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NASA NTRS2016

Additively Manufactured Low Cost Upper Stage Combustion Chamber

Over the past two years NASA's Low Cost Upper Stage Propulsion (LCUSP) project has developed Additive Manufacturing (AM) technologies and design tools aimed at reducing the costs and manufacturing time of regeneratively cooled rocket engine components. High pressure/high temperature combustion chambers and nozzles must be regeneratively cooled to survive their operating environment, causing their design fabrication to be costly and time consuming due to the number of individual steps and different processes required. Under LCUSP, AM technologies in Sintered Laser Melting (SLM) GRCop-84 and Electron Beam Freeform Fabrication (EBF3) Inconel 625 have been significantly advanced, allowing the team to successfully fabricate a 25k-class regenerative chamber. Estimates of the costs and schedule of future builds indicate cost reductions and significant schedule reductions will be enabled by this technology. Characterization of the microstructural and mechanical properties of the SLM-produced GRCop-84, EBF3 Inconel 625 and the interface layer between the two has been performed and indicates the properties will meet the design requirements. The LCUSP chamber is to be tested with a previously demonstrated SLM injector in order to advance the Technology Readiness Level (TRL) and demonstrate the capability of the application of these processes. NASA is advancing these technologies to reduce cost and schedule for future engine applications and commercial needs.

Protz, Christopher↗

NASA NTRS1989

Development of mid-infrared solid state lasers for spaceborne lidar

Laser performance of Ho(3+):Tm(3+):Cr(3+):YAG crystals was investigated under both Cr:GSAG laser and flashlamp pumping. A flashlamp pumped Cr:GSAG laser was built to simulate high power quasi-CW laser diode pumping of a 2.1 micrometer holmium laser. The 2.1 micrometer output laser energy exceeded more than 14 mJ, the highest value reported to date under laser pumping near 785 nm. This was obtained in a pulse length of nearly 650 microsec from a 3 x 3 mm Ho:Tm:Cr:YAG rod by using the flashlamp-pumped Cr:CSAG laser as a pumping source at the diode laser wavelength, 785 micrometers. In addition, Ho:Tm:Cr:YAG crystals with various Tm(3+) concentrations were evaluated for flashlamp-pumped normal mode and Q-switched 2.1 micrometer laser operations under a wide variety of experimental conditions in order to understand internal dynamic processes among the ions and to determine an optimum lasing condition. An increase of the laser slope efficiency was observed with the increase of the Tm(3+) concentration from 2.5 to 4.5 atomic percent. The thermal dependence of the laser performance was also investigated. Q-switched laser output energies corresponding to nearly 100 percent of the normal-mode laser energies were obtained in a strong single spike of 200 ns pulse length by optimizing the opening time of a lithium niobate Q-switch.

Whitney, Donald A.↗

NASA NTRS1990

Development of mid-infrared solid state lasers for spaceborne lidar

Researchers investigated laser performance of Ho(3+):Tm(3+):Cr(3+):YAG crystals under both Cr:GSAG laser and flashlamp pumping. A flashlamp pumped Cr:GSAG laser was built to simulate high power quasi-CW laser diode pumping of a 2.1 micron holmium laser. The 2.1 micron output laser energy exceeded more than 14 mJ, the highest value reported to date under laser pumping near 785 nm. This was obtained in a pulse length of nearly 650 microns from a 3 x 3 mm Ho:Tm:Cr:YAG rod by using the flashlamp-pumped Cr:GSAG laser as a pumping source at the diode laser wavelength, 785 microns. In addition, Ho:Tm:Cr:YAG crystals with various Tm(3+) concentrations have been evaluated for flashlamp-pumped normal mode and Q-switched 2.1 micron laser operations under a wide variety of experimental conditions in order to understand internal dynamic processes among the ions and to determine an optimum lasing condition. An increase of the laser slope efficiency was observed with the increase of the Tm(3+) concentration from 2.5 atomic percent to 4.5 atomic percent. The thermal dependence of the laser performance was also investigated. Q-switched laser output energies corresponding to nearly 100 percent of the normal-mode laser energies were obtained in a strong single spike of 200 ns pulse length by optimizing the opening time of a lithium niobate Q-switch.

