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NASA NTRS1981

Assessment of solar-assisted gas-fired heat pump systems

As a possible application for the Goldstone Energy Project, the performance of a 10 ton heat pump unit using a hybrid solar gas energy source was evaluated in an effort to optimize the solar collector size. The heat pump system is designed to provide all the cooling and/or heating requirements of a selected office building. The system performance is to be augmented in the heating mode by utilizing the waste heat from the power cycle. A simplified system analysis is described to assess and compute interrrelationships of the engine, heat pump, and solar and building performance parameters, and to optimize the solar concentrator/building area ratio for a minimum total system cost. In addition, four alternative heating cooling systems, commonly used for building comfort, are described; their costs are compared, and are found to be less competitive with the gas solar heat pump system at the projected solar equipment costs.

Lansing, F. L.↗

NASA NTRS1981

The effects of controls and controllable and storage loads on the performance of stand-alone photovoltaic systems

Stand-alone photovoltaic systems have been modeled and analyzed from sunlight in to consumer product out. By including the consumer product in the analysis, concepts such as 'product storage' (a storage tank for water or cold-plates for refrigeration) and loads controllable by the system controller have been added to the system analysis. From a controls analysis viewpoint, this adds state variables to the system. The result is that the system controller can make operating control decisions on the energy flow between these various system elements to optimize system performance and reduce system cost. The effects on system performance of various control schemes employing these concepts are presented. Analysis of water pumping and/or refrigeration systems show possible performance improvements of greater than 15% with the addition of controllable loads with product storage.

Cull, R. C.↗

NASA NTRS1983

Prediction of structures and magnetic orientations in solid alpha and beta-O2

A quasi-harmonic-lattice-dynamics method coupled with a pattern-recognition optimization scheme is used to determine the minimum energy structures and magnetic orientations of solid oxygen. It is shown that the magnetic interaction is responsible for the stability of alpha-O2 with respect to beta-O2 at zero temperature and pressure. The calculated alpha-O2 lattice parameters, magnetic orientations, and sublimation energy are in good agreement with experiment. Phonon dispersion curves are calculated at vector k not equal to zero and the acoustic sound velocities are determined. The rms translational and orientational fluctuations from equilibrium are also calculated. The beta-O2 phase is described by constraining the magnetic moments so that the magnetic Hamiltonian preserves the hexagonal symmetry of the crystal. The calculated lattice parameters are in good agreement with the experiments, and a three-sublattice, quasi-helical magnetic orientation is predicted from structural and energetic considerations.

Etters, R. D.↗

NASA NTRS1989

The Advanced Composition Explorer

The Advanced Composition Explorer (ACE) was recently selected as one of two new Explorer-class missions to be developed for launch during the mid-1990's. ACE will observe particles of solar, interplanetary, interstellar, and galactic origins, spanning the energy range from that of the solar wind (approx. 1 keV/nucleon) to galactic cosmic ray energies (several hundred MeV/nucleon). Definitive studies will be made of the abundance of nearly all isotopes from H to Zn (1 less than or = Z less than or = 30), with exploratory isotope studies extending to Zr (Z = 40). To accomplish this, the ACE payload includes six high-resolution spectrometers, each designed to provide the optimum charge, mass, or charge-state resolution in its particular energy range, and each having a geometry factor optimized for the expected flux levels, so as to provide a collecting power a factor of 10 to 1000 times greater than previous or planned experiments. The payload also includes several instruments of standard design that will monitor solar wind and magnetic field conditions and energetic H, He, and electron fluxes. The scientific objectives, instrumentation, spacecraft, and mission approach that were defined for ACE during the Phase-A study period are summarized.

Stone, E. C.↗

NASA NTRS1993

Practical methods for near-term piloted Mars missions

An evaluation is made of ways of using near-term technologies for direct and semidirect manned Mars missions. A notable feature of the present schemes is the in situ propellant production of CH4/O2 and H2O on the Martian surface in order to reduce surface consumable and return propellant requirements. Medium-energy conjunction class trajectories are shown to be optimal for such missions. Attention is given to the backup plans and abort philosophy of these missions. Either the Russian Energia B or U.S. Saturn VII launch vehicles may be used.

