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NASA NTRS2018

Human Exploration of Mars: Preliminary Lists of Crew Tasks

This is a preliminary report of ongoing research that has identified 1,125 tasks that are likely to be performed during initial human expeditions to Mars. The purpose of the report is to facilitate immediate access to the task inventory by researchers whose efforts might benefit from concrete examples of the work that will likely be performed by the first human explorers of Mars and the tasks for which crew members must be prepared to perform in response to emergencies. The research that led to the task lists is being conducted under Cooperative Agreement NNX15AW34G / NNX16AQ86G for the Human Factors and Behavioral Performance Element, Human Performance Program, NASA’s Johnson Space Center. The study is ongoing and will conclude with a final report that documents all research activities and presents the results of task and ability analyses and the implications of study results to crew size and composition, personnel selection and training, and design of equipment and procedures. The research addresses the Risk of Inadequate Mission, Process, and Task Design and the Risk of Performance Errors Due to Training Deficiencies by identifying the work that will be performed during an expedition to Mars and the abilities, skills, and knowledge that will be required of crew members. The study began by developing the comprehensive inventory of 1,125 tasks that are likely to be performed during the 12 phases of initial human expeditions to Mars, from launch to landing 30 months later. This full-mission task inventory was generated by a comprehensive review of documentation and concepts of operations with the understanding that plans and tasks might change in response to continuing technological development. Note: This interim report includes no discussion of analyses and has been prepared solely to facilitate dissemination of the task lists to others whose research might benefit from detailed information about the work and other activities that are likely to be performed during the human exploration of Mars.

Stuster, Jack W.↗

NASA NTRS1979

Diffusion and phase change characterization by mass spectrometry

The high temperature diffusion of trace elements in metals and alloys was investigated. Measurements were made by high sensitivity mass spectrometry in which individual atoms were detected, and quantitative data was obtained for zircaloy-2, 304 stainless steel, and tantalum. Additionally, a mass spectrometer was also an analytical tool for determining an allotropic phase change for stainless steel at 955 C, and a phase transition region between 772 C and 1072 C existing for zircaloy-2. Diffusion rates were measured in thin (0.001" (0.0025 cm) and 0.0005" (0.0013 cm)) ribbons which were designed as high temperature thermal ion sources, with the alkali metals as naturally occurring impurities. In the temperature and pressure regime where diffusion measurements were made, the solute atoms evaporated from the ribbon filaments when the impurities diffused to the surface, with a fraction of these impurity atoms ionized according to the Langmuir-Saha relation. The techniques developed can be applied to many other alloys important to space vehicles and supersonic transports; and, with appropriate modifications, to the diffusion of impurities in composites.

Koslin, M. E.↗

NASA NTRS1991

Cold equation of state in a strong magnetic field - Effects of inverse beta-decay

The influence of a high magnetic field (B is greater than 10 exp 12 G) on the degenerate matter equation of state appropriate to a neutron star is studied. The regime dominated by relativistic electrons up to the neutron drip density is highlighted. The equilibrium matter composition and equation of state, allowing for inverse beta-decay. Two different equilibrium models are determined: an ideal neutron-proton-electron (npe) gas and the more realistic model of Baym, Pethick, and Sutherland (1971) consisting of a Coulomb lattice of heavy nuclei embedded in an electron gas. For a sufficiently high field strength, the magnetic field has an appreciable effect, changing the adiabatic index of the matter and the nuclear transition densities. The influence of a strong field on some simple nonequilibrium processes, including beta-decay and inverse beta-decay (electron capture) is also considered. The effects produced by the magnetic field are mainly due to the changes in the transverse electron quantum orbits and the allowed electron phase space induced by the field.

Lai, Dong↗

NASA NTRS1985

Basic cryogenics and materials. Phase 1

The effects of cryogenic temperatures on the mechanical and physical properties of materials are summarized. Heat capacity and thermal conductivity are considered in the context of conservation of liquid nitrogen, thermal stability of the gas stream, and the response time for changes in operating temperature. Particular attention is given to the effects of differential expansion and failure due to thermal fatigue. Factors affecting safety are discussed, including hazards created due to the inadvertent production of liquid oxygen and the physiological effects of exposure to liquid and gaseous nitrogen, such as cold burns and asphyxiation. The preference for using f.c.c. metals at low temperatures is explained in terms of their superior toughness. The limitations on the use of ferritic steels is also considered. Nonmetallic materials are discussed, mainly in the context of their LOX compatibility and their use in the form of foams and fibers as insultants, seals, and fiber reinforced composites.

