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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 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
NASA NTRS2023

Reactive Additive Manufacturing for Fourth Industrial Revolution Exploration Systems (Ramfire) Aluminum 6061-Ram2 Nozzle Testing

The NASA Marshall Space Flight Center (MSFC) has applied various forms of metallic additive manufacturing (AM) in liquid rocket engine component design, development, and testing since 2010. These AM techniques reduce hardware cost, shorten fabrication schedules, increase reliability by reducing the number of joints, and improve hardware performance by allowing unconventional design. The RAMFIRE project, funded under Space Technology Mission Directorate (STMD) Game Changing Development (GCD) Program, has furthered the use of novel AM liquid rocket nozzles in collaboration with Elementum 3D. The project advanced novel large-scale AM aluminum material technology for significant weight savings in rocket engines and launch vehicles. Previously, aluminum alloys were difficult to weld and print using additive manufacturing. Elementum 3D’s patented Aluminum 6061-RAM2 alloy allows for aluminum alloys to be printed using various AM techniques and at various scales. The alloy can be leveraged for welding wire, showing drastic improvements in aluminum weldability. The RAMFIRE project focuses on five key areas: 1) Laser Powder Directed Energy Deposition (LP-DED) AL6061-RAM2 feedstock specification and verification, 2) LP-DED process development and validation, 3) LP-DED printed AL6061-RAM2 microstructural and mechanical property characterization, 4) Hot-fire test a 7k-lbf thrust class regeneratively cooled nozzle, 5) Print large scale regeneratively cooled nozzle. Hot-fire testing demonstrates potential of advanced space technologies to NASA and potential users by providing the relevant environments to advance TRL levels to the 5/6 range.

Al6061-RAM2↗
NASA NTRSDate not supplied

Effect of Heat Treatment on the Microstructure and Mechanical Properties of Monel K500 Alloy Fabricated Via L-PBF and LP-DED

This study examines and compares the effect of different heat treatments (HT) on the microstructure and mechanical properties of Monel K500 fabricated using laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) technologies. The as-fabricated Monel K500 specimens exhibited dendritic microstructure and elemental micro-segregation due to high cooling rates induced during the fabrication process. The applicability of HT proposed in the literature for wrought Monel K500 was investigated for L-PBF and LP-DED using four different HT procedures involving hot isostatic pressing (HIP), solution annealing (SA), and aging. The mechanical properties of test specimens were evaluated using uniaxial tensile testing at room temperature. The microstructural evolution of test specimens during HT was analyzed using a scanning electron microscope. For all HT conditions investigated, L-PBF Monel K500 specimens consistently displayed higher strength and lower ductility compared to the LP-DED counterparts. The HT procedure involving HIP at 1160°C for 3hr at 100 MPa, SA at 1100°C for 15 min, and three step aging at 610°C for 16 hr, 540°C for 6 hr, and 480°C for 8 hr resulted in highest strength for both L-PBF and LP-DED fabricated Monel K500.

Additive manufacturing↗
NASA NTRS2024

Extreme Temperature Additively Manufactured GRX-810 Alloy Development and Hot-fire Testing for Liquid Rocket Engines

Additive manufacturing (AM) has revolutionized component design for liquid rocket engines by offering rapid manufacturing capabilities. This has led to significant opportunities for development and flight programs in the propulsion industry, resulting in cost and schedule savings, as well as performance improvements through new designs and alloy development. A noteworthy example is the GRX-810 oxide dispersion strengthened (ODS) alloy, which was specifically developed for extreme temperatures. This Ni-Co-Cr based alloy was created using integrated computational materials engineering (ICME) techniques to focus on a new class of materials with exceptional temperature and oxidation-resistant properties. The GRX-810 alloy utilizes AM processes to incorporate nano-scale yttria particles throughout its microstructure, resulting in remarkable enhancements. Compared to traditional Nickel-based superalloys, the GRX-810 alloy offers a two-fold increase in tensile strength, 1,000-fold better creep properties, and two-fold improvement in oxidation resistance. NASA successfully demonstrated the development and manufacturing of components using the GRX-810 alloy through laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Extensive efforts were made to model, evaluate metallurgical properties, develop heat treatment processes, characterize the microstructure, and determine mechanical properties. The GRX-810 alloy was specifically designed for aerospace applications, including liquid rocket engine injectors, preburners, turbines, and hot-section components, capable of withstanding temperatures up to 1,100 °C. The objective of this alloy development is to bridge the temperature gap between traditional Nickel-based superalloys and refractory alloys. This paper provides a comprehensive comparison of the GRX-810 alloy with other aerospace alloys, discussing its microstructure, mechanical properties, processing advancements, component development, and hot-fire testing results. The ultimate goal of this development was to elevate the Technology Readiness Level (TRL) of the GRX-810 alloy, enabling its integration into NASA and commercial aerospace applications.