Whitney, Donald A.↗

NASA NTRS2003

Laser-Based Relative Navigation and Guidance for Space Shuttle Proximity Operations

American manned spacecraft have used visual piloting techniques in the terminal phase of randezvous during the Gemini, Apollo, Skylab, and Space Shuttle programs. In the last several years, space- shuttle astronauts have used the Rendezvous and Proximity Operations Program (RPOP), running; on a laptop computer, as a guidance and navigation aid during proximity operations. By processing measurements to the target satellite taken by a laser sensor, RPOP provides the shuttle crew with a more accurate relative position and velocity than from any other source. The inclusion of guidance algorithms allows RPOP to determine delta-velocities to fly very efficient, repeatable trajectories. This paper will focus on the guidance and navigation algorithms in RPOP, as well as results from simulation and flight. Although developed for shuttle proximity operations, the RPOP algorithms have potential applicability to an automated vehicle.

Laser sensors↗

NASA NTRS1992

Laser Transmitter Module (LTM) for LITE

In Dec. 1991 TITAN SPECTRON successfully completed its six year effort to design, build, space qualify, test, and deliver the Laser Transmitter Module (LTM) for NASA LaRC's LITE program. The delivered LTM is a three color Q-switched flashlamp pumped Nd:YAG laser that is described as the first true world-class lidar in space. The preliminary design and verification tests results were first presented at the 14th International Laser Radar Conference (ILRC) in 1988. This paper describes not only the delivered product but also the verification and space qualification processes that resulted in the world's first space qualified high powered laser system for environmental exploration from space. Video of the laser operating in a Class 100 clean room and subsystems undergoing 10 G vibration tests will provide a vivid illustration of the key elements that separate a space qualified system from its laboratory counterpart. Flight laser performance measurements form the baseline in post-delivery test results to be presented at this conference.

Chang, John↗

NASA NTRS2002

Laser Induced Aluminum Surface Breakdown Model

Laser powered propulsion systems involve complex fluid dynamics, thermodynamics and radiative transfer processes. Based on an unstructured grid, pressure-based computational aerothermodynamics; platform, several sub-models describing such underlying physics as laser ray tracing and focusing, thermal non-equilibrium, plasma radiation and air spark ignition have been developed. This proposed work shall extend the numerical platform and existing sub-models to include the aluminum wall surface Inverse Bremsstrahlung (IB) effect from which surface ablation and free-electron generation can be initiated without relying on the air spark ignition sub-model. The following tasks will be performed to accomplish the research objectives.

Chen, Yen-Sen↗

NASA NTRS2015

Computational Process Modeling for Additive Manufacturing (OSU)

Powder-Bed Additive Manufacturing (AM) through Direct Metal Laser Sintering (DMLS) or Selective Laser Melting (SLM) is being used by NASA and the Aerospace industry to "print" parts that traditionally are very complex, high cost, or long schedule lead items. The process spreads a thin layer of metal powder over a build platform, then melts the powder in a series of welds in a desired shape. The next layer of powder is applied, and the process is repeated until layer-by-layer, a very complex part can be built. This reduces cost and schedule by eliminating very complex tooling and processes traditionally used in aerospace component manufacturing. To use the process to print end-use items, NASA seeks to understand SLM material well enough to develop a method of qualifying parts for space flight operation. Traditionally, a new material process takes many years and high investment to generate statistical databases and experiential knowledge, but computational modeling can truncate the schedule and cost -many experiments can be run quickly in a model, which would take years and a high material cost to run empirically. This project seeks to optimize material build parameters with reduced time and cost through modeling.

Bagg, Stacey↗

NASA NTRS1992

Low thrust chemical rocket technology

An on-going technology program to improve the performance of low thrust chemical rockets for spacecraft on-board propulsion applications is reviewed. Improved performance and lifetime is sought by the development of new predictive tools to understand the combustion and flow physics, introduction of high temperature materials and improved component designs to optimize performance, and use of higher performance propellants. Improved predictive technology is sought through the comparison of both local and global predictions with experimental data. Predictions are based on both the RPLUS Navier-Stokes code with finite rate kinetics and the JANNAF methodology. Data were obtained with laser-based diagnostics along with global performance measurements. Results indicate that the modeling of the injector and the combustion process needs improvement in these codes and flow visualization with a technique such as 2-D laser induced fluorescence (LIF) would aid in resolving issues of flow symmetry and shear layer combustion processes. High temperature material fabrication processes are under development and small rockets are being designed, fabricated, and tested using these new materials. Rhenium coated with iridium for oxidation protection was produced by the Chemical Vapor Deposition (CVD) process and enabled an 800 K increase in rocket operating temperature. Performance gains with this material in rockets using Earth storable propellants (nitrogen tetroxide and monomethylhydrazine or hydrazine) were obtained through component redesign to eliminate fuel film cooling and its associated combustion inefficiency while managing head end thermal soakback. Material interdiffusion and oxidation characteristics indicated that the requisite lifetimes of tens of hours were available for thruster applications. Rockets were designed, fabricated, and tested with thrusts of 22, 62, 440 and 550 N. Performance improvements of 10 to 20 seconds specific impulse were demonstrated. Higher performance propellants were evaluated: Space storable propellants, including liquid oxygen (LOX) as the oxidizer with nitrogen hydrides or hydrocarbon as fuels. Specifically, a LOX/hydrazine engine was designed, fabricated, and shown to have a 95 pct theoretical c-star which translates into a projected vacuum specific impulse of 345 seconds at an area ratio of 204:1. Further performance improvment can be obtained by the use of LOX/hydrogen propellants, especially for manned spacecraft applications, and specific designs must be developed and advanced through flight qualification.

