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NASA NTRS2020

Technology Advancements for Channel Wall Nozzle Manufacturing In Liquid Rocket Engines

A regeneratively-cooled or dump-cooled nozzle is a critical component for expansion of hot gases to enable high temperature and performance in liquid rocket engines systems. Regeneratively-cooled channel wall nozzles are a design solution used across the propulsion industry as a simplified method to fabricate the nozzle structure with internal coolant passages. The scale and complexity of the channel wall nozzle (CWN) design can be challenging to fabricate which results in extended lead times and higher costs. Some of these challenges include: 1) Unique and high temperature materials, 2) Tight tolerances on large parts during manufacturing and assembly to contain high pressure propellants, 3) Thin-walled features to maintain adequate wall temperatures, and 4) Unique manufacturing process operations and complex tooling. The United States (U.S.) National Aeronautics and Space Administration (NASA) and U.S. specialty manufacturing vendors are maturing modern fabrication techniques to reduce complexity and decrease costs associated with channel wall nozzle manufacturing technology. Additive Manufacturing (AM) is one of the key technology advancements under evaluation for channel wall nozzles. Much of additive manufacturing for propulsion components has focused on laser powder bed fusion (L-PBF), but the scale is not yet feasible for application to large scale nozzles. NASA is evolving directed energy deposition (DED) techniques for nozzles including arc-based deposition, blown powder deposition, and Laser Wire Direct Closeout (LWDC). There are different approaches being considered for fabrication of the nozzle, and each of these DED processes offer unique process steps for rapid fabrication. The arc-based and blown powder deposition techniques are used for the forming of the CWN liner. A variety of materials are being demonstrated including Inconel 625, Haynes 230, JBK-75, and NASA HR-1. The blown powder DED process is also being demonstrated for forming an integral channel nozzle in a single operation in similar materials. The LWDC process is a method for closing out the channels within the liner and forming the structural jacket using a localized laser wire deposition technique. Identical materials mentioned above have been used for this process in addition to bimetallic closeout (C-18150–SS347, and C-18150–Inconel 625). NASA has completed process development, material characterization, and hot-fire testing on a variety of these channel wall nozzle fabrication technique. This publication presents an overview of the various channel wall nozzle manufacturing processes and materials under evaluation including results from the hot-fire testing. Future development and technology focus areas is also discussed relative to channel wall nozzle manufacturing.

Additive manufacturing↗

NASA NTRS2018

Evaluation of Low Noise Integration Concepts and Propulsion Technologies for Future Supersonic Civil Transports

This report covers the entire effort of GE Global Research's NASA Prime Contract NNC15CA02C "Evaluation of Low Noise Integration Concepts and Propulsion Technologies for Future Supersonic Civil Transports". GE Global Research was supported by GE Aviation and Lockheed Martin in exploring the potential of wing shielding, flight path optimization, and jet noise technology to target aggressive community noise levels of 10 EPNdB lower than Chapter 14 for a future (mid-term) commercial supersonic transport aircraft.

fan noise↗

NASA NTRS2016

SMART NAS Test Bed Overview

These slides presents an overview of SMART NAS Test Bed. The test bed is envisioned to be connected to operational systems and to allow a new concept and technology to be evaluated in its realistic environment. Its role as an accelerator of concepts and technologies development, its use-case-driven development approach, and its state are presented.

national airspace system↗

NASA NTRS2016

SMART NAS Test Bed Overview

These slides presents an overview of SMART NAS Test Bed. The test bed is envisioned to be connected to operational systems and to allow a new concept and technology to be evaluated in its realistic environment. Its role as an accelerator of concepts and technologies development, its use cases and use-case-driven development approach, and its state are presented.

rapid development↗

NASA NTRS2019

Channel Wall Nozzle Manufacturing Technology Advancements for Liquid Rocket Engines