GRX-810↗
NASA NTRS2024

Extreme Temperature Additively Manufactured GRX-810 Alloy Development and Hot-fire Testing for Liquid Rocket Engines

Additive manufacturing (AM) has revolutionized component design for liquid rocket engines by offering rapid manufacturing capabilities. This has led to significant opportunities for development and flight programs in the propulsion industry, resulting in cost and schedule savings, as well as performance improvements through new designs and alloy development. A noteworthy example is the GRX-810 oxide dispersion strengthened (ODS) alloy, which was specifically developed for extreme temperatures. This Ni-Co-Cr based alloy was created using integrated computational materials engineering (ICME) techniques to focus on a new class of materials with exceptional temperature and oxidation-resistant properties. The GRX-810 alloy utilizes AM processes to incorporate nano-scale yttria particles throughout its microstructure, resulting in remarkable enhancements. Compared to traditional Nickel-based superalloys, the GRX-810 alloy offers a two-fold increase in tensile strength, 1,000-fold better creep properties, and two-fold improvement in oxidation resistance. NASA successfully demonstrated the development and manufacturing of components using the GRX-810 alloy through laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Extensive efforts were made to model, evaluate metallurgical properties, develop heat treatment processes, characterize the microstructure, and determine mechanical properties. The GRX-810 alloy was specifically designed for aerospace applications, including liquid rocket engine injectors, preburners, turbines, and hot-section components, capable of withstanding temperatures up to 1,100 °C. The objective of this alloy development is to bridge the temperature gap between traditional Nickel-based superalloys and refractory alloys. This paper provides a comprehensive comparison of the GRX-810 alloy with other aerospace alloys, discussing its microstructure, mechanical properties, processing advancements, component development, and hot-fire testing results. The ultimate goal of this development was to elevate the Technology Readiness Level (TRL) of the GRX-810 alloy, enabling its integration into NASA and commercial aerospace applications.

GRX-810↗
NASA NTRSDate not supplied

Heat Treatment Optimization of Laser Powder Bed Fusion Additive Manufacture C103

Laser Powder Bed Fusion (L-PBF) and Laser Powder Directed Energy Deposition (LP-DED) additive manufacture C103 is in development for propulsion applications that operate under extreme environments. The standard post-process heat treatment has called for vacuum stress relief, however, depending on the application or certification requirements hot isostatic press (HIP) may be required. Although C103 density responds well to HIP the associated grain growth results in a reduction in mechanical properties. An investigation was conducted to look at the potential benefit of leveraging HIP followed by rapid cooling to minimize grain growth. A series of heat treatment schedules varying temperature and pressure were conducted followed by microstructural and mechanical characterization.

Additive Manufacturing↗
NASA NTRSDate not supplied

Experimental Characterization of Additively Manufactured Nickel-Titanium Shape Memory Alloy Heat Pipes