Schneider, Steven J.↗

NASA NTRS1991

Theoretical and experimental analysis of injection seeding a Q-switched alexandrite laser

Injection seeding is a method for achieving linewidths of less than 500 MHz in the output of broadband, tunable, solid state lasers. Dye lasers, CW and pulsed diode lasers, and other solid state lasers have been used as injection seeders. By optimizing the fundamental laser parameters of pump energy, Q-switched pulse build-up time, injection seed power and mode matching, one can achieve significant improvements in the spectral purity of the Q-switched output. These parameters are incorporated into a simple model for analyzing spectral purity and pulse build-up processes in a Q-switched, injection-seeded laser. Experiments to optimize the relevant parameters of an alexandrite laser show good agreement.

Prasad, C. R.↗

NASA NTRS1994

Containerless liquid-phase processing of ceramic materials

Containerless melting and solidification provides a powerful tool for investigation and synthesis of ceramic and glass materials. The work described in this article explored and extended the limits of ground-based experimentation by using aero-acoustic and aerodynamic levitation in combination with laser beam heating and melting to investigate ceramic and glass processing. Results of liquid-phase processing experiments on calcia-gallia and calcia-gallia-silica glass-forming mixtures, aluminum oxide, and ceramic superconductors are summarized. The work is discussed in the context of low gravity experimental and materials synthesis requirements and opportunities.

Weber, J. K. R.↗

NASA NTRS1994

Removal of Residual Chromium from Aluminum Oxide by Containerless Liquid-phase Processing

Berneuil sapphire was purified of Cr 3+ by containerless melting and processing at ca. 2550 K in high purity argon, dry air and pure oxygen. Recovered material was examined by laser induced fluorescence and Raman spectroscopy. The Cr 3+ fluorescence intensity decreased in processed specimens at rates proportional to the chromium concentration and p(O 2 ) 0.21 . The initial chromium concentration was ca. 5 ppm and decreased by factors of ca. 50, 3000, and 2x10 5 after processing for 300 seconds in argon, air and oxygen, respectively. Evidence is presented that the Cr 3+ was removed predominantly as CrO 2 (g) and not by conversion to other oxidation states of chromium in the condensed phase. A comparison of the Raman peak shifts for as-received and processed samples indicates that considerable stress was retained during containerless solidification of the highly undercooled melts.

sapphire↗

NASA NTRS1993

Study of optical techniques for the Ames unitary wind tunnel: Digital image processing, part 6

A survey of digital image processing techniques and processing systems for aerodynamic images has been conducted. These images covered many types of flows and were generated by many types of flow diagnostics. These include laser vapor screens, infrared cameras, laser holographic interferometry, Schlieren, and luminescent paints. Some general digital image processing systems, imaging networks, optical sensors, and image computing chips were briefly reviewed. Possible digital imaging network systems for the Ames Unitary Wind Tunnel were explored.

Lee, George↗

NASA NTRS2001

Laser Induced Aluminum Surface Breakdown Model

Laser powered propulsion systems involve complex fluid dynamics, thermodynamics and radiative transfer processes. Based on an unstructured grid., pressure-based computational aerothermodynamics, platform, several sub-nio"'dels describing such underlying physics as laser ray tracing and focusing, thermal non-equilibrium, plasma radiation and air spark ignition have been developed. This proposed work shall extend the numerical platform and existing sub-models to include the aluminum wall surface Inverse Bremsstrahlung (113) effect from which surface ablation and free-electron generation can be initiated without relying on the air spark ignition sub-model. The following tasks will be performed to accomplish the research objectives.