A regeneratively-cooled nozzle is a critical component for expansion of the hot gases to enable high temperature and performance liquid rocket engines systems. Channel wall nozzles are a design solution used across the propulsion industry as a simplified method to fabricate the nozzle structure with internal coolant passages. The scale and complexity of the channel wall nozzle (CWN) design is challenging to fabricate leading to extended lead times and higher costs. Some of these challenges include: 1) unique and high temperature materials, 2) Tight tolerances during manufacturing and assembly to contain high pressure propellants, 3) thin-walled features to maintain adequate wall temperatures, and 4) Unique manufacturing process operations and tooling. The United States (U.S.) National Aeronautics and Space Administration (NASA) along with U.S. specialty manufacturing vendors are maturing modern fabrication techniques to reduce complexity and decrease costs associated with channel wall nozzle manufacturing technology. Additive Manufacturing (AM) is one of the key technology advancements being evaluated for channel wall nozzles. Much of additive manufacturing for propulsion components has focused on powder bed fusion, but the scale is not yet feasible for application to large scale nozzles. NASA is evolving directed energy deposition (DED) techniques for nozzles including arc-based deposition, blown powder deposition, and Laser Wire Direct Closeout (LWDC). There are different approaches being considered for fabrication of the nozzle and each of these DED processes offer unique process steps for rapid fabrication. The arc-based and blown powder deposition techniques are being used for the forming of the CWN liner. A variety of materials are being demonstrated including Inconel 625, Haynes 230, JBK-75, and NASA HR-1. The blown powder DED process is also being demonstrated for forming an integral channel nozzle in a single operation in similar materials. The LWDC process is a method for closing out the channels within the liner and forming the structural jacket using a localized laser wire deposition technique. Identical materials mentioned above have been used for this process in addition to bimetallic closeout (C-18150–SS347, and C-18150–Inconel 625). NASA has completed process development, material characterization, and hot-fire testing on a variety of these channel wall nozzle fabrication techniques. This paper will present an overview of the various processes and materials being evaluated and the results from the hot-fire testing. Future development and technology focus areas will also be discussed relative to channel wall nozzle manufacturing.

Gradl, Paul R.↗

NASA NTRSDate not supplied

Air Sparge Pilot Study in the DNAPL Source Zone at Launch Complex 34

Multiple releases of trichloroethene (TCE) occurred at Launch Complex 34 (LC34) between the late 1950s and 1968. A 2007 conceptual site model estimated a 2-acre dense non-aqueous phase liquid (DNAPL) source area with mass in excess of 90,000 pounds, nearly 40 years after termination of launch activities. Located on a barrier island, LC34 currently has no complete exposure pathways and a historical groundwater flow radial from the DNAPL source zone (DSZ), the focus area of this study. The geology at LC34 is classified as Layers 1 through 9 with each layer representing a different lithology. These lithologies contribute to large variations in hydraulic conductivity (1x10-3 cm/sec to 1x10-8 cm/sec) with notable fine-grained units at Layer 4 (sandy clay) and Layer 7 (fine silty sand). Historically, technologies implemented at LC34 have been split vertically based on technology limitations and lithology. Remedial technologies have been evaluated to control and/or remediate the DSZ in the past; however, more aggressive technologies required significant cost and would likely leave considerable mass. Thus, an adaptive site management strategy has been implemented that adopts a treatment train approach which began in 2009 with hydraulic containment via pump and treat to control mass discharge from the DSZ while removing mass as a secondary benefit. Concurrently, hot spot areas in the larger dissolved plume are being treated by air sparging to reduce overall mass and the plume footprint. In 2019, a re-characterization of the DSZ was completed to update conditions in support of implementing more aggressive technologies as part of the treatment train approach. The results showed that the DSZ remained relatively the same size but with a slightly different morphology. Moreover, data showed that the fine-grained units (Layers 4 and 7) are storing most of the remaining mass, with TCE concentrations suggestive of DNAPL extending into Layer 7 (approximately 80 to 100 ft below land surface). Based on the current conditions, more aggressive technologies are still cost prohibitive; therefore, a different approach is warranted to determine the next implementable step in the treatment train. Air sparging is being proposed as a technology alternative based on several factors including lower treatment costs. A pilot study was conducted to test the feasibility of air sparging in the DSZ as the next step in the treatment train for that area.