Zubrin, Robert M.↗

NASA NTRS1998

Prebiotic Polymer Synthesis and the Origin of Glycolytic Metabolism

Our research resulted in several discoveries which contributed to understanding the origin and operation of life. (1) Most importantly, we discovered a new pathway of prebiotic amino acid synthesis in which formaldehyde and glycolaldehyde (formose reaction substrates) react with ammonia to give alanine and homoserine in the presence of thiol catalysts. The thiol-dependent synthesis of amino acids undoubtedly occurs via amino acid thioester intermediates capable of forming peptides. This 'one-pot' reaction system operates under mild aqueous conditions, and like modern amino acid biosynthesis, uses sugar intermediates which are converted to amino acids by energy-yielding redox disproportionation. Preliminary evidence suggests that this type of process can be "evolved" by a serial transfer methods that lead to enrichment of autocatalytic molecules. (2) We established that prebiotic peptide polymers can be made by condensation of amino acid thioesters (homocysteine thiolactone and S-(N-beta-orotidyl- diaminopropionic acid) ethanethiol), and that prebiotic polydisulfide polymers can be generated by oxidation of dithiols with iron(III) in minerals. (3) In our analysis of metabolism we discovered the primary energy source of biosynthesis -- chemical energy made available by the redox disproportionation of substrate carbon groups. We concluded that the energy and reactivity of sugars make them the optimal substrate for the origin and operation of terrestrial (or extraterrestrial) life. (4) Since it is likely that the use of optimal sugar substrates in biosynthesis sets the average oxidation number of functional biocarbon throughout the Universe near 0.0 (the reduction level of formaldehyde), we proposed that a line(s) in the microwave spectrum of formaldehyde could be rationally selected as a frequency for interstellar communication that symbolizes life. (5) Finally, in preparation for the analysis of Martian meteorite samples, we upgraded our HPLC system to one femtomole sensitivity, and developed a new electrophoretic method of sample preparation for HPLC analysis of the meteoritic amino acids. In a sample of the KT boundary layer from Sussex Wyoming, we found about 300 picomoles per gram of meteoritic alpha-aminoisobutyric acid per gram of KT layer.

Weber, Arthur L.↗

NASA NTRS2000

Active Control Technology at NASA Langley Research Center

NASA Langley has a long history of attacking important technical opportunities from a broad base of supporting disciplines. The research and development at Langley in this subject area range from the test tube to the test flight. The information covered here will range from the development of innovative new materials, sensors and actuators, to the incorporation of smart sensors and actuators in practical devices, to the optimization of the location of these devices, to, finally, a wide variety of applications of these devices utilizing Langley's facilities and expertise. Advanced materials are being developed for sensors and actuators, as well as polymers for integrating smart devices into composite structures. Contributions reside in three key areas: computational materials; advanced piezoelectric materials; and integrated composite structures. The computational materials effort is focused on developing predictive tools for the efficient design of new materials with the appropriate combination of properties for next generation smart airframe systems. Research in the area of advanced piezoelectrics includes optimizing the efficiency, force output, use temperature, and energy transfer between the structure and device for both ceramic and polymeric materials. For structural health monitoring, advanced non-destructive techniques including fiber optics are being developed for detection of delaminations, cracks and environmental deterioration in aircraft structures. The computational materials effort is focused on developing predictive tools for the efficient design of new materials with the appropriate combination of properties for next generation smart airframe system. Innovative fabrication techniques processing structural composites with sensor and actuator integration are being developed.