Chen, Yen-Sen↗

NASA NTRSDate not supplied

Metal Additive Manufacturing for Rocket Engines: Successes and Failures

NASA has been developing additive manufacturing (AM) for various technical and programmatic advantages for complex rocket engine and aerospace components. This maturation has focused on various AM processes, new alloys, characterizing material properties, developing standards, producing demonstrator parts, and integrating AM hardware in liquid rocket engines through test-fail-fix cycles, as well as application and dissemination of lessons learned of the AM lifecycle. The importance of proper AM processing was made evident in the failure of a Laser Powder Bed Fusion (L-PBF) copper-alloy combustion chamber during a hot-fire test due to a degraded material quality. The hot-fire test aimed to demonstrate high duty cycle under a risk-tolerant development project, where consequences of component failure would be minimal. However, the unintentional component failure emphasized the necessity of robust material characterization and rigorous process control procedures for the safe use of AM components in critical applications. This presentation provides an overview of the development failure, a discussion on the evaluation of the failed chamber and supplemental chambers produced at the same time, a representative material samples that included intentional build witness lines, and a summary of the key results and recommendations from the evaluations. NASA continues to approach AM processes and designs with a level of risk and acceptance of failures that is appropriate for the project objectives, with the overall goal of safe implementation of AM technology and transferring AM technology into commercial space applications. This presentation with provide critical awareness to the community lessons learned on proper implementation of AM.

L-PBF↗

NASA NTRSDate not supplied

Successes and Failures of Metal Additive Manufacturing for Rocket Engines

Additive Manufacturing↗

NASA NTRS1978

Automated space fabrication of structural elements

A description is presented of an automated space fabrication technique for basic structural elements, taking into account as representative the design loads and requirements of the solar power satellite structure. Roll forming for continuous cap and brace members is applicable for all proposed metallic materials. Spot-welding, electron beam welding, ultrasonic welding, laser welding, cold welding, and various mechanical fastening techniques are applicable for the automated fabrication process. Termination of the formed cap and brace members can be accomplished by sawing, shearing, punching, and laser cutting. The most cost effective materials were found to be the aluminum alloys. Selected for further study were AL20224T3 and AL2219-T62. In the area of fiber composites, thermoplastic matrix materials with graphite fibers were selected for future studies.

Engler, E. E.↗

NASA NTRS1993

Spacesuit glove manufacturing enhancements through the use of advanced technologies

The sucess of astronauts performing extravehicular activity (EVA) on orbit is highly dependent upon the performance of their spacesuit gloves.A study has recently been conducted to advance the development and manufacture of spacesuit gloves. The process replaces the manual techniques of spacesuit glove manufacture by utilizing emerging technologies such as laser scanning, Computer Aided Design (CAD), computer generated two-dimensional patterns from three-dimensionl surfaces, rapid prototyping technology, and laser cutting of materials, to manufacture the new gloves. Results of the program indicate that the baseline process will not increase the cost of the gloves as compared to the existing styles, and in production, may reduce the cost of the gloves. perhaps the most important outcome of the Laserscan process is that greater accuracy and design control can be realized. Greater accuracy was achieved in the baseline anthropometric measurement and CAD data measurement which subsequently improved the design feature. This effectively enhances glove performance through better fit and comfort.

Cadogan, David↗

NASA NTRS1995

Analysis of measurements for solid state laser remote lidar system

The merits of using lidar systems for remote measurements of various atmospheric processes such as wind, turbulence, moisture, and aerosol concentration are widely recognized. Although the lidar technology has progressed considerably over the past two decades, significant research particularly in the area of solid state lidars remains to be conducted in order to fully exploit this technology. The work performed by the UAH (University of Alabama in Huntsville) personnel under this Delivery Order concentrated on analyses of measurements required in support of solid state laser remote sensing lidar systems which are to be designed, deployed, and used to measure atmospheric processes and constituents. UAH personnel has studied and recommended to NASA/MSFC the requirements of the optical systems needed to characterize the detection devices suitable for solid state wavelengths and to evaluate various heterodyne detection schemes. The 2-micron solid state laser technology was investigated and several preliminary laser designs were developed and their performance for remote sensing of atmospheric winds and clouds from a spaceborne platform were specified. In addition to the laser source and the detector, the other critical technologies necessary for global wind measurements by a spaceborne solid state coherent lidar systems were identified to be developed and demonstrated. As part of this work, an analysis was performed to determine the atmospheric wind velocity estimation accuracy using the line-of-sight measurements of a scanning coherent lidar. Under this delivery order, a computer database of materials related to the theory, development, testing, and operation of lidar systems was developed to serve as a source of information for lidar research and development.

Amzajerdian, Farzin↗