Launch Complex 34↗

NASA NTRS2014

Optical Multi-Gas Monitor Technology Demonstration on the International Space Station

There are a variety of both portable and fixed gas monitors onboard the International Space Station (ISS). Devices range from rack-mounted mass spectrometers to hand-held electrochemical sensors. An optical Multi-Gas Monitor has been developed as an ISS Technology Demonstration to evaluate long-term continuous measurement of 4 gases. Based on tunable diode laser spectroscopy, this technology offers unprecedented selectivity, concentration range, precision, and calibration stability. The monitor utilizes the combination of high performance laser absorption spectroscopy with a rugged optical path length enhancement cell that is nearly impossible to misalign. The enhancement cell serves simultaneously as the measurement sampling cell for multiple laser channels operating within a common measurement volume. Four laser diode based detection channels allow quantitative determination of ISS cabin concentrations of water vapor (humidity), carbon dioxide, ammonia and oxygen. Each channel utilizes a separate vertical cavity surface emitting laser (VCSEL) at a different wavelength. In addition to measuring major air constituents in their relevant ranges, the multiple gas monitor provides real time quantitative gaseous ammonia measurements between 5 and 20,000 parts-per-million (ppm). A small ventilation fan draws air with no pumps or valves into the enclosure in which analysis occurs. Power draw is only about 3 W from USB sources when installed in Nanoracks or when connected to 28V source from any EXPRESS rack interface. Internal battery power can run the sensor for over 20 hours during portable operation. The sensor is controlled digitally with an FPGA/microcontroller architecture that stores data internally while displaying running average measurements on an LCD screen and interfacing with the rack or laptop via USB. Design, construction and certification of the Multi-Gas Monitor were a joint effort between Vista Photonics, Nanoracks and NASA-Johnson Space Center (JSC). Vista Photonics developed the core technology and built the sensor. Nanoracks designed, constructed the enclosure, interfaces, and battery power management circuitry, integrated all subsystems into the enclosure, and then managed the certification tests, documentation and manifesting. The unit was calibrated in the JSC Toxicology Laboratory. The Multi-Gas Monitor is manifested to fly as a technology demonstration to the ISS in November 2013 and will operate for at least 6 months with data sent to the ground for evaluation. The primary goal is to demonstrate long term interference free operation in the real spacecraft environment.

Pilgrim, Jeffrey S.↗

NASA NTRS1994

Design and evaluation of a Stochastic Optimal Feed-forward and Feedback Technology (SOFFT) flight control architecture

This paper describes the design and evaluation of a stochastic optimal feed-forward and feedback technology (SOFFT) control architecture with emphasis on the feed-forward controller design. The SOFFT approach allows the designer to independently design the feed-forward and feedback controllers to meet separate objectives and then integrate the two controllers. The feed-forward controller has been integrated with an existing high-angle-of-attack (high-alpha) feedback controller. The feed-forward controller includes a variable command model with parameters selected to satisfy level 1 flying qualities with a high-alpha adjustment to achieve desired agility guidelines, a nonlinear interpolation approach that scales entire matrices for approximation of the plant model, and equations for calculating feed-forward gains developed for perfect plant-model tracking. The SOFFT design was applied to a nonlinear batch simulation model of an F/A-18 aircraft modified for thrust vectoring. Simulation results show that agility guidelines are met and that the SOFFT controller filters undesired pilot-induced frequencies more effectively during a tracking task than a flight controller that has the same feedback control law but does not have the SOFFT feed-forward control.

Ostroff, Aaron J.↗

NASA NTRS1993

Reliability Prediction

RELAV, a NASA-developed computer program, enables Systems Control Technology, Inc. (SCT) to predict performance of aircraft subsystems. RELAV provides a system level evaluation of a technology. Systems, the mechanism of a landing gear for example, are first described as a set of components performing a specific function. RELAV analyzes the total system and the individual subsystem probabilities to predict success probability, and reliability. This information is then translated into operational support and maintenance requirements. SCT provides research and development services in support of government contracts.

Source record↗

NASA NTRS2008

Development of Laser, Detector, and Receiver Systems for an Atmospheric CO2 Lidar Profiling System

A ground-based Differential Absorption Lidar (DIAL) is being developed with the capability to measure range-resolved and column amounts of atmospheric CO2. This system is also capable of providing high-resolution aerosol profiles and cloud distributions. It is being developed as part of the NASA Earth Science Technology Office s Instrument Incubator Program. This three year program involves the design, development, evaluation, and fielding of a ground-based CO2 profiling system. At the end of a three-year development this instrument is expected to be capable of making measurements in the lower troposphere and boundary layer where the sources and sinks of CO2 are located. It will be a valuable tool in the validation of NASA Orbiting Carbon Observatory (OCO) measurements of column CO2 and suitable for deployment in the North American Carbon Program (NACP) regional intensive field campaigns. The system can also be used as a test-bed for the evaluation of lidar technologies for space-application. This DIAL system leverages 2-micron laser technology developed under a number of NASA programs to develop new solid-state laser technology that provides high pulse energy, tunable, wavelength-stabilized, and double-pulsed lasers that are operable over pre-selected temperature insensitive strong CO2 absorption lines suitable for profiling of lower tropospheric CO2. It also incorporates new high quantum efficiency, high gain, and relatively low noise phototransistors, and a new receiver/signal processor system to achieve high precision DIAL measurements.