Antcliff, Richard R.↗

NASA NTRS2001

Computational Analyses of Propulsion Aeroacoustics for Mixed Flow Nozzle Pylon Installation at Takeoff

A CFD analyses is presented for a set of baseline and noise suppression mixed flow nozzles with and without a pylon installation. The five model configurations are as follows; a baselinecore/fan dual-stream nozzle with an external plug, a chevron mixer nozzle with a peak on the symmetry plane with external plug, both of the above nozzles with an installed bifurcatingpylon and lastly a clocked chevron mixer nozzle such that a trough is aligned with the center of the pylon. The fluid flow is simulated by solving the asymptotically steady, compressible, Reynolds-averaged Navier-Stokes equations using an implicit, up-wind, flux-difference splitting finite volume scheme and standard two equation k-epsilon turbulence model with a linear stress representation. All computations are performed using the multiblock, parallel, structuredcode PAB3D. Results indicate that the clocked chevron with pylon case achieves the most optimal levels of average and peak turbulence kinetic energy and vorticity and therefore is expected to be the quietest of the five configurations tested. Further study is required to refine expressions which are indicative of noise and mate these with rigorous noise prediction models.

Massey, Steven J.↗

NASA NTRS1997

Combined Numerical/Analytical Perturbation Solutions of the Navier-Stokes Equations for Aerodynamic (Ejector Nozzle) Flows

In spite of the rapid advances in both scalar and parallel computational tools, the large number and breadth of variables involved in aerodynamic systems make the use of parabolized or even boundary layer fluid flow models impractical for both preliminary design and inverse design problems. Given this restriction, we have concluded that reduced or approximate models are an important family of tools for design purposes. This study of a combined perturbation/numerical modeling methodology with an application to ejector-mixer nozzles (shown schematically in the following figure) is nearing completion. The work is being funded by a grant from the NASA Lewis Research Center to Texas A&M University. These ejector-mixer nozzle models are designed to be of use to the High Speed Civil Transport Program and may be adopted by both NASA and industry. A computer code incorporating the ejector-mixer models is under development. This code, the Differential Reduced Ejector/Mixer Analysis (DREA), can be run fast enough to be used as a subroutine or to be called by a design optimization routine. Simplified conservation equations--x-momentum, energy, and mass conservation--are used to define the model. Unlike other preliminary design models, DREA requires minimal empirical input and includes vortical mixing and a fully compressible formulation among other features. DREA is being validated by comparing it with results obtained from open literature and proprietary industry data. Preliminary results for a subsonic ejector and a supersonic ejector are shown. In addition, dedicated experiments have been performed at Texas A&M. These experiments use a hydraulic/gas flow analog to provide information about the inviscid mixing interface structure. Final validation and documentation of this work is expected by May of 1997. However, preliminary versions of DREA can be expected in early 1997. In summary, DREA provides a sufficiently detailed and realistic ejector-mixer nozzle model at a computational cost compatible with preliminary design applications.

DeChant, Lawrence J.↗

NASA NTRS2008

Expert System Control of Plant Growth in an Enclosed Space

The Expert System is an enclosed, controlled environment for growing plants, which incorporates a computerized, knowledge-based software program that is designed to capture the knowledge, experience, and problem-solving skills of one or more human experts in a particular discipline. The Expert System is trained to analyze crop/plant status, to monitor the condition of the plants and the environment, and to adjust operational parameters to optimize the plant-growth process. This system is intended to provide a way to remotely control plant growth with little or no human intervention. More specifically, the term control implies an autonomous method for detecting plant states such as health (biomass) or stress and then for recommending and implementing cultivation and/or remediation to optimize plant growth and to minimize consumption of energy and nutrients. Because of difficulties associated with delivering energy and nutrients remotely, a key feature of this Expert System is its ability to minimize this effort and to achieve optimum growth while taking into account the diverse range of environmental considerations that exist in an enclosed environment. The plant-growth environment for the Expert System could be made from a variety of structures, including a greenhouse, an underground cavern, or another enclosed chamber. Imaging equipment positioned within or around the chamber provides spatially distributed crop/plant-growth information. Sensors mounted in the chamber provide data and information pertaining to environmental conditions that could affect plant development. Lamps in the growth environment structure supply illumination, and other additional equipment in the chamber supplies essential nutrients and chemicals.

May, George↗

NASA NTRS2014

Multi-shock Shield Performance at 16.5 MJ for Catalogued Debris

While orbital debris of ten centimeters or more are tracked and catalogued, the difficulty of finding and accurately accounting for forces acting on the objects near the ten centimeter threshold results in both uncertainty of their presence and location. These challenges result in difficult decisions for operators balancing potential costly operational approaches with system loss risk. In this paper, numerical simulations and an experiment using the multi‐shock shield system is described for a cylindrical projectile composed of Nylon, aluminum and void that is approximately 8 cm in diameter and 10 cm in length weighing 670 g impacting the multi‐shock shield normal to the surface with approximately 16.5 MJ of kinetic energy. The multi‐shock shield system has been optimized to facilitate the fragmentation, spread and deceleration of the projectile remnants using hydrodynamic simulations of the impact event. The characteristics and function of each of the layers of the multi‐shock system will be discussed along with considerations for deployment and improvement.

Miller, J. E.↗

NASA NTRSDate not supplied

Bistable Deployable Composite Booms With Parabolic Cross-Sections

This paper investigates how stable equilibrium states in the extended and coiled configurations can be predicted in thin-shelled composite booms with parabolic cross-sections. These conic shapes potentially offer greater stiffness properties when compared to circular cross-sections, which is critical for improving the load bearing performance of deployed booms. Inducing bistability through the choice of composite shell layups in parabolic booms would allow for controllable self-deployment due to a less energetic coiled state when compared to monostable booms. An inextensional analytical model is used to predict the stable coiled diameters of tape spring and Collapsible Tubular Mast (CTM) booms with parabolic cross-sections. The parabolic section is discretized into circular segments using biarc spline interpolation, which allows them to be integrated into the strain energy minimization procedure used to obtain the equilibrium states. When the parabolic booms are parametrically compared against circular booms with identical layups, flattened height, and mass, the former are found to generally have better stiffness performance while being less efficient in stowed volume as evidenced by larger coiled diameters. Analytical coiled diameters and their strain energy are verified with finite element simulations for optimal parabolic tape spring and CTM booms.

Andrew J. Lee↗

NASA NTRS2023

AI-3000K Infrared Line List for Hot CO 2

AI-3000K is a semi-empirical IR line list constructed for hot CO 2 spectra analysis and simulation up to 3000 – 4000 K. Compared to previously published Ames-1000K and UCL-4000, it represents a major upgrade, utilizing a new algorithm for optimization and including the latest improvements in potential energy surface (PES), dipole moment surface (DMS), and room temperature IR line list (Ames-2021 296K). To maximize the success of introducing experimental based accurate line positions, a new PES (X01d) was refined with respect to >800 selected CDSD2019 [Tashkun et al. JQSRT (2019) 228, 124] energy levels in the range of 0 – 24,000 cm -1 , with σ rms = 0.5 – 0.7 cm -1 . Most differences between the X01d PES based levels and CDSD2019 energies are within ± 2 cm -1 . A new DMS is fitted from extrapolated CCSD(T)/aug-cc-pV(T,Q,5)Z dipole calculations, with σ rms = 5.1 × 10 -6 au for 11,155 geometries up to 40,000 cm -1 , denoted Ames-2021–40K. Compared to the best available Ames-2021 DMS and room temperature IR line list [Huang et al J. Phys. Chem. A (2022) 126, 5940], the relative intensity differences are expected to be ∼ 1 ‰. The line position accuracy of ''X01d + Ames-2021–40K'' IR line list is significantly improved by adopting CDSD2019 energy levels up to 24,000 cm -1 (J ≤ 150). The Einstein A21 coefficients for E' < 15,000 cm -1 transitions are replaced by more accurate values from the Ames-2021 296K IR line list. In short, the AI-3000K is the X01d PES and Ames-2021–40K DMS based line list enhanced with the A 21 of Ames-2021 296K line list and CDSD energy levels. It provides continuous coverage from 0 to 20,000 cm -1 for the four most abundant isotopologues: 12 C 16 O 2 (626), 13 C 16 O 2 (636), 16 O 12 C 18 O (628), and 16 O 12 C 17 O (627). The impacts of isotopologue and E'/E'' cutoffs have been examined. Intensity convergence (not accuracy) of AI-3000K line list is quantitatively estimated in 1 cm -1 bins. It is better than 99% in the whole range of 0 – 20,000 (or 10,000) cm -1 at 1000 K (or 2000 K), or better than 90% in the whole range of 0 – 15,000 (or 9000) cm -1 at 2000 K (or 3000 K), respectively. Convergence beyond 3000 K will require a new PES and DMS for E' > 40,000 cm -1 . The AI-3000K and HITEMP based IR simulations are compared to high resolution shock tube experiments for CO 2 -Ar mixture up to 2000 K. With line position accuracy comparable to that of HITEMP, AI-3000K IR line list yields better agreements at more frequencies. Potential sources of discrepancies with experiment are discussed.

AI-3000K↗

NASA NTRS1998

Thermophotovoltaic Energy Conversion Development Program

Completely integrated thermophotovoltaic (TPV) power sources in the range of 100 to 500 watts are being developed. The technical approach taken in this project focuses on optimizing the integrated performance of the primary subsystems in order to yield high energy conversion efficiency and cost effectiveness. An important aspect of the approach is the use of a narrow band fibrous emitter radiating to a bandgap matched photovoltaic array to minimize thermal and optical recuperation requirements, as well as the non-recoverable heat losses. For the prototype system, fibrous ytterbia emitters radiating in a narrow band centered at 980 nm are matched with high efficiency silicon photoconverters. The integrated system includes a dielectric stack filter for optical energy recovery and a ceramic recuperator for thermal energy recovery. The prototype TPV system uses a rapid mix distributed fuel delivery system with controlled feeding of the fuel and heated air into a flame at the surface of the emitter. This makes it possible to operate at air preheat temperatures well above the auto-ignition temperature of the fuel thereby substantially increasing the system efficiency. The system has been operated with air preheat temperatures up to 1367 K and has produced a uniform narrow band radiation over the surface of the emitter with this approach. The design of the system is described and test data for the system and some of the key components are presented. The results from a system model, which show the impact of various parameters on system performance, are also discussed.

Shukla, Kailash↗

NASA NTRS2006

An Energy Balance Model to Predict Chemical Partitioning in a Photosynthetic Microbial Mat

Studies of biosignature formation in photosynthetic microbial mat communities offer potentially useful insights with regards to both solar and extrasolar astrobiology. Biosignature formation in such systems results from the chemical transformation of photosynthetically fixed carbon by accessory microorganisms. This fixed carbon represents a source not only of reducing power, but also energy, to these organisms, so that chemical and energy budgets should be coupled. We tested this hypothesis by applying an energy balance model to predict the fate of photosynthetic productivity under dark, anoxic conditions. Fermentation of photosynthetically fixed carbon is taken to be the only source of energy available to cyanobacteria in the absence of light and oxygen, and nitrogen fixation is the principal energy demand. The alternate fate for fixed carbon is to build cyanobacterial biomass with Redfield C:N ratio. The model predicts that, under completely nitrogen-limited conditions, growth is optimized when 78% of fixed carbon stores are directed into fermentative energy generation, with the remainder allocated to growth. These predictions were compared to measurements made on microbial mats that are known to be both nitrogen-limited and populated by actively nitrogen-fixing cyanobacteria. In these mats, under dark, anoxic conditions, 82% of fixed carbon stores were diverted into fermentation. The close agreement between these independent approaches suggests that energy balance models may provide a quantitative means of predicting chemical partitioning within such systems - an important step towards understanding how biological productivity is ultimately partitioned into biosignature compounds.

Hoehler, Tori M.↗

NASA NTRS2019

Materials and Processes for New Propulsion Systems with Reduced Environmental Impact

Aeronautics research at NASA Glenn Research Center includes development, characterization and modeling of high temperature, lightweight materials and fabrication processes for aircraft propulsion systems with increased efficiency and reduced emissions, fuel burn and noise. Current propulsion materials research includes Ceramic Matrix Composites and Environmental Barrier Coatings, Polymer Matrix Composites and Additive Manufacturing processes. This presentation will summarize recent progress and plans in these areas. Ceramic Matrix Composites for Turbine Components: As part of NASA's Aeronautics research, Glenn Research Center has developed Ceramic Matrix Composites for 2700 degrees Fahrenheit turbine engine applications in the next generation of ultra-efficient aircraft. In this presentation, the development of advanced fiber and matrix constituents that enabled this advancement will be reviewed, and characterization of the resulting improvements in mechanical properties and durability will be summarized. Progress toward the development and validation of models predicting the effects of the engine environment on durability of Ceramic Matrix Composites and Environmental Barrier Coatings will be summarized. Progress and plans for collaborative research with industry and other government agencies will be reviewed. Polymer Matrix Composites for Powertrain and Impact Protection: A lightweight, hybrid polymer matrix composite/steel gear concept for rotorcraft power transmission applications was evaluated at realistic speed, torque, and power conditions. Dynamic testing was performed at 5000 horsepower and 5400 revolutions per minute with no performance degradation. Test results demonstrated the potential of hybrid composite / metal gears to reduce gear weight by approximately 15 percent, enabling the implementation of multi-speed drive systems, which would otherwise have a weight penalty, for increased speed and efficiency. Results of post-test inspection and endurance tests will be presented. Separately, ballistic impact tests demonstrated improved damage tolerance in polymer matrix composites by incorporating lightweight, thermoplastic veil materials between selected composite plies during the composite fabrication process. Results of impact tests and post-test inspection will be presented. Additive Manufacturing for Electric Propulsion: Additive Manufacturing processes offer the potential to fabricate new, high power density electric motor designs with complex geometries, multi-material components and optimally designed components that would not be feasible with traditional manufacturing processes. High performance stator components using advanced 3-phase conductive coils were fabricated using direct printing with optimized silver pastes. Additional additive manufacturing methods are being used to fabricate rotors and motor housing components. Systems studies show that the higher performance and lower weight motors offer improved energy efficiency and reduced emissions. Improvements to motor performance resulting from optimized materials and component designs will be presented.

Additive Manufacturing↗

NASA NTRS2019

High-Performance Computing Optimization for Aladyn – Adaptive Neural Network Molecular Dynamics Mini-Application

This report provides a description and performance evaluation of the optimization techniques for high performance computing (HPC) implementation of the open source Computational Materials mini-application Aladyn (https://github.com/nasa/aladyn). Aladyn is a basic molecular dynamics code written in FORTRAN 2003, which is designed to demonstrate the use of adaptive neural networks (ANNs) in atomistic simulations. The role of ANNs is to efficiently reproduce the very complex energy landscape resulting from the atomic interactions in materials with the accuracy of the more expensive quantum mechanics-based calculations. The ANN is trained on a large set of atomic structures calculated using the density functional theory (DFT) method. While achieving orders of magnitude faster computational performance than DFT, the ANN-based approach was still very computationally demanding compared to the conventional approach of using empirically fitted energy functions. After its initial development, Aladyn was evaluated and optimized by experts at the NASA Advanced Supercomputing (NAS) division to exploit modern supercomputer architectures. The code has been optimized for execution on multicore central processing units (CPUs), including Intel® Skylake microarchitecture, and on graphic accelerators, such as Nvidia® V100 graphic processing units (GPUs), using Open Multi-Processing (OpenMP) and Open Accelerators (OpenACC) programming interfaces. The optimization achieved a speedup of 4.7 times the baseline version on CPU performance and an additional 2.4 times on CPU+GPU performance. Atomistic computer simulations are a fundamental tool in materials research to model material properties form physics-based first principles. Atomic interaction, governed by Quantum Mechanics (QM) require sophisticated and highly computationally demanding mathematical models to calculate [1]. Classical methods use approximate functional forms, empirically fitted through a set of variable parameters to emulate atomic energies as direct functions of atomic coordinates [2]. While empirical potentials are computationally much simpler, allowing simulations of large-scale systems of up to a trillion (1012) atoms [3], they are substantially less accurate compared to quantum calculations and applicable only to very specific atomic configurations or predefined crystallographic phases. A recently suggested approach is to use heuristic machine learning methods [4], such as those based on Adaptive Neural Networks (ANNs) to predict atomic energies, after being trained on a sufficiently large database of QM-calculated structures [5,6]. This approach reduces significantly the computational complexity, allowing for simulations of orders of magnitude larger systems compared to QM-based methods without compromising accuracy. Still, compared to classical methods using empirical energy functions, ANN methods remain two- to three orders of magnitude more computationally demanding. Hence, the computational cost of simulations, together with the need for extensive training of ANNs, still makes the practical implementation of ANN-based methods quite challenging. The purpose of the Aladyn mini-application software [7], available as open source at https://github.com/nasa/aladyn, is to be a testbed for exploring possible optimization strategies to develop highly scalable parallel algorithms for ANN-based atomistic simulations. Aladyn is aimed at utilizing the architecture of the high-end modern highperformance computing (HPC) hardware based on multicore central processing units (CPUs) equipped with graphic processing unit (GPU) accelerators. Specifically, the goal is to optimize the performance on a single HPC compute node, before implementing scaling to multi-node parallelization using message passing interface (MPI). At the same time, the open source code of Aladyn can serve as a training model for students and professors in academia.

Yamakov, Vesselin I.↗

NASA NTRSDate not supplied

Process Development and Hot-fire Testing of Additively Manufactured NASA HR-1 for Liquid Rocket Engine Applications

Additive manufacturing (AM) has provided new design and manufacturing opportunities to reduce cost and schedules, consolidate parts, and optimize performance. One technique being evaluated is Laser Powder Directed Energy Deposition (LP-DED), which provides a significant increase in scale compared to Laser Powder Bed Fusion (L-PBF). NASA along with industry partners have been developing the LP-DED process to demonstrate internal channel geometry and development components for use in liquid rocket engine channel cooled nozzles. Optimized materials in the extreme high pressure and hydrogen environment for liquid rocket engines remains a key challenge. NASA has advanced an enabling material called NASA HR-1 (Hydrogen Resistant -1) as a solution using AM techniques. NASA HR-1 is a high-strength Fe-Ni superalloy designed to resist high pressure, hydrogen environment embrittlement, oxidation, and corrosion. NASA HR-1 meets materials requirements for liquid rocket engine components, including good hydrogen resistance, high conductivity, good low cycle fatigue performance, and high elongation and strength for components in high heat flux environments. Material properties and process characterization have been completed on the high density thin-wall material in addition to advancements of the supply chain. NASA has also completed fabrication of several subscale and full-scale channel wall nozzles in LP-DED NASA HR-1 and completed hot-fire testing. This includes refinement of the process to produce thin-walls and various channel geometries to meet the requirements for channel wall nozzle applications. This paper will provide an overview of the LP-DED process development, material characterization and properties, component manufacturing, and hot-fire testing. Hot-fire testing was completed for a lander-class 7K-lbf thrust chamber using Liquid Oxygen (LOX)/Methane. The design overview and results from hot-fire testing will be presented in addition to hardware development for future testing on 2K-lbf and 35k-lbf thrust chambers and large-scale manufacturing technology demonstrators.

Additive Manufacturing↗