel will be the pre-computed coefficients which facilitate the on-line calculation of wall interference, and (2) Support system effects estimation: The effects on the wall pressure measurements due to the presence of the model support systems will be evaluated.

Lo, C. F.↗
NASA NTRS1999

A Generalized Wall Function

The asymptotic solutions, described by Tennekes and Lumley (1972), for surface flows in a channel, pipe or boundary layer at large Reynolds numbers are revisited. These solutions can be extended to more complex flows such as the flows with various pressure gradients, zero wall stress and rough surfaces, etc. In computational fluid dynamics (CFD), these solutions can be used as the boundary conditions to bridge the near-wall region of turbulent flows so that there is no need to have the fine grids near the wall unless the near-wall flow structures are required to resolve. These solutions are referred to as the wall functions. Furthermore, a generalized and unified law of the wall which is valid for whole surface layer (including viscous sublayer, buffer layer and inertial sublayer) is analytically constructed. The generalized law of the wall shows that the effect of both adverse and favorable pressure gradients on the surface flow is very significant. Such as unified wall function will be useful not only in deriving analytic expressions for surface flow properties but also bringing a great convenience for CFD methods to place accurate boundary conditions at any location away from the wall. The extended wall functions introduced in this paper can be used for complex flows with acceleration, deceleration, separation, recirculation and rough surfaces.

Shih, Tsan-Hsing↗
NASA NTRS2000

Thermocapillary Flow and Aggregation of Bubbles on a Solid Wall

During the electrolytic evolution of oxygen bubbles forming on a vertically oriented transparent tin oxide electrode, bubbles were found to be mutually attractive. The mechanism of the aggregation had never been explained satisfactorily until Guelcher et al. attributed it to thermocapillary flow. The gradient of surface tension of the liquid at the bubble's surface, which was established because of reaction heat and ohmic heat loss at the electrode wall, drives flow of the liquid adjacent to each bubble; the bubble "pumps" fluid along its surface away from the wall. Fluid flows toward the bubble to conserve mass and entrains nearby bubbles in the flow pattern. The same logic would apply when two bubbles of equal size are adjacent to each other on a warm wall. Each bubble drives thermocapillary flow and hence entrains the other in its flow pattern, which drives the aggregation. Our objective here is to perform experiments where the temperature gradient at the wall is well known and controlled. The theory can be quantitatively tested by studying aggregation of bubble pairs of equal size, and by varying system parameters such as temperature gradient, bubble size and fluid viscosity. The results are then compared with the theory in a quantitatively rigorous manner. We demonstrate that the theory without adjustable parameters is capable of quantitatively modeling the rate of aggregation of two bubbles. The equations governing the thermocapillary flow around a single stationary bubble on a heated or cooled wall in a semi-infinite domain were solved. Both Reynolds number and Marangoni number were much less than unity. The critical result is that liquid in the vicinity of a warm wall flows toward a stationary collector bubble. Consequently the thermocapillary flow around the stationary bubble entrains another bubble toward itself. The bubbles undergo hindered translation parallel to the wall with velocity U while the fluid flow field is described with u. Two velocities were equated by using a wall hindrance parameter q: U = qu [1] which shows the velocity of bubble is proportional to the entraining velocity. The hindrance parameter q can experimentally be measured independently. q can also be calculated by solving the equations of motion for a bubble translating parallel to a solid wall. The experimental cell is cylindrical with an ID of 10 cm and consists of a 1 cm deep main cell filled with silicone oil and flanked by two thermal reservoirs. The upper thermal reservoir was heated and the lower thermal reservoir was cooled so that the bubbles aggregate. Two types of silicone oil (eta = 0.02 and 0.50 Pa s) were used. Two equal sized air bubbles were injected into the cell with a syringe. The center-to-center distance of bubbles was observed through a microscope. Bubble radius ranged from 0.40 mm to 0.65 mm and the temperature gradients along with the cell ranged from 1400 to 5000 K/m. The bubbles aggregated when heat flows from the wall to the fluid. The velocities of bubbles were in the range of 1 - 10 microns/s. The separation r decreased more quickly when the temperature gradient was higher, bubble size was larger, and the oil viscosity was lower. r decreased more rapidly as the bubbles approached each other. Dimensionless time was arbitrarily set to be zero when the dimensionless center-to-center distance between the bubbles was 4. All the bubble trajectories fall onto one line, especially in the range of dimensionless distance from 4 to 3. This means the relative movement of the bubble pair is proportional to the temperature gradient and bubble size and it is inversely proportional to the viscosity of the oil. This result strongly suggests that the thermocapillary flow-based aggregation mechanism is correct. A value of q can be estimated by fitting the scaled data to Eq. [1]. A best fit value of q was obtained as q = 0.26 with a standard deviation of 0.03. Independent experimental results for q for a 0.5 mm radius bubble, give values of q in the range 0.11 to 0.23. The value of q obtained from solving the equations of motion reveals q has values in the range 0.23 - 0.30. Since the full scale of possible values of q is zero to one, the maximum deviation of independently determined values of q from the best fit value was 15% of this full scale. Thus reasonable quantitative agreement between theory and experiment has been obtained.

