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NASA NTRSDate not supplied

NASA's Composite Overwrap Lessons Learned on 40k Thrust Chamber Assemblies

Filament wound carbon fiber/polymer composite overwraps combined with additively manufactured (AM) copper alloy combustion chambers are a critical part of NASA’s Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project. The composite overwrap is a high strength-to-weight material and allows for significant weight reduction of the high-pressure thrust chamber assembly, reduction of overall cost, and reduced fabrication time while offering structural robustness. Integrated AM/composite overwrap chamber assemblies using 2,000 lbf (2k) and 7,000 lbf (7k) thrust were successfully hot fire tested at NASA Marshall Space Flight Center (MSFC). These assemblies allowed the team to learn lessons related to the design, analysis, and manufacturing of these integrated assemblies