Results for “technology readiness level” — Page 17

NASA NTRS2007

The Autonomous Precision Landing and Hazard Detection and Avoidance Technology (ALHAT)

As NASA plans to send humans back to the Moon and develop a lunar outpost, technologies must be developed to place humans and cargo safely, precisely, repeatedly, on the lunar surface with the capability to avoid surface hazards. Exploration Space Architecture Study requirements include the need for global lunar surface access with safe, precise landing without lighting constraints on terrain that may have landing hazards for human scale landing vehicles. Landing accuracies of perhaps 1,000 meters for sortie crew missions to 10 s of meters for Outpost class missions are required. The Autonomous precision Landing Hazard Avoidance Technology (ALHAT) project will develop the new and unique descent and landing Guidance, Navigation and Control (GNC) hardware and software technologies necessary for these capabilities. The ALHAT project will qualify a lunar descent and landing GNC system to a Technology Readiness Level (TRL) of 6 capable of supporting lunar crewed, cargo, and robotic missions. The (ALHAT) development project was chartered by NASA Headquarters in October 2006. The initial effort to write a project plan and define an ALHAT Team was followed by a fairly aggressive research and analysis effort to determine what technologies existed that could be developed and applied to the lunar landing problems indicated above. This paper describes the project development, research, analysis and concept evolution that has occurred since the assignment of the project. This includes the areas of systems engineering, GNC, sensors, sensor algorithms, simulations, fielding testing, laboratory testing, Hardware-In-The-Loop testing, system avionics and system certification concepts.

Epp, Chirold D.↗

NASA NTRSDate not supplied

Bypass Duct Acoustic Liner Design With and Without Bifurcation Effects

The growth in air traffic and the commitment to sustainable aviation continue to provide new challenges to reducing aircraft noise levels. Acoustic liner design methodologies must therefore provide the capability to efficiently predict the acoustic benefits of novel liner configurations within complex aircraft nacelle geometries. With these observations in mind, a broadband acoustic liner optimization process has been developed and assessed through a series of design and experimental studies at increasing technology readiness levels. This work applies the design process to the aft-fan noise component and explores the effects of bypass duct bifurcations (e.g., the pylon and lower bifurcation). In addition to this new application, the design study is expanded to include the use of a commercially available duct propagation code. Despite the different general workflow for the two propagation codes, consistent optimized impedance spectra and in-duct attenuation predictions were obtained for several acoustic treatment options. The preliminary results are promising, and this work increases confidence in the enhanced broadband liner design methodology and lays the groundwork for complimentary use of the codes in future studies. The potential benefits of acoustic treatment on the upper and lower bifurcations are also demonstrated. The knowledge gained through this preliminary stage of the liner design process will be used to guide the identification of candidate liner designs for a proposed static engine test within the next year.

Acoustic Liner Design↗

NASA NTRSDate not supplied

Bypass Duct Acoustic Liner Design with and without Bifurcation Effects

The growth in air traffic and the commitment to sustainable aviation continue to provide new challenges to reducing aircraft noise levels. Acoustic liner design methodologies must therefore provide the capability to efficiently predict the acoustic benefits of novel liner configurations within complex aircraft nacelle geometries. With these observations in mind, a broadband acoustic liner optimization process has been developed and assessed through a series of design and experimental studies at increasing technology readiness levels. This work applies the design process to the aft-fan noise component and explores the effects of bypass duct bifurcations (e.g., the pylon and lower bifurcation). In addition to this new application, the design study is expanded to include the use of a commercially available duct propagation code. Despite the different general workflow for the two propagation codes, consistent optimized impedance spectra and in-duct attenuation predictions were obtained for several acoustic treatment options. The preliminary results are promising, and this work increases confidence in the enhanced broadband liner design methodology and lays the groundwork for complimentary use of the codes in future studies. The potential benefits of acoustic treatment on the upper and lower bifurcations are also demonstrated. The knowledge gained through this preliminary stage of the liner design process will be used to guide the identification of candidate liner designs for a proposed static engine test within the next year.

Acoustic Liner Design↗

NASA NTRSDate not supplied

Deformable Mirror Technology Roadmap: Architecting A Path to TRL5 for Future Exoplanet Direct Imaging Space Missions

The Deformable Mirror Technology Roadmap (DMTR) is a working group tasked by NASA’s Exoplanet Program Office to study the path to bring deformable mirror (DM) systems to a Technology Readiness Level 5. DMs, and their drive electronics and harnessing, are the critical component of any exoplanet direct imaging coronagraph, and there is no device that exists today which can meet the ambitious performance goals expected for NASA’s Habitable Worlds Observatory (HWO). Here we present progress on surveying the field of DM technologies, defining a first cut set of device requirements, and recommending a development and verification maturation program.

Tyler D. Groff↗

NASA NTRSDate not supplied

Advancement of Novel Additively Manufactured Alloys for Space Applications

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

Additive Manufacturing↗

NASA NTRS2008

The NASA Evolutionary Xenon Thruster (NEXT): NASA's Next Step for U.S. Deep Space Propulsion

NASA s Evolutionary Xenon Thruster (NEXT) project is developing next generation ion propulsion technologies to enhance the performance and lower the costs of future NASA space science missions. This is being accomplished by producing Engineering Model (EM) and Prototype Model (PM) components, validating these via qualification-level and integrated system testing, and preparing the transition of NEXT technologies to flight system development. The project is currently completing one of the final milestones of the effort, that is operation of an integrated NEXT Ion Propulsion System (IPS) in a simulated space environment. This test will advance the NEXT system to a NASA Technology Readiness Level (TRL) of 6 (i.e., operation of a prototypical system in a representative environment), and will confirm its readiness for flight. Besides its promise for upcoming NASA science missions, NEXT may have excellent potential for future commercial and international spacecraft applications.

Schmidt, George R.↗

NASA NTRS2016

High Data Rate Architecture (HiDRA)

One of the greatest challenges in developing new space technology is in navigating the transition from ground based laboratory demonstration at Technology Readiness Level 6 (TRL-6) to conducting a prototype demonstration in space (TRL-7). This challenge is com- pounded by the relatively low availability of new spacecraft missions when compared with aeronautical craft to bridge this gap, leading to the general adoption of a low-risk stance by mission management to accept new, unproven technologies into the system. Also in consideration of risk, the limited selection and availability of proven space-grade components imparts a severe limitation on achieving high performance systems by current terrestrial technology standards. Finally from a space communications point of view the long duration characteristic of most missions imparts a major constraint on the entire space and ground network architecture, since any new technologies introduced into the system would have to be compliant with the duration of the currently deployed operational technologies, and in some cases may be limited by surrounding legacy capabilities. Beyond ensuring that the new technology is verified to function correctly and validated to meet the needs of the end users the formidable challenge then grows to additionally include: carefully timing the maturity path of the new technology to coincide with a feasible and accepting future mission so it flies before its relevancy has passed, utilizing a limited catalog of available components to their maximum potential to create meaningful and unprecedented new capabilities, designing and ensuring interoperability with aging space and ground infrastructures while simultaneously providing a growth path to the future. The International Space Station (ISS) is approaching 20 years of age. To keep the ISS relevant, technology upgrades are continuously taking place. Regarding communications, the state-of-the-art communication system upgrades underway include high-rate laser terminals. These must interface with the existing, aging data infrastructure. The High Data Rate Architecture (HiDRA) project is designed to provide networked store, carry, and forward capability to optimize data flow through both the existing radio frequency (RF) and new laser communications terminal. The networking capability is realized through the Delay Tolerant Networking (DTN) protocol, and is used for scheduling data movement as well as optimizing the performance of existing RF channels. HiDRA is realized as a distributed FPGA memory and interface controller that is itself controlled by a local computer running DTN software. Thus HiDRA is applicable to other arenas seeking to employ next-generation communications technologies, e.g. deep space. In this paper, we describe HiDRA and its far-reaching research implications.

DTN↗

NASA NTRS2009

A Study on Advanced Lithium-Based Battery Cell Chemistries to Enhance Lunar Exploration Missions

NASA's Exploration Technology Development Program (ETDP) Energy Storage Project conducted an advanced lithium-based battery chemistry feasibility study to determine the best advanced chemistry to develop for the Altair lunar lander and the Extravehicular Activities (EVA) advanced lunar surface spacesuit. These customers require safe, reliable energy storage systems with extremely high specific energy as compared to today's state-of-the-art batteries. Based on customer requirements, the specific energy goals for the development project are 220 watt-hours per kilogram (Wh/kg) delivered at the battery level at 0 degrees Celsius (degrees Celcius) at a C/10 discharge rate. Continuous discharge rates between C/5 and C/2, operation over 0 to 30 degrees C, and 200 cycles are targeted. The team, consisting of members from NASA Glenn Research Center, Johnson Space Center, and Jet Propulsion laboratory, surveyed the literature, compiled information on recent materials developments, and consulted with other battery experts in the community to identify advanced battery materials that might be capable of achieving the desired results with further development. A variety of electrode materials were considered, including layered metal oxides, spinel oxides, and olivine-type cathode materials, and lithium metal, lithium alloy, and silicon-based composite anode materials. lithium-sulfur systems were also considered. Hypothetical cell constructs that combined compatible anode and cathode materials with suitable electrolytes, separators, current collectors, headers, and cell enclosures were modeled. While some of these advanced materials are projected to obtain the desired electrical performance, there are risks that also factored into the decision making process. The risks include uncertainties due to issues such as safety of a system containing some of these materials, ease of scaling-up of large batches of raw materials, adaptability of the materials to processing using established or reasonable cost manufacturing techniques, manufacturability of the materials in dimensions required for integration into battery cells of practical capacities, low Technology Readiness levels (TRl), and the ability to achieve the desired performance by the customer need dates. The advanced cell chemistry options were evaluated with respect to multiple quantitative and qualitative attributes while considering their projected performance at the end of the available development timeframe. Following a rigorous ranking process, a chemistry that combines a lithiated nickel manganese cobalt oxide (lithium NMC) cathode with a silicon-based composite anode was selected as the technology that can offer the best combination of safety, specific energy, energy density, and likelihood of success. Tasks over the next three years will focus on development of electrode materials, compatible electrolytes, and separator materials, and integration of promising components to assess their combined performance in working cells. Cells of the chosen chemistry will be developed to TRl 6 by 2014 and will then be transferred to the customers for infusion into their mission paths.

Reid, Concha↗

NASA NTRSDate not supplied

Application of Analytical Hierarchy Process for Narrowing Down Nep Candidate Reactor Designs

Nuclear electric propulsion (NEP)-powered vehicles have been contemplated for human Mars missions. The nuclear power system contemplates using a high temperature light-weight nuclear reactor for the production of electrical power in the range of 2-5 MWe with a 3-10 year service life. A myriad of technology options exist for achieving these mission objectives. The analytic hierarchy process (AHP), a multi-attribute decision method, is being used to narrow down the candidate designs. The AHP is a structured decision process that fuses model-supplied quantitative data with subjective assessments to facilitate decisions that involve multiple competing criteria. Proven end-to-end nuclear design and systems analysis tools will be used to provide quantitative performance data such as end-to-end system reliability, system robustness to recover from off-normal conditions, system specific weight (α in kg/kWe), and the ability to meet the service life-time and power level requirements. Three high assay low enriched uranium (HALEU) reactor concepts, namely, gas-, heat pipe- and pumped liquid-cooled nuclear cores coupled to a He/Xe gas or supercritical CO2- Brayton power conversion system are being modeled using the AHP to understand the trade-offs associated with these design combinations. In addition to the reactor and power conversion options, there are a myriad of additional components and subsystems – e.g., radiators, heat exchangers, and recuperators – that also figure into the evaluation process. The choice of the right overall system is a multidimensional problem that has to include not only quantitative data, but also the so called “external factors”, examples of which include the component and subsystem Technology Readiness Levels (TRLs), the associated Advancement Degrees of Difficulty (AD2), the cost and schedule required to achieve a technical maturity consistent with mission infusion, alignment with the priorities of NASA’s Space Nuclear Propulsion program, and alignment with other ongoing government and commercial investments in micro reactors. Focused expert elicitations form the basis for qualitative data set. As a final step, decision-makers individually express their opinions regarding the relative importance of the criteria and preferences among the alternatives through pairwise comparisons. The paper will describe the AHP approach, progress to-date applying it to the NEP human Mars mission problem, and preliminary results. Use of AHP provides sufficient flexibility for incorporating industry input at different stages as the technologies evolve through additional research and development. It is expected that the decision process will be ongoing and expanded to examine additional options and technology choices, culminating in a defensible set of candidate reactor concepts that will form the basis for developing a multi-year NEP technology maturation strategy. .

Dasari V Rao↗

NASA NTRSDate not supplied

NASA's Photovoltaic Energy Research Plans and Programs

This presentation reports efforts at the NASA Glenn Research Center (GRC) in research and development of photovoltaics and solar arrays for unique mission needs. The work of the photovoltaic team spans low technology readiness levels (TRL) in areas of cell development to high TRL in support of flight experiments and space missions. This presentation will highlight the various solar power programs and characterization and test facilities at NASA GRC. The photovoltaic work at NASA GRC focuses on multiple areas from helping to meet NASA mission specific needs to overall improvements to space solar cell technology including increasing cell efficiency, reduced cost, reduced weight, and improved radiation tolerance. We support higher power systems like Solar Electric Propulsion for Gateway and power for Lunar and Mars Surface Missions (rovers, landers, power stations, etc.) including work to understand the impact of dust on these systems. The overarching goal of the GRC photovoltaic group is to serve as an independent source of verification and validation of solar technologies for other government agencies and industry, to provide expertise to flight missions, and to build on interactions and collaborations within the technical community.

Photovoltaics↗

NASA NTRS2024

Terrestrial Proving Ground Capabilities Needed for Lunar In Situ Resource Utilization (ISRU) & Construction Concepts of Operation

Incorporating any new technology or system into a human exploration mission or architecture requires development well in advance of the mission to eliminate technology, cost, and schedule risk concerns. It is often stated that technologies need to be at a Technology Readiness Level (TRL) of 6, i.e. ‘system/subsystem model or prototype demonstration in a relevant environment (ground or space)’, by Authority To Proceed (ATP) or by the Preliminary Design Review (PDR) for the mission at the latest. There are two game changing capabilities for sustained human exploration of space that can have a significant effect on the overall exploration architecture and the technologies and systems included in the architecture. The first game changing capability, known as In Situ Resource Utilization (ISRU), involves the search for, acquisition, and processing of resources on the Moon and Mars into mission consumables and usable products, and the second is the ability to utilize space resources in the construction of roads, structures, and surface infrastructure. ISRU and surface construction capabilities have the potential to greatly reduce the cost and risk of human exploration while enabling sustained lunar surface and commercial operations. However, ISRU and surface construction systems are complex and must operate in extremely harsh environments, with abrasive regolith and pervasive dust, for long-periods of time, with potentially limited opportunities for maintenance and repair by humans. The complexity of these capabilities and operations also means that there are a limited number of companies that can design, build, and operate end-to-end systems on their own. The majority of the technologies being developed for these systems are by small companies and at the component or subsystem level. With the overarching strategy of the United States National Aeronautics and Space Administration (NASA) Space Technology Mission Directorate (STMD) to enable industry to implement ISRU and surface infrastructure for Artemis and space commercialization, it is therefore important to establish processes and capabilities to promote and foster collaborations among large and small companies involved in ISRU and surface infrastructure development. For ISRU and infrastructure systems and capabilities to be used in Artemis missions and future commercial lunar surface operations, a coordinated framework with virtual/physical integration and testing locations, or ‘Proving Grounds’, needs to be established and operated on a regular basis and open to all. This paper will discuss the ISRU and surface construction near and long-term concepts of operations, and review operations and lessons-learned from the previous ISRU analog field tests. From this information, requirements and capabilities will be proposed to support and enable the integration and testing of ISRU and construction systems with industry, academia, and international agencies, as well as what facilities and organizations could help establish these Proving Grounds.

ISRU↗

NASA NTRS2005

Development of Inflatable Entry Systems Technologies

Achieving the objectives of NASA s Vision for Space Exploration will require the development of new technologies, which will in turn require higher fidelity modeling and analysis techniques, and innovative testing capabilities. Development of entry systems technologies can be especially difficult due to the lack of facilities and resources available to test these new technologies in mission relevant environments. This paper discusses the technology development process to bring inflatable aeroshell technology from Technology Readiness Level 2 (TRL-2) to TRL-7. This paper focuses mainly on two projects: Inflatable Reentry Vehicle Experiment (IRVE), and Inflatable Aeroshell and Thermal Protection System Development (IATD). The objectives of IRVE are to conduct an inflatable aeroshell flight test that demonstrates exoatmospheric deployment and inflation, reentry survivability and stability, and predictable drag performance. IATD will continue the development of the technology by conducting exploration specific trade studies and feeding forward those results into three more flight tests. Through an examination of these projects, and other potential projects, this paper discusses some of the risks, issues, and unexpected benefits associated with the development of inflatable entry systems technology.

Player, Charles J.↗

NASA NTRS2008

RESOLVE Projects: Lunar Water Resource Demonstration and Regolith Volatile Characterization

To sustain affordable human and robotic space exploration, the ability to live off the land at the exploration site will be essential. NASA calls this ability in situ resource utilization (ISRU) and is focusing on finding ways to sustain missions first on the Moon and then on Mars. The ISRU project aims to develop capabilities to technology readiness level 6 for the Robotic Lunar Exploration Program and early human missions returning to the Moon. NASA is concentrating on three primary areas of ISRU: (1) excavating, handling, and moving lunar regolith, (2) extracting oxygen from lunar regolith, and (3) finding, characterizing, extracting, separating, and storing volatile lunar resources, especially in the permanently shadowed polar craters. To meet the challenges related to technology development for these three primary focus areas, the Regolith and Environment Science and Oxygen and Lunar Volatile Extraction (RESOLVE) project was initiated in February 2005, through funding by the Exploration Systems Mission Directorate. RESOLVE's objectives are to develop requirements and conceptual designs and to perform breadboard concept verification testing of each experiment module. The final goal is to deliver a flight prototype unit that has been tested in a relevant lunar polar environment. Here we report progress toward the third primary area creating ways to find, characterize, extract, separate, and store volatile lunar resources. The tasks include studying thermal, chemical, and electrical ways to collect such volatile resources as hydrogen, water, nitrogen, methane, and ammonia. We approached this effort through two subtasks: lunar water resource demonstration (LWRD) and regolith volatile characterization (RVC).

Source record↗

NASA NTRSDate not supplied

Comparative Analysis of Thermal Conversion Technologies for Deep Space Missions

Radioisotope power systems (RPS) utilizing Plutonium-238 as a heat source for thermal-to-electric energy conversion have been used as a reliable power source for NASA’s deep space missions for sixty years. Recent innovations and improvements to thermal energy technologies show potential increases to radioisotope system efficiencies from current measurements of ~5-7% to efficiencies upwards of 20%. This report surveys and ranks recent, innovative thermal-to-electric energy conversion research technologies. Technologies being developed at universities and industry are compared with respect to thermal conversion method and relevant key performance parameters. Key performance parameters are identified as system specific power per kg, efficiency, power output, technology readiness level, and system mass. Analytical Hierarchy Process (AHP) was utilized to create weighted values for each evaluation criterion. The AHP tables combined with decision matrices create table scores for past, present, and potential future systems. The table score was combined with a conversion method score in an adjustable system to add value to flight-proven or well-tested thermal conversion technologies such as thermoelectrics. While the three highest-ranking systems reviewed are currently being developed by NASA’s RPS Program, the additional highest-ranking systems not under-development by RPS could warrant further research.

Radioisotope Power System↗

NASA NTRS2023

Intravenous Fluid Generation Mini (IVGEN Mini) Summary and Related Research

This paper assists the ongoing effort to support NASA Glenn’s mission and its Human Research Program (HRP) core competency by investigating a technology demonstration to mitigate human health and performance risks during space exploration. Crew health and performance are critical to successful human exploration beyond low Earth orbit. Four hundred forty-two medical conditions have been identified and may present and require treatment during long-duration space exploration missions. One hundred fifteen out of four hundred forty-two identified medical conditions would require medical fluid treatment, generating a need for an on-demand or continuous supply of medical fluid. Intravenous Fluid Generation Mini (IVGEN Mini) is a technology demonstration designed to demonstrate a water purification and pharmaceutical mixing system that can make intravenous (IV) fluid in microgravity and builds on the success of the original Intravenous Fluid Generation for Exploration Missions (IVGEN) experiment, which flew on the ISS in March 2010. IVGEN Mini seeks to increase the Technology Readiness Level (TRL) and the overall function of the original IVGEN experiment to reduce the dependence of a needed medical consumable and streamline the size of the device and process to generate IV fluid IVGEN Mini is funded by the Advanced Exploration Systems (AES) directorate via the Exploration Medical Integrated Product Team (XMIPT) as a part of their mission to advance exploration medical technologies to benefit the overall health and safety of crews for beyond low Earth orbit space missions. This paper discusses a collection of related research topics such as microgravity fluid mixing and studying past efforts of IV fluid usage in extreme environments to aid IVGEN Mini project scientists in developing the IVGEN Mini technology.

iv generation↗

NASA NTRS2007

TRL-6 for JWST Wavefront Sensing and Control

NASA's Technology Readiness Level (TRL)-6 is documented for the James Webb Space Telescope (JWST) Wavefront Sensing and Control (WFSC) subsystem. The WFSC subsystem is needed to align the Optical Telescope Element (OTE) after all deployments have occurred, and achieves that requirement through a robust commissioning sequence consisting of unique commissioning algorithms, all of which are part of the WFSC algorithm suite. This paper identifies the technology need, algorithm heritage, describes the finished TRL-6 design platform, and summarizes the TRL-6 test results and compliance. Additionally, the performance requirements needed to satisfy JWST science goals as well as the criterion that relate to the TRL-6 Testbed Telescope (TBT) performance requirements are discussed

Feinberg, Lee↗

NASA NTRSDate not supplied

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

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

Additive Manufacturing↗

NASA NTRSDate not supplied

Metal Additive Manufacturing Developments for Propulsion Applications

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

Additive Manufacturing↗