Kasumi, Hiroki↗
NASA NTRS2003

Temperature modulates the cell wall mechanical properties of rice coleoptiles by altering the molecular mass of hemicellulosic polysaccharides

The present study was conducted to investigate the mechanism inducing the difference in the cell wall extensibility of rice (Oryza sativa L. cv. Koshihikari) coleoptiles grown under various temperature (10-50 degrees C) conditions. The growth rate and the cell wall extensibility of rice coleoptiles exhibited the maximum value at 30-40 degrees C, and became smaller as the growth temperature rose or dropped from this temperature range. The amounts of cell wall polysaccharides per unit length of coleoptile increased in coleoptiles grown at 40 degrees C, but not at other temperature conditions. On the other hand, the molecular size of hemicellulosic polysaccharides was small at temperatures where the cell wall extensibility was high (30-40 degrees C). The autolytic activities of cell walls obtained from coleoptiles grown at 30 and 40 degrees C were substantially higher than those grown at 10, 20 and 50 degrees C. Furthermore, the activities of (1-->3),(1-->4)-beta-glucanases extracted from coleoptile cell walls showed a similar tendency. When oat (1-->3),(1-->4)-beta-glucans with high molecular mass were incubated with the cell wall enzyme preparations from coleoptiles grown at various temperature conditions, the extensive molecular mass downshifts were brought about only by the cell wall enzymes obtained from coleoptiles grown at 30-40 degrees C. There were close correlations between the cell wall extensibility and the molecular mass of hemicellulosic polysaccharides or the activity of beta -glucanases. These results suggest that the environmental temperature regulates the cell wall extensibility of rice coleoptiles by modifying mainly the molecular mass of hemicellulosic polysaccharides. Modulation of the activity of beta-glucanases under various temperature conditions may be involved in the alteration of the molecular size of hemicellulosic polysaccharides.

Cellulose/chemistry/metabolism↗
NASA NTRS2005

CFD Code Validation of Wall Heat Fluxes for a G02/GH2 Single Element Combustor

This paper puts forth the case for the need for improved injector design tools to meet NASA s Vision for Space Exploration goals. Requirements for this improved tool are outlined and discussed. The potential for Computational Fluid Dynamics (CFD) to meet these requirements is noted along with its current shortcomings, especially relative to demonstrated solution accuracy. The concept of verification and validation is introduced as the primary process for building and quantifying the confidence necessary for CFD to be useful as an injector design tool. The verification and validation process is considered in the context of the Marshall Space Flight Center (MSFC) Combustion Devices CFD Simulation Capability Roadmap via the Simulation Readiness Level (SRL) concept. The portion of the validation process which demonstrates the ability of a CFD code to simulate heat fluxes to a rocket engine combustor wall is the focus of the current effort. The FDNS and Loci-CHEM codes are used to simulate a shear coaxial single element G02/GH2 injector experiment. The experiment was conducted a t a chamber pressure of 750 psia using hot propellants from preburners. A measured wall temperature profile is used as a boundary condition to facilitate the calculations. Converged solutions, obtained from both codes by using wall functions with the K-E turbulence model and integrating to the wall using Mentor s baseline turbulence model, are compared to the experimental data. The initial solutions from both codes revealed significant issues with the wall function implementation associated with the recirculation zone between the shear coaxial jet and the chamber wall. The FDNS solution with a corrected implementation shows marked improvement in overall character and level of comparison to the data. With the FDNS code, integrating to the wall with Mentor s baseline turbulence model actually produce a degraded solution when compared to the wall function solution with the K--E model. The Loci-CHEM solution, produced by integrating to the wall with Mentor s baseline turbulence model, matches both the heat flux rise rate in the near injector region and the peak heat flux level very well. However, it moderately over predicts the heat fluxes downstream of the reattachment point. The Loci-CHEM solution achieved by integrating to the wall with Mentor s baseline turbulence model was clearly superior to the other solutions produced in this effort.