Ismail, Syed↗

NASA NTRS1986

Small Engine Component Technology (SECT) studies

A study was conducted to identify component technology requirements for small, expendable gas turbine engines that would result in substantial improvements in performance and cost by the year 2000. A subsonic, 2600 nautical mile (4815 km) strategic cruise missile mission was selected for study. A baseline (state-of-the-art) engine and missile configuration were defined to evaluate the advanced technology engines. Two advanced technology engines were configured and evaluated using advanced component efficiencies and ceramic composite materials; a 22:1 overall pressure ratio, 3.85 bypass ratio twin-spool turbofan; and an 8:1 overall pressure, 3.66 bypass ratio, single-spool recuperated turbofan with 0.85 recuperator effectiveness. Results of mission analysis indicated a reduction in fuel burn of 38 and 47 percent compared to the baseline engine when using the advanced turbofan and recuperated turbofan, respectively. While use of either advanced engine resulted in approximately a 25 percent reduction in missile size, the unit life cycle (LCC) cost reduction of 56 percent for the advanced turbofan relative to the baseline engine gave it a decisive advantage over the recuperated turbofan with 47 percent LCC reduction. An additional range improvement of 10 percent results when using a 56 percent loaded carbon slurry fuel with either engine. These results can be realized only if significant progress is attained in the fields of solid lubricated bearings, small aerodynamic component performance, composite ceramic materials and integration of slurry fuels. A technology plan outlining prospective programs in these fields is presented.

Meyer, P. K.↗

NASA NTRS2019

Structural Dynamic Testing Results for Air-Independent Proton Exchange Membrane (PEM) Fuel Cell Technologies for Space Applications

In 2016, the NASA Advanced Exploration Systems (AES) project office funded research at the NASA Glenn Research Center to evaluate the maturity of the Proton Exchange Membrane (PEM) fuel cell technology and its viability for supporting launch vehicle and space applications. This technology evaluation included vibration, reactant purity, and vacuum exposure sensitivity testing. The evaluation process did not include microgravity testing. This paper discusses the vibration sensitivity testing of two air-independent fuel cell stacks provided by different vendors to assess the ability of currently available fuel cell stack hardware to survive the projected random vibrational environment that would be encountered in an upper stage launch vehicle. Baseline performance testing was utilized to quantify stack performance and overboard leak rate at standard atmospheric conditions in order to provide a reference for post-test comparison. Both fuel cell stacks were tested at a random vibration qualification level of 10.4 grms for five minutes in each axis. Low-level sinusoidal sweeps were conducted before and after each random vibration level run to see if any significant change in resonances were detected. Following vibration facility testing, the baseline performance testing was repeated. Test results demonstrated no measurable change in fuel cell electrochemical or mechanical performance, indicating that the two evaluated PEM fuel cell stacks may be suitable for space applications pending microgravity testing.

Gilligan, Ryan P.↗

NASA NTRS2026

Parametric-Based Heat Rejection Trade Study for Lunar and Martian Surface Operations