Wigley, D. A.↗

NASA NTRS1996

Analysis of Two-Phase Flow in Damper Seals for Cryogenic Turbopumps

Cryogenic damper seals operating close to the liquid-vapor region (near the critical point or slightly su-cooled) are likely to present two-phase flow conditions. Under single phase flow conditions the mechanical energy conveyed to the fluid increases its temperature and causes a phase change when the fluid temperature reaches the saturation value. A bulk-flow analysis for the prediction of the dynamic force response of damper seals operating under two-phase conditions is presented as: all-liquid, liquid-vapor, and all-vapor, i.e. a 'continuous vaporization' model. The two phase region is considered as a homogeneous saturated mixture in thermodynamic equilibrium. Th flow in each region is described by continuity, momentum and energy transport equations. The interdependency of fluid temperatures and pressure in the two-phase region (saturated mixture) does not allow the use of an energy equation in terms of fluid temperature. Instead, the energy transport is expressed in terms of fluid enthalpy. Temperature in the single phase regions, or mixture composition in the two phase region are determined based on the fluid enthalpy. The flow is also regarded as adiabatic since the large axial velocities typical of the seal application determine small levels of heat conduction to the walls as compared to the heat carried by fluid advection. Static and dynamic force characteristics for the seal are obtained from a perturbation analysis of the governing equations. The solution expressed in terms of zeroth and first order fields provide the static (leakage, torque, velocity, pressure, temperature, and mixture composition fields) and dynamic (rotordynamic force coefficients) seal parameters. Theoretical predictions show good agreement with experimental leakage pressure profiles, available from a Nitrogen at cryogenic temperatures. Force coefficient predictions for two phase flow conditions show significant fluid compressibility effects, particularly for mixtures with low mass content of vapor. Under these conditions, an increase on direct stiffness and reduction of whirl frequency ratio are shown to occur. Prediction of such important effects will motivate experimental studies as well as a more judicious selection of the operating conditions for seals used in cryogenic turbomachinery.

Arauz, Grigory L.↗

NASA NTRS2003

Solar Effects on Climate and the Maunder Minimum: Minimum Certainty

The current state of our understanding of solar effects on climate is reviewed. As an example of the relevant issues, the climate during the Maunder Minimum is compared with current conditions in GCM simulations that include a full stratosphere and parameterized ozone response to solar spectral irradiance variability and trace gas changes. The GISS Global Climate/Middle Atmosphere Model coupled to a q-flux/mixed layer model is used for the simulations, which begin in 1500 and extend to the present. Experiments were made to investigate the effect of total versus spectrally-varying solar irradiance changes; spectrally-varying solar irradiance changes on the stratospheric ozone/climate response with both pre-industrial and present trace gases; and the impact on climate and stratospheric ozone of the preindustrial trace gases and aerosols by themselves. The results showed that: (1) the Maunder Minimum cooling relative to today was primarily associated with reduced anthropogenic radiative forcing, although the solar reduction added 40% to the overall cooling. There is no obvious distinguishing surface climate pattern between the two forcings. (2)The global and tropical response was greater than 1 C, in a model with a sensitivity of 1.2 C per W m-2. To reproduce recent low-end estimates would require a sensitivity 1/4 as large. (3) The global surface temperature change was similar when using the total and spectral irradiance prescriptions, although the tropical response was somewhat greater with the former, and the stratospheric response greater with the latter. (4) Most experiments produce a relative negative phase of the NAO/AO during the Maunder Minimum, with both solar and anthropogenic forcing equally capable, associated with the tropical cooling and relative poleward EP flux refraction. (5) A full stratosphere appeared to be necessary for the negative AO/NAO phase, as was the case with this model for global warming experiments, unless the cooling was very large, while the ozone response played a minor role and did not influence surface temperature significantly. (6) Stratospheric ozone was most affected by the difference between present day and preindustrial atmospheric composition and chemistry, with increases in the upper and lower stratosphere during the Maunder Minimum. While the estimated UV reduction led to ozone decreases, this was generally less important than the anthropogenic effect except in the upper middle stratosphere, as judged by two different ozone photochemistry schemes. (7) The effect of the reduced solar irradiance on stratospheric ozone and on climate was similar in Maunder Minimum and current atmospheric conditions.