Lin, Jeff↗
NASA NTRS2005

Navier-Stokes Computations With One-Equation Turbulence Model for Flows Along Concave Wall Surfaces

This report presents the use of a time-marching three-dimensional compressible Navier-Stokes equation numerical solver with a one-equation turbulence model to simulate the flow fields developed along concave wall surfaces without and with a downstream extension flat wall surface. The 3-D Navier- Stokes numerical solver came from the NASA Glenn-HT code. The one-equation turbulence model was derived from the Spalart and Allmaras model. The computational approach was first calibrated with the computations of the velocity and Reynolds shear stress profiles of a steady flat plate boundary layer flow. The computational approach was then used to simulate developing boundary layer flows along concave wall surfaces without and with a downstream extension wall. The author investigated the computational results of surface friction factors, near surface velocity components, near wall temperatures, and a turbulent shear stress component in terms of turbulence modeling, computational mesh configurations, inlet turbulence level, and time iteration step. The computational results were compared with existing measurements of skin friction factors, velocity components, and shear stresses of the developing boundary layer flows. With a fine computational mesh and a one-equation model, the computational approach could predict accurately the skin friction factors, near surface velocity and temperature, and shear stress within the flows. The computed velocity components and shear stresses also showed the vortices effect on the velocity variations over a concave wall. The computed eddy viscosities at the near wall locations were also compared with the results from a two equation turbulence modeling technique. The inlet turbulence length scale was found to have little effect on the eddy viscosities at locations near the concave wall surface. The eddy viscosities, from the one-equation and two-equation modeling, were comparable at most stream-wise stations. The present one-equation turbulence model is an effective approach for turbulence modeling in the near solid wall surface region of flow over a concave wall.

Wang, Chi R.↗
NASA NTRS2015

Validation of a Node-Centered Wall Function Model for the Unstructured Flow Code FUN3D

In this paper, the implementation of two wall function models in the Reynolds averaged Navier-Stokes (RANS) computational uid dynamics (CFD) code FUN3D is described. FUN3D is a node centered method for solving the three-dimensional Navier-Stokes equations on unstructured computational grids. The first wall function model, based on the work of Knopp et al., is used in conjunction with the one-equation turbulence model of Spalart-Allmaras. The second wall function model, also based on the work of Knopp, is used in conjunction with the two-equation k-! turbulence model of Menter. The wall function models compute the wall momentum and energy flux, which are used to weakly enforce the wall velocity and pressure flux boundary conditions in the mean flow momentum and energy equations. These wall conditions are implemented in an implicit form where the contribution of the wall function model to the Jacobian are also included. The boundary conditions of the turbulence transport equations are enforced explicitly (strongly) on all solid boundaries. The use of the wall function models is demonstrated on four test cases: a at plate boundary layer, a subsonic di user, a 2D airfoil, and a 3D semi-span wing. Where possible, different near-wall viscous spacing tactics are examined. Iterative residual convergence was obtained in most cases. Solution results are compared with theoretical and experimental data for several variations of grid spacing. In general, very good comparisons with data were achieved.

Carlson, Jan-Renee↗
NASA NTRSDate not supplied

Evaluation of Wall-Modeled Les for Flow Over A Multi-Element Airfoil

We perform wall-modeled large-eddy simulations (WMLES) of turbulent flow over a 30P30N multielement airfoil at various angles of attack to assess its ability to accurately predict lift using an unstructured node-based finite-volume methodology. The flow conditions are based on the experiments reported in Klausmeyer & Lin [NASA /TM-112858]. The oncoming flow Mach number is 0.2, and the stowed chord-based Reynolds number (𝑅𝑒𝑐) is 9 million. The angle of attack (𝛼) is varied between 8◦ and 23◦ with the expected stall angle of around 21◦. The simulated geometry is periodic in the span, thus any three-dimensional effects present in the experiment are ignored. We first analyze the predictions with baseline isotropic and anisotropic grids containing over 16 grid points per boundary-layer thickness. The near-wall streamwise/nominal spacing ratio is 0.4 at the leading/trailing edges of the slat, main element and flap, and 1 elsewhere, and the first wall-normal/nominal spacing ratio is 0.375 over most of the airfoil for the anisotropic grid, while these are unity for the isotropic grid. It is found that the predicted lift and wall pressures, near-wall velocity profiles, and the location of onset of resolved turbulence are sensitive to the near-wall grid anisotropy. Further sensitivities were explored at lower angles of attack by independently varying the streamwise and wall-normal grid anisotropies. The effects of both off-wall and near-wall grid refinement were also quantified. For the grid resolutions used here, our results suggest that the first wall-normal spacing, which coincides with the WMLES exchange location, has a dominant effect on the predictions for this flow configuration.