Establishing and maintaining a sustained presence on the lunar and/or Martian surfaces will require a diverse portfolio of surface elements (e.g., habitation, mobility, power generation, etc.). Many of these systems generate excess heat that must be rejected across a wide range of magnitudes, temperatures, and duty cycles and under variable environmental conditions. To identify the most promising heat rejection approaches for this diverse portfolio, a heat rejection trade study was conducted to evaluate the performance of different technology approaches across a spectrum of surface environments and heat-load requirements. The trade study consisted of three stages: (1) development of a parametric-based modeling framework, (2) creation of a database of heat rejection technologies, surface elements, and environmental conditions for the Moon and Mars, and (3) execution of a quantitative analysis of various heat rejection technologies across different operating conditions and surface elements. The modeling framework is developed in Python and Excel to prioritize small model size and hence low computational cost to enable large parametric sweeps while avoiding the reliance on proprietary software. Individual heat rejection processes are represented as simple Excel models, and a centralized Python script interfaces with the models to coordinate the parametric study. These simple sizing models were developed to take heat load requirements and environmental parameters as inputs and compute mass, power, and volume as outputs. Rather than assess each heat rejection technology separately for each surface element, a unified parametric space was developed to evaluate all technologies across all elements. This parametric space includes factors related to heat load (e.g., magnitude or temperature) and environment (e.g., surface temperature, sky temperature, solar flux). This effort generated a database containing information on over 60 heat rejection technologies and 30 surface elements. For each surface element, the expected heat rejection requirements were documented and analyzed to determine the most common needs shared across all elements. Environmental conditions at various lunar and Martian latitudes were also established for worst-case hot and worst-case cold scenarios. High-fidelity heat rejection models are currently under development. Preliminary trades between heat rejection technologies including radiators, venting technologies, convective coolers, and more have been conducted to identify promising options. This presentation will summarize the preliminary trade results and provide an overview and discussion of the expected heat loads and thermal environments for sustained surface operations on the Moon and Mars.

Heat Rejection↗

NASA NTRS2009

Nondestructive Evaluation of Advanced Fiber Reinforced Polymer Matrix Composites: A Technology Assessment

Because of their increasing utilization in structural applications, the nondestructive evaluation (NDE) of advanced fiber reinforced polymer composites continues to receive considerable research and development attention. Due to the heterogeneous nature of composites, the form of defects is often very different from a metal and fracture mechanisms are more complex. The purpose of this report is to provide an overview and technology assessment of the current state-of-the-art with respect to NDE of advanced fiber reinforced polymer composites.

Yolken, H. Thomas↗

NASA NTRS2000

Assessment of Remote Sensing Technologies for Location of Hydrogen and Helium Leaks

The objective of this initial phase of this research effort is to: 1) Evaluate remote sensing technologies for location of leaks of gaseous molecular hydrogen (H2) and gaseous helium (He) in air, for space transportation applications; and 2) Develop a diffusion model that predicts concentration of H2 or He gas as a function of leak rate and distance from the leak.

Sellar, R. Glenn↗

NASA NTRS1977

Advanced supersonic propulsion study, phase 4

Installation characteristics for a Variable Stream Control Engine (VSCE) were studied for three advanced supersonic airplane designs. Sensitivity of the VSCE concept to change in technology projections was evaluated in terms of impact on overall installed performance. Based on these sensitivity results, critical technology requirements were reviewed, resulting in the reaffirmation of the following requirements: low-noise nozzle system; a high performance, low emissions duct burner and main burner; hot section technology; variable geometry components; and propulsion integration features, including an integrated electronic control system.

Howlett, R. A.↗

NASA NTRS1985

System technology analysis of aeroassisted orbital transfer vehicles. Moderate lift/drag (0.75-1.5). Volume 1A, part 1: Executive summary, phase 1

Activities and significant results of Phase 1 of a study to access aeroassisted orbit transfer vehicle (AOTV) system technology are summarized. Broad concept evaluations were performed and the technology requirements and sensitivities for ground based AOTV's over a range of vehicle hypersonic lift/drag (L/D) from 0.75 to 1.5 were systematically identified and assessed. The four major task areas included systems analysis, system/subsystem trades, technology payoff assessment and plan, and cost analysis. Findings indicate that substantial performance improvements and hence cost benefit can be obtained by developing enhanced technologies such as: (1) low thrust advanced expander LOX-hydrogen engines with specific impulse of 480 to 490 sec; (2) reducing the external thermal protection system weight and increasing the maximum allowable bond/structure temperature; and (3) reducing the structural shell weight by improving the quality of the design allowable data, or use of advanced structural materials. Results also show that use of mid L/D AOTV's provide significant aerodynamic plane change capability and control authority over trajectory dispersions and off-nominal atmospheres.

Source record↗

NASA NTRS1992

NASA's In-Space Technology Experiments Program

The objective of the In-Space Technology Experiments Program is to evaluate and validate innovative space technologies and to provide better knowledge of the effects of microgravity and the space environment. The history, organization, methodology, and current program characteristics are presented. Results of the tank pressure control experiment and the middeck zero-gravity dynamics experiment are described to demonstrate the types of technologies that have flown and the experimental results obtained from these low-cost space flight experiments.

Levine, J.↗