Shape memory alloys (SMA) have been identified for use in spacecraft components as replacement for conventional deployment mechanisms. They may be used in thermal management components such as radiators to create self-deploying radiators. One SMA, NiTi, has also been developed for additive manufacturing processes. Heat pipes are a common way to create highly effective and lightweight spaceflight radiators, and heat pipes can also be made from NiTi and related alloys. The wick is the critical element of a functioning heat pipe, and recent progress over the past years has led to the development of additively manufactured heat pipe wicks in various materials. The combination of these efforts is the focus of this project: creating an additively manufactured, shape memory alloy self-deploying heat pipe radiator. This paper will focus on the experimental characterization of these additively manufactured NiTi heat pipes. The heat pipe coupons were additively manufactured by direct metal laser sintering (DMLS), with an integral liquid cooled condenser. Heat is input to the heat pipe via a thin film heater. Thermocouples were spot welded to the heat pipes to measure temperature at several axial locations. The heat pipes were tested with two working fluids: water and ethanol. Ethanol is not an ideal working fluid for heat pipes but is useful in characterizing them because it wets well to a wide variety of surfaces. Water is in general a superior working fluid for heat pipes, but its contact angle and therefore wicking performance strongly depends on the surface chemistry of the surface it is in contact with. A particular measurement of interest in this test is the evaporator to condenser thermal conductance, which will be compared in the full paper to recently published correlations for additively manufactured heat pipes. Experimental results for two straight geometry and one bellows geometry heat pipe will be presented. The bellows geometry is of interest for condenser of the self-deploying radiator design.

Additive manufacturing↗
NASA NTRS2008

Range Imaging without Moving Parts

Range-imaging instruments of a type now under development are intended to generate the equivalent of three-dimensional images from measurements of the round-trip times of flight of laser pulses along known directions. These instruments could also provide information on characteristics of targets, including roughnesses and reflectivities of surfaces and optical densities of such semi-solid objects as trees and clouds. Unlike in prior range-imaging instruments based on times of flight along known directions, there would be no moving parts; aiming of the laser beams along the known directions would not be accomplished by mechanical scanning of mirrors, prisms, or other optical components. Instead, aiming would be accomplished by using solid-state devices to switch input and output beams along different fiber-optic paths. Because of the lack of moving parts, these instruments could be extraordinarily reliable, rugged, and long-lasting. An instrument of this type would include an optical transmitter that would send out a laser pulse along a chosen direction to a target. An optical receiver coaligned with the transmitter would measure the temporally varying intensity of laser light reflected from the target to determine the distance and surface characteristics of the target. The transmitter would be a combination of devices for generating precise directional laser illumination. It would include a pulsed laser, the output of which would be coupled into a fiber-optic cable with a fan-out and solid-state optical switches that would enable switching of the laser beam onto one or more optical fibers terminated at known locations in an array on a face at the focal plane of a telescope. The array would be imaged by the telescope onto the target space. The receiver optical system could share the aforementioned telescope with the transmitter or could include a separate telescope aimed in the same direction as that of the transmitting telescope. In either case, light reflected from the target would be focused by the receiver optical system onto an array of optical fibers matching the array in the transmitter. These optical fibers would couple the received light to one or more photodetector( s). Optionally, the receiver could include solid-state optical switches for choosing which optical fiber(s) would couple light to the photodetector(s). This instrument architecture is flexible and can be optimized for a wide variety of applications and levels of performance. For example, it is scalable to any number of pixels and pixel resolutions and is compatible with a variety of ranging and photodetection methodologies, including, for example, ranging by use of modulated (including pulsed and encoded) light signals. The use of fixed arrays of optical fibers to generate controlled illumination patterns would eliminate the mechanical complexity and much of the bulk of optomechanical scanning assemblies. Furthermore, digital control of the selection of the fiber-optic pathways for the transmitted beams could afford capabilities not seen in previous three-dimensional range-imaging systems. Instruments of this type could be specialized for use as, for example, proximity detectors, three-dimensional robotic vision systems, airborne terrain-mapping systems, and inspection systems.

Blair, J. Bryan↗
NASA NTRS1981

Solar-pumped gas laser development

The direct conversion of solar radiation into an inverted population for extraction in an optical cavity holds promise as a relatively simple system design. Broad-band photoabsorption in the visible or near-UV range is required to excite large volumes of gas and to ensure good solar absorption efficiency. The state excited must be a metastable state which is not quenched by the parent gas. The emission bandwidth must be less than approximately 10 A. The system should show chemical reversibility and an insensitivity to increasing temperature. Other properties such as good quantum efficiency and kinetic efficiency are also implied. A search of electronic-vibrational transitions in diatomic molecules satisfying these conditions is now in progress. A photodissociation-pumped atomic iodine laser is now being tested under solar pumping conditions. Photodissociation studies for thallium spin-flip metastable formation will begin in the near future.