Rind, David↗

NASA NTRS1985

Graphite Formation in Cast Iron

In the first phase of the project it was proven that by changing the ratio between the thermal gradient and the growth rate for commercial cast iron samples solidifying in a Bridgman type furnace, it is possible to produce all types of graphite structures, from flake to spheroidal, and all types of matrices, from ferritic to white at a certain given level of cerium. KC-135 flight experiments have shown that in a low-gravity environment, no flotation occurs even in spheroidal graphite cast irons with carbon equivalent as high as 5%, while extensive graphite flotation occurred in both flake and spheroidal graphite cast irons, in high carbon samples solidified in a high gravity environment. This opens the way for production of iron-carbon composite materials, with high carbon content (e.g., 10%) in a low gravity environment. By using KC-135 flights, the influence of some basic elements on the solidification of cast iron will be studied. The mechanism of flake to spheroidal graphite transition will be studied, by using quenching experiments at both low and one gravity for different G/R ratios.

Stefanescu, D. M.↗

NASA NTRS1999

Analysis of X-Ray Microradiographs of Al-Au Interface Quench Profile using Modeling of Solidification Including Double-Diffusion and Convection in the Melt

Experimental data on Al-0.8Au horizontal solidification of a 1 mm thick specimen in a BN crucible shows the effect of growth rate on the solidification interface shape. For translation rates below 0.5 micron/s the interface maintains a plain and flat shape. When the translation rate is 3 to 5 micron/s or more, the interface appearance changes to two planar zones, with the zone closer to the bottom having higher inclination. The interface shapes were measured by first quenching in place during growth. X-ray microscopy shows the interface shape within the quenched sample by viewing through the side of the specimen. In order to provide theoretical explanation of the phenomena, numerical modeling was undertaken using finite element code FIDAP. Double diffusion convection in Al-0.8Au melt and crystal-melt interface curvature during directional solidification was analyzed numerically. Actual thermophysical properties of Al-0.8Au including the binary Al-Au phase diagram were used. Although convection in the sample is weak, for the slower translation rate convection and diffusion is sufficient for the redistribution of initial compositional stratification caused by gravity. When translation rate is raised, neither convection nor diffusion can provide proper mixing so that solidification temperatures differ significantly near the bottom within the bulk of the sample. As a result, the solid-liquid interface appears to have two planar zones with different inclination.

Bune, Andris V.↗

NASA NTRS2017

Precipitation Strengthenable NiTiPd High Temperature Shape Memory Alloys

In binary NiTi alloys, it has long been known that Ni-rich alloys can be heat treated to produce precipitates which both strengthen the matrix against dislocations and improve the behavior of the material under thermal and mechanical cycling. Within recent years, the same effect has been observed in Ni-rich NiTiHf high temperature shape memory alloys and heat treatment regimens have been defined which will reliably produce improved properties. In NiTiPd alloys, precipitation has also been observed, but studies are still underway to define reliable heat treatments and compositions which will provide a balance of strengthening and good thermomechanical properties. For this study, a series of NiTi-32 at.Pd alloys was produced to determine the effect of changing nickeltitanium content on the transformation behavior and heat treatability of the material. Samples were aged at temperatures between 350C and 450C for times up to 100 hours. Actuation type behavior was evaluated using uniaxial constant force thermal cycling (UCFTC) to determine the effect of composition and aging on the material behavior. TEMSEM was used to evaluate the microstructure and determine the types of precipitates formed. The correlation between composition, heat treat, microstructure, and thermomechanical behavior will be addressed and discussed.