Computational Fluid Dynamics↗
DOE OSTI2020

Wall Upgrades for Deep Energy Savings in Residential Buildings: Interim Results from a Multi-Year Study

The Pacific Northwest National Laboratory, Oak Ridge National Laboratory and the University of Minnesota are conducting a three-year, multipart study on residential retrofit wall assemblies. The project is funded by the U.S. Department of Energy’s Building Technology Office and will identify, test and verify wall assemblies for hygrothermal performance in retrofit applications. The study includes a comprehensive literature review and expert advisory group, which inform wall selection. Selected wall assemblies are then thermally simulated using EnergyPlus and THERM, and hygrothermally simulated using WUFI, to model both thermal and moisture performance of the wall assembly. Eight wall assemblies are then experimentally tested in an in-situ laboratory environment at the University of Minnesota, with a typical residential wall used as a baseline. The in-situ experiment looks at the physical hygrothermal performance of each assembly. The simulation and experimental results will be combined with an economic analysis to produce a techno-economic study of residential wall systems for deep energy retrofits. This paper presents progress after year one of the study. Wall system modeling and laboratory testing is scheduled to begin in November, 2019. We will discuss the parameters for wall selection and experimental design, which includes approaches to modeling and simulation, along with the physical experiment design. This paper will also outline the parameters for the techno-economic analysis, and criteria used to inform model development.

Antonopoulos, Chrissi A.↗
DOE OSTI2020

Cellulose synthase interactive1- and microtubule-dependent cell wall architecture is required for acid growth in Arabidopsis hypocotyls

Auxin-induced cell elongation relies in part on the acidification of the cell wall, a process known as acid growth that presumably triggers expansin-mediated wall loosening via altered interactions between cellulose microfibrils. Cellulose microfibrils are a major determinant for anisotropic growth and they provide the scaffold for cell wall assembly. Little is known about how acid growth depends on cell wall architecture. To explore the relationship between acid growth-mediated cell elongation and plant cell wall architecture, two mutants (jia1-1 and csi1-3) that are defective in cellulose biosynthesis and cellulose microfibril organization were analyzed. The study revealed that cell elongation is dependent on CSI1-mediated cell wall architecture but not on the overall crystalline cellulose content. We observed a correlation between loss of crossed-polylamellate walls and loss of auxin- and fusicoccin-induced cell growth in csi1-3. Furthermore, induced loss of crossed-polylamellate walls via disruption of cortical microtubules mimics the effect of csi1 in acid growth. We hypothesize that CSI1- and microtubule-dependent crossed-polylamellate walls are required for acid growth in Arabidopsis hypocotyls.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2020

Theory and Practice in Measuring In-Vitro Extensibility of Growing Plant Cell Walls

This chapter summarizes four extensometer techniques for measuring cell wall extensibility in vitro and discusses how the results of these methods relate to the concept and ideal measurement of cell wall extensibility in the context of plant cell growth. These in-vitro techniques are particularly useful for studies of the molecular basis of cell wall extension. Measurements of breaking strength, elastic compliance and plastic compliance may be informative about changes in cell wall structure, whereas measurements of wall stress relaxation and creep are sensitive to both changes in wall structure and wall-loosening processes, such as those mediated by expansins and some lytic enzymes. As a result, a combination of methods is needed to obtain a broader view of cell wall behavior and properties connected with the concept of cell wall extensibility.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Burst pressure models and validations for thick-walled pipelines containing corrosion defects

Corrosion is one major threat to pipeline integrity. Over the past decades, many corrosion models have been developed for determining the remaining strength of corroded pipelines, including ASME B31.G, Modified B31.G, LPC, PCORRC and their modified models. All these corrosion models are applicable only to large diameter, thin-walled pipelines with a diameter to wall thickness ratio D/t ≥ 20. In practice, many pipelines have a small diameter and thick wall with a D/t ratio < 20, and thus an adequate corrosion model is needed for assessing remaining strength for corroded thick-walled pipelines. This paper briefly reviews the theoretical burst pressure models for defect-free thin and thick-walled pipelines and four representative corrosion assessment models for thin-walled corroded pipelines. On this basis, two modified corrosion models are proposed to thick-walled pipelines in terms of the average shear stress yield theory. To verify the proposed corrosion models, comprehensive validations are performed. Numerical validations include the elastic-plastic finite element analysis to determine burst pressure for pipelines without and with corrosion defects and the model evaluation using a large dataset of available FEA results of burst pressure for machined defects. Experimental validations include a set of burst pressure tests for defect-free thick-walled pipes with different thicknesses and the model evaluation using one large burst dataset for machined defects with flat bottoms and another large dataset for real corrosion defects with curved river bottom profiles. Both numerical and experimental validations show that the proposed corrosion models can more accurately predict the remaining strength for corroded thin and thick-walled pipelines.

Pipeline↗
DOE OSTI2023

Structure and growth of plant cell walls

Plant cells build nanofibrillar walls that are central to plant growth, morphogenesis and mechanics. Starting from simple sugars, three groups of polysaccharides, namely, cellulose, hemicelluloses and pectins, with very different physical properties are assembled by the cell to make a strong yet extensible wall. Here, this Review describes the physics of wall growth and its regulation by cellular processes such as cellulose production by cellulose synthase, modulation of wall pH by plasma membrane H + -ATPase, wall loosening by expansin and signalling by plant hormones such as auxin and brassinosteroid. In addition, this Review discusses the nuanced roles, properties and interactions of cellulose, matrix polysaccharides and cell wall proteins and describes how wall stress and wall loosening cooperatively result in cell wall growth.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2023

Numerical Investigation of Wall-Cooling Effect on Aero-Optical Distortions for Hypersonic Boundary Layer

Compressible wall-modeled large-eddy simulations of Mach 8 turbulent boundary-layer flows over a flat plate were carried out for the conditions of the hypersonic wind tunnel at Sandia National Laboratories. The simulations provide new insight into the effect of wall cooling on the aero-optical path distortions for hypersonic turbulent boundary-layer flows. Four different wall-to-recovery temperature ratios, 0.3, 0.48, 0.71, and 0.89, are considered. Despite the much lower grid resolution, the mean velocity, temperature, and resolved Reynolds stress profiles from the simulation for a temperature ratio of 0.48 are in good agreement with those from a reference direct numerical simulation. The normalized root-mean-square optical path difference obtained from the present simulations is compared with that from reference direct numerical simulations, Sandia experiments, as well as predictions obtained with a semi-analytical model by Notre Dame University. Here the present analysis focuses on the effect of wall cooling on the wall-normal density correlations, on key underlying assumptions of the aforementioned model such as the strong Reynolds analogy, and on the elevation angle effect on the optical path difference. Wall cooling is found to increase the velocity fluctuations and decrease the density fluctuations, resulting in an overall reduction of the normalized optical path distortion. Compared to the simulations, the basic strong Reynolds analogy overpredicts the temperature fluctuations for cooled walls. Also different from the strong Reynolds analogy, the velocity and temperature fluctuations are not perfectly anticorrelated. Finally, as the wall temperature is raised, the density correlation length, away from the wall but inside the boundary layer, increases significantly for beam paths tilted in the downstream direction.

42 ENGINEERING↗
DOE OSTI2022

The regulation of the cell wall by glycosylphosphatidylinositol-anchored proteins in Arabidopsis

A polysaccharides-based cell wall covers the plant cell, shaping it and protecting it from the harsh environment. Cellulose microfibrils constitute the cell wall backbone and are embedded in a matrix of pectic and hemicellulosic polysaccharides and glycoproteins. Various environmental and developmental cues can regulate the plant cell wall, and diverse glycosylphosphatidylinositol (GPI)-anchored proteins participate in these regulations. GPI is a common lipid modification on eukaryotic proteins, which covalently tethers the proteins to the membrane lipid bilayer. Catalyzed by a series of enzymic complexes, protein precursors are post-translationally modified at their hydrophobic carboxyl-terminus in the endomembrane system and anchored to the lipid bilayer through an oligosaccharidic GPI modification. Ultimately, mature proteins reach the plasma membrane via the secretory pathway facing toward the apoplast and cell wall in plants. In Arabidopsis, more than three hundred GPI-anchored proteins (GPI-APs) have been predicted, and many are reported to be involved in diverse regulations of the cell wall. In this review, we summarize GPI-APs involved in cell wall regulation. GPI-APs are proposed to act as structural components of the cell wall, organize cellulose microfibrils at the cell surface, and during cell wall integrity signaling transduction. Besides regulating protein trafficking, the GPI modification is potentially governed by a GPI shedding system that cleaves and releases the GPI-anchored proteins from the plasma membrane into the cell wall.

59 BASIC BIOLOGICAL SCIENCES↗
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↗