Wilson, J. W.↗
NASA NTRS1999

Sensitive detection of Escherichia coli O157:H7 in food and water by immunomagnetic separation and solid-phase laser cytometry

Rapid, direct methods are needed to assess active bacterial populations in water and foods. Our objective was to determine the efficiency of bacterial detection by immunomagnetic separation (IMS) and the compatibility of IMS with cyanoditolyl tetrazolium chloride (CTC) incubation to determine respiratory activity, using the pathogen Escherichia coli O157:H7. Counterstaining with a specific fluorescein-conjugated anti-O157 antibody (FAb) following CTC incubation was used to allow confirmation and visualization of bacteria by epifluorescence microscopy. Broth-grown E. coli O157:H7 was used to inoculate fresh ground beef (<17% fat), sterile 0.1% peptone, or water. Inoculated meat was diluted and homogenized in a stomacher and then incubated with paramagnetic beads coated with anti-O157 specific antibody. After IMS, cells with magnetic beads attached were stained with CTC and then an anti-O157 antibody-fluorescein isothiocyanate conjugate and filtered for microscopic enumeration or solid-phase laser cytometry. Enumeration by laser scanning permitted detection of ca. 10 CFU/g of ground beef or <10 CFU/ml of liquid sample. With inoculated meat, the regression results for log-transformed respiring FAb-positive counts of cells recovered on beads versus sorbitol-negative plate counts in the inoculum were as follows: intercept = 1.06, slope = 0.89, and r2 = 0. 95 (n = 13). The corresponding results for inoculated peptone were as follows: intercept = 0.67, slope = 0.88, and r2 = 0.98 (n = 24). Recovery of target bacteria on beads by the IMS-CTC-FAb method, compared with recovery by sorbitol MacConkey agar plating, yielded greater numbers (beef, 6.0 times; peptone, 3.0 times; water, 2.4 times). Thus, within 5 to 7 h, the IMS-CTC-FAb method detected greater numbers of E. coli O157 cells than were detected by plating. The results show that the IMS-CTC-FAb technique with enumeration by either fluorescence microscopy or solid-phase laser scanning cytometry gave results that compared favorably with plating following IMS.

Non-NASA Center↗
NASA NTRS1973

Gasdynamic lasers and photon machines.

The basic operational highlights of CO2-N2 gasdynamic lasers (GDL's) are described. Features common to powerful gas lasers are indicated. A simplified model of the vibrational kinetics of the system is presented, and the importance of rapid expansion nozzles is shown from analytic solutions of the equations. A high-power pulsed GDL is described, along with estimations of power extraction. A closed-cycle laser is suggested, leading to a description of a photon generator/engine. Thermodynamic analysis of the closed-cycle laser illustrates in principle the possibility of direct conversion of laser energy to work.

Christiansen, W. H.↗
NASA NTRS1985

Microprocessor-Controlled Laser Balancing System

Material removed by laser action as part tested for balance. Directed by microprocessor, laser fires appropriate amount of pulses in correct locations to remove necessary amount of material. Operator and microprocessor software interact through video screen and keypad; no programing skills or unprompted system-control decisions required. System provides complete and accurate balancing in single load-and-spinup cycle.

Demuth, R. S.↗
NASA NTRS2005

Ultrafast Laser Beam Switching and Pulse Train Generation by Using Coupled Vertical-Cavity, Surface-Emitting Lasers (VCSELS)

Ultrafast directional beam switching is achieved using coupled VCSELs. This approach is demonstrated to achieve beam switching frequencies of 40 GHz and more and switching directions of about eight degrees. This switching scheme is likely to be useful for ultrafast optical networks at frequencies much higher than achievable with other approaches.

Peter M Goorjian↗
NASA NTRS1978

Systems efficiency and specific mass estimates for direct and indirect solar-pumped closed-cycle high-energy lasers in space

Based on expected advances in technology, the maximum system efficiency and minimum specific mass have been calculated for closed-cycle CO and CO2 electric-discharge lasers (EDL's) and a direct solar-pumped laser in space. The efficiency calculations take into account losses from excitation gas heating, ducting frictional and turning losses, and the compressor efficiency. The mass calculations include the power source, radiator, compressor, fluids, ducting, laser channel, optics, and heat exchanger for all of the systems; and in addition the power conditioner for the EDL's and a focusing mirror for the solar-pumped laser. The results show the major component masses in each system, show which is the lightest system, and provide the necessary criteria for solar-pumped lasers to be lighter than the EDL's. Finally, the masses are compared with results from other studies for a closed-cycle CO2 gasdynamic laser (GDL) and the proposed microwave satellite solar power station (SSPS).

Monson, D. J.↗
NASA NTRS1981

A solar simulator-pumped atomic iodine laser

An atomic iodine laser, a candidate for the direct solar-pumped gas laser, was excited with a 4-kW beam from a xenon arc solar simulator. Continuous lasing at 1.315 micron for over 10 ms was obtained for static filling of n-C3F7I vapor. By momentarily flowing the lasant, a 30-Hz pulsed output was obtained for about 200 ms. The peak laser power observed was 4 W for which the system efficiency reached 0.1%. These results indicate that direct solar pumping of a gas laser for power conversion in space is indeed feasible.

Lee, J. H.↗
NASA NTRS1991

Laser-induced stimulated Raman scattering in the forward direction of a droplet - Comparison of Mie theory with geometrical optics

This paper uses Mie theory to treat electromagnetic scattering and to evaluate field enhancement in the forward direction of a small droplet irradiated by a high-energy beam and compares the results of calculations with the field-enhancement evaluation obtained via geometrical optics treatment. Results of this comparison suggest that the field enhancement located at the critical ring region encircling the axis in the forward direction of the droplet can support laser-induced Raman scattering. The results are supported by experimental observations of the interaction of a 120-micron-diam water droplet with a high-energy Nd:YAG laser beam.

Srivastava, Vandana↗
NASA NTRS1978

Semiclassical theory of unimolecular dissociation induced by a laser field

A semiclassical nonperturbative theory of direct photodissociation in a laser field is developed in which photon absorption and dissociation are treated in a unified fashion. This is achieved by visualizing nuclear dynamics as a representative particle moving on electronic-field surfaces. Methods are described for calculating dissociation rates and probabilities by Monte Carlo selection of initial conditions and integration of classical trajectories on these surfaces. This unified theory reduces to the golden rule expression in the weak-field and short-time limits, and predicts nonlinear behavior, i.e., breakdown of the golden rule expression in intense fields. Field strengths above which lowest-order perturbation theory fails to work have been estimated for some systems. Useful physical insights provided by the electronic-field representation have been illustrated. Intense field effects are discussed which are amenable to experimental observation. The semiclassical methods used here are also applicable to multiple-surface dynamics in fieldfree unimolecular and bimolecular reactions.

Yuan, J.-M.↗
NASA NTRS2003

Theodolite with CCD Camera for Safe Measurement of Laser-Beam Pointing

The simple addition of a charge-coupled-device (CCD) camera to a theodolite makes it safe to measure the pointing direction of a laser beam. The present state of the art requires this to be a custom addition because theodolites are manufactured without CCD cameras as standard or even optional equipment. A theodolite is an alignment telescope equipped with mechanisms to measure the azimuth and elevation angles to the sub-arcsecond level. When measuring the angular pointing direction of a Class ll laser with a theodolite, one could place a calculated amount of neutral density (ND) filters in front of the theodolite s telescope. One could then safely view and measure the laser s boresight looking through the theodolite s telescope without great risk to one s eyes. This method for a Class ll visible wavelength laser is not acceptable to even consider tempting for a Class IV laser and not applicable for an infrared (IR) laser. If one chooses insufficient attenuation or forgets to use the filters, then looking at the laser beam through the theodolite could cause instant blindness. The CCD camera is already commercially available. It is a small, inexpensive, blackand- white CCD circuit-board-level camera. An interface adaptor was designed and fabricated to mount the camera onto the eyepiece of the specific theodolite s viewing telescope. Other equipment needed for operation of the camera are power supplies, cables, and a black-and-white television monitor. The picture displayed on the monitor is equivalent to what one would see when looking directly through the theodolite. Again, the additional advantage afforded by a cheap black-and-white CCD camera is that it is sensitive to infrared as well as to visible light. Hence, one can use the camera coupled to a theodolite to measure the pointing of an infrared as well as a visible laser.

Crooke, Julie A.↗