Transformation strain↗

NASA NTRS2004

New Effective Material Couple--Oxide Ceramic and Carbon Nanotube-- Developed for Aerospace Microsystem and Micromachine Technologies

The prime driving force for using microsystem and micromachine technologies in transport vehicles, such as spacecraft, aircraft, and automobiles, is to reduce the weight, power consumption, and volume of components and systems to lower costs and increase affordability and reliability. However, a number of specific issues need to be addressed with respect to using microsystems and micromachines in aerospace applications--such as the lack of understanding of material characteristics; methods for producing and testing the materials in small batches; the limited proven durability and lifetime of current microcomponents, packaging, and interconnections; a cultural change with respect to system designs; and the use of embedded software, which will require new product assurance guidelines. In regards to material characteristics, there are significant adhesion, friction, and wear issues in using microdevices. Because these issues are directly related to surface phenomena, they cannot be scaled down linearly and they become increasingly important as the devices become smaller. When microsystems have contacting surfaces in relative motion, the adhesion and friction affect performance, energy consumption, wear damage, maintenance, lifetime and catastrophic failure, and reliability. Ceramics, for the most part, do not have inherently good friction and wear properties. For example, coefficients of friction in excess of 0.7 have been reported for ceramics and ceramic composite materials. Under Alternate Fuels Foundation Technologies funding, two-phase oxide ceramics developed for superior high-temperature wear resistance in NASA's High Operating Temperature Propulsion Components (HOTPC) project and new two-layered carbon nanotube (CNT) coatings (CNT topcoat/iron bondcoat/quartz substrate) developed in NASA's Revolutionary Aeropropulsion Concepts (RAC) project have been chosen as a materials couple for aerospace applications, including micromachines, in the nanotechnology lubrication task because of their potential for superior friction and wearf properties in air and in an ultrahigh vacuum, spacelike environment. At the NASA Glenn Research Center, two-phase oxide ceramic eutectics, Al2O3/ZrO2(Y2O3), were directionally solidified using the laser-float-zone process, and carbon nanotubes were synthesized within a high-temperature tube furnace at 800 C. Physical vapor deposition was used to coat all quartz substrates with 5-nm-thick iron as catalyst and bondcoat, which formed iron islands resembling droplets and serving as catalyst particles on the quartz. A series of scanning electron micrographs showing multiwalled carbon nanotubes directionally grown as aligned "nanograss" on quartz is presented. Unidirectional sliding friction eperiments were conducted at Glenn with the two-layered CNT coatings in contact with the two-phase Al2O3/ZrO2(Y2O3) eutectics in air and in ultrachigh vacuum. The main criteria for judging the performance of the materials couple for solid lubrication and antistick applications in a space environment were the coefficient of friction and the wear resistance (reciprocal of wear rate), which had to be less than 0.2 and greater than 10(exp 5) N(raised dot)/cubic millimetes, respectively, in ultrahigh vacuum. In air, the coefficient of friction for the CNT coatings in contact with Al2O3/ZrO2 (Y2O3) eutectics was 0.04, one-fourth of that for quartz. In an ultrahigh vacuum, the coefficient of friction for CNT coatings in contact with Al2O3/ZrO2 (Y2O3) was one-third of that for quartz. The two-phase Al2O3/ZrO2 (Y2O3) eutectic coupled with the two-layered CNT coating met the coefficient of friction and wear resistance criteria both in air and in an ultrahigh vacuum, spacelike environment. This material's couple can dramatically improve the stiction (or adhesion), friction, and wear resistance of the contacting surfaces, which are major issues for microdevices and micromachines.

Miyoshi, Kazuhisa↗

NASA NTRS2015

Enhanced Weathering Strategies for Stabilizing Climate and Averting Ocean Acidification

Chemical breakdown of rocks, weathering, is an important but very slow part of the carbon cycle that ultimately leads to CO2 being locked up in carbonates on the ocean floor. Artificial acceleration of this carbon sink via distribution of pulverized silicate rocks across terrestrial landscapes may help offset anthropogenic CO2 emissions. We show that idealized enhanced weathering scenarios over less than a third of tropical land could cause significant drawdown of atmospheric CO2 and ameliorate ocean acidification by 2100. Global carbon cycle modelling driven by ensemble Representative Concentration Pathway (RCP) projections of twenty-first-century climate change (RCP8.5, business-as-usual; RCP4.5, medium-level mitigation) indicates that enhanced weathering could lower atmospheric CO2 by 30-300 ppm by 2100, depending mainly on silicate rock application rate (1 kg or 5 kg m(exp -2) yr (exp -1)) and composition. At the higher application rate, end-of-century ocean acidification is reversed under RCP4.5 and reduced by about two-thirds under RCP8.5. Additionally, surface ocean aragonite saturation state, a key control on coral calcification rates, is maintained above 3.5 throughout the low latitudes, thereby helping maintain the viability of tropical coral reef ecosystems. However, we highlight major issues of cost, social acceptability, and potential unanticipated consequences that will limit utilization and emphasize the need for urgent efforts to phase down fossil fuel emissions.

Taylor, Lyla L.↗

NASA NTRS2015

Enhanced Weathering Strategies for Stabilizing Climate and Averting Ocean Acidification - Supplementary Information

Chemical breakdown of rocks, weathering, is an important but very slow part of the carbon cycle that ultimately leads to CO2 being locked up in carbonates on the ocean floor. Artificial acceleration of this carbon sink via distribution of pulverized silicate rocks across terrestrial landscapes may help offset anthropogenic CO2 emissions. We show that idealized enhanced weathering scenarios over less than a third of tropical land could cause significant drawdown of atmospheric CO2 and ameliorate ocean acidification by 2100. Global carbon cycle modelling driven by ensemble Representative Concentration Pathway (RCP) projections of twenty-first-century climate change (RCP8.5, business-as-usual; RCP4.5, medium-level mitigation) indicates that enhanced weathering could lower atmospheric CO2 by 30-300 ppm by 2100, depending mainly on silicate rock application rate (1 kg or 5 kg m(exp. -2) yr (exp -1)) and composition. At the higher application rate, end-of-century ocean acidification is reversed under RCP4.5 and reduced by about two-thirds under RCP8.5. Additionally, surface ocean aragonite saturation state, a key control on coral calcification rates, is maintained above 3.5 throughout the low latitudes, thereby helping maintain the viability of tropical coral reef ecosystems. However, we highlight major issues of cost, social acceptability, and potential unanticipated consequences that will limit utilization and emphasize the need for urgent efforts to phase down fossil fuel emissions.

Taylor, Lyla L.↗

NASA NTRS2000

Modernization and Activation of the NASA Ames 11- by 11-Foot Transonic Wind Tunnel

The Unitary Plan Wind Tunnel (UPWT) was modernized to improve performance, capability, productivity, and reliability. Automation systems were installed in all three UPWT tunnel legs and the Auxiliaries facility. Major improvements were made to the four control rooms, model support systems, main drive motors, and main drive speed control. Pressure vessel repairs and refurbishment to the electrical distribution system were also completed. Significant changes were made to improve test section flow quality in the 11-by 11-Foot Transonic leg. After the completion of the construction phase of the project, acceptance and checkout testing was performed to demonstrate the capabilities of the modernized facility. A pneumatic test of the tunnel circuit was performed to verify the structural integrity of the pressure vessel before wind-on operations. Test section turbulence, flow angularity, and acoustic parameters were measured throughout the tunnel envelope to determine the effects of the tunnel flow quality improvements. The new control system processes were thoroughly checked during wind-off and wind-on operations. Manual subsystem modes and automated supervisory modes of tunnel operation were validated. The aerodynamic and structural performance of both the new composite compressor rotor blades and the old aluminum rotor blades was measured. The entire subsonic and supersonic envelope of the 11-by 11-Foot Transonic leg was defined up to the maximum total pressure.

Kmak, Frank J.↗

NASA NTRS1986

Optical distance measuring instrument

An optical instrument, such as a stability monitor or a target range finder, uses an unstabilized laser to project a composite optical signal of coherent light having two naturally occurring longitudinal mode components. A beamsplitter divides the signal into a reference beam which is directed toward one photodetector and a transmitted beam which illuminates and is reflected from a distant target onto a second photodetector optically isolated from the first photodetector. Both photodetectors are operated on the square law principle to provide electrical signals modulated at a frequency equal to the separation between the frequencies of the two longitudinal mode components of the optical signal projected by the laser. Slight movement of the target may be detected and measured by electrically monitoring the phase difference between the two signals provided by the photodetectors and the range of the target measured with the aid of a microprocessor by changing the separation between the longitudinal modes by shifting the length of the resonator cavity in an iterative series of increments.

Abshire, J. B.↗

NASA NTRS2005

The Insoluble Carbonaceous Material of CM Chondrites as Possible Source of Discrete Organics During the Asteroidal Aqueous Phase

The larger portion of the organic carbon in carbonaceous chondrites (CC) is present as a complex and heterogeneous macromolecular material that is insoluble in acids and most solvents (IOM). So far, it has been analyzed only as a whole by microscopy (TEM) and spectroscopy (IR, NMR, EPR), which have offered and overview of its chemical nature, bonding, and functional group composition. Chemical or pyrolytic decomposition has also been used in combination with GC-MS to identify individual compounds released by these processes. Their value in the recognition of the original IOM structure resides in the ability to properly interpret the decomposition pathways for any given process. We report here a preliminary study of IOM from the Murray meteorite that combines both the analytical approaches described above, under conditions that would realistically model the IOM hydrothermal exposure in the meteorite parent body. The aim is to document the possible release of water and solvent soluble organics, determine possible changes in NMR spectral features, and ascertain, by extension, the effect of this loss on the frame of the IOM residue. Additional information is included in the original extended abstract.

Yabuta, H.↗

NASA NTRS2021

Dissolution Rates of Allophane with Variable Fe Contents: Implications for Aqueous Alteration and the Preservation of X-ray Amorphous Materials on Mars

Recent measurements from Mars document X-ray amorphous/nano-crystalline materials in multiple locations across the planet. However, despite their prevalence, little is known about these materials or what their presence implies for the history of Mars. The X-ray amorphous component of the martian soil in Gale crater has an X-ray diffraction pattern that can be partially fit with allophane (approximately Al2O3•(SiO2)1.3-2•(H2O)2.5-3), and the low-temperature water release data are consistent with allophane. The chemical data from Gale crater suggest that other silicate materials similar to allophane, such as Fe-substituted allophane (approximately (Fe2O3)0.01-0.5(Al2O3)0.5-0.99•(SiO2)2•3H2O), may also be present. In order to investigate the properties of these potential poorly crystalline components of the martian soil, Fe-free allophane (Fe:Al = 0), Fe-poor allophane (Fe:Al = 1:99), and Fe-rich allophane (Fe:Al = 1:1) were synthesized and then characterized using electron microscopy and Mars-relevant techniques, including infrared spectroscopy, X-ray diffraction, and evolved gas analysis. Dissolution experiments were performed at acidic (initial pH values pH0 = 3.01, pH0 = 5.04), near-neutral (pH0 = 6.99), and alkaline (pH0 = 10.4) conditions in order to determine dissolution kinetics and alteration phases for these poorly crystalline materials. Dissolution rates (rdiss), based on the rate of Si release into solution, show that these poorly crystalline materials dissolve approximately an order of magnitude faster than crystalline phases with similar compositions at all pH conditions. For Fe-free allophane, logrdiss = -10.65 – 0.15 × pH; for Fe-poor allophane, logrdiss = -10.35 – 0.22 × pH; and for Fe-rich allophane, logrdiss = -11.46 – 0.042 × pH at 25°C, where rdiss has the units of mol m-2 s-1. The formation of incipient phyllosilicate-like phases was detected in Fe-free and Fe-rich allophane reacted in aqueous solutions with pH0 = 10.4 (steady-state pH ≈ 8). Mars-analog instrument analyses demonstrate that Fe-free allophane, Fe-poor allophane, and Fe-rich allophane are appropriate analogs for silicate phases in the martian amorphous soil component. Therefore, similar materials on Mars must have had limited interaction with liquid water since their formation. Combined with chemical changes expected from weathering, such as phyllosilicate formation, the rapid alteration of these poorly crystalline materials may be a useful tool for evaluating the extent of aqueous alteration in returned samples of martian soils.

S J Ralston↗

NASA NTRS2026

Microstructural Evolution and Mechanical Properties of LP-DED NASA HR-1 – A Hydrogen Resistant AM Superalloy for Space Propulsion Applications

The National Aeronautics and Space Administration (NASA) has actively pursued metal additive manufacturing (AM) technologies for spaceflight applications since the late 2000s. AM offers transformative advantages in cost, schedule, part consolidation, and design flexibility. Among the various AM techniques, laser powder directed energy deposition (LP-DED) is particularly well suited for fabricating complex geometries with fine feature resolution. In propulsion systems that utilize high-pressure gaseous hydrogen—such as liquid hydrogen rocket engines—hydrogen environment embrittlement (HEE) presents a serious threat to material performance 1,2 . Mechanical property degradation under these conditions can compromise component reliability, especially under cyclic loading. To address this challenge, NASA developed NASA HR-1 (Hydrogen Resistant-1) as a solution for liquid rocket engine components operating in hydrogen-rich environments, using the LP-DED technique 3-9 . A key component in a liquid rocket engine is the exhaust nozzle, which is typically regeneratively cooled (regen) due to the high heat flux. NASA HR-1 was specifically developed for regen nozzle applications using hydrogen as a propellant, providing resistance to HEE, a critical issue for many materials. The AM version of NASA HR-1 was also formulated to achieve high ultimate tensile strength, along with high yield strength and ductility in this environment 5,6 . Low-cycle fatigue (LCF) is another important consideration in nozzle design, as components are expected to endure multiple starts and missions. Additionally, the LP-DED version of the alloy exhibits improved thermal conductivity compared to its wrought counterpart, which benefits nozzle cooling. Overall, NASA HR-1 offers an excellent balance of high strength, HEE resistance, LCF performance, thermal conductivity, and ductility to meet the demanding requirements of channel-cooled nozzles and other components used with hydrogen and other propellants. The LP-DED–processed NASA HR-1 requires several post-processing heat treatment steps to achieve the material properties desirable for its intended application 6 . These steps include stress relief, homogenization, solution annealing, and aging for precipitation hardening. The stress relief treatment mitigates residual stresses accumulated during the LP-DED process and minimizes the potential for distortion. Homogenization, a common step for AM materials, reduces elemental segregation and promotes recrystallization to develop a more equiaxed grain structure. The subsequent solution annealing treatment heats the part to a solid solution temperature to dissolve the undesirable η-phase that forms during cooling from homogenization, followed by rapid cooling to retain an η-phase–free microstructure. Finally, aging promotes precipitation of the strengthening γ′ phase in the alloy. The integration of compositional design and optimized thermal processing enables high-quality LP-DED NASA HR-1 components with excellent microstructural and mechanical stability. Improved chemical and microstructure homogeneity enhances ductility and fatigue resistance—both critical for safe and reliable operation in high-pressure hydrogen environments. NASA has successfully fabricated and hot-fire tested multiple subscale and full-scale channel wall nozzles using LP-DED NASA HR-1 5,6, 9-14 . These efforts included process refinements to support thin-wall construction and various channel geometries. Throughout development, several key observations emerged. After homogenization, the as-built columnar grain structure transforms into a fully equiaxed microstructure. However, subsequent treatments—such as solution annealing and aging—result in changes that are more difficult to track. The grain structure remains largely unchanged, and the γ′ precipitates, typically 5–10 nm in diameter, are beyond the resolution of scanning electron microscopy (SEM). While transmission electron microscopy (TEM) can resolve these fine precipitates, TEM sample preparation is time-consuming and difficult for LP-DED material. As an alternative, differential scanning calorimetry (DSC) offers a useful, qualitative approach to monitor precipitate evolution throughout different stages of heat treatment. The overall goal is to improve the understanding of how heat treatment affects the microstructure and mechanical performance of LP-DED NASA HR-1. This paper presents heat treatment design considerations, microstructural characterization, mechanical testing – including tensile and LCF testing in both air and hydrogen environments.

Superalloy↗

NASA NTRS2001

Long-Term Creep and Creep Rupture Behavior of Woven Ceramic Matrix Composites

Tensile creep behavior of SiC/SiNC ceramic matrix composites at elevated temperatures and at various stress levels have been investigated for turbine engine applications. The objective of this research is to present creep behavior of SiC/SiCN composites at stress levels above and below the monotonic proportional limit strength and predict the life at creep rupture conditions. Tensile creep-rupture tests were performed on an Instron 8502 servohydraulic testing machine at constant load conditions up to a temperature limit of 1000 C. Individual creep curves indicate three stages such as primary, secondary, and tertiary. The creep rate increased linearly at an early stage and then gradually became exponential at higher strains. The stress exponent and activation energy were also obtained at 700 and 1000 C. The specimen lifetime was observed to be 55 hrs at 121 MPa and at 700 C. The life span reduced to 35 hrs at 143 MPa and at 1000 C. Scanning electron microscopy observations revealed significant changes in the crystalline phases and creep damage development. Creep failures were accompanied by extensive fiber pullout, matrix cracking, and debonding along with fiber fracture. The creep data was applied to Time-Temperature-Stress superposition model and the Manson-Haferd parametric model for long-time life prediction.

Haque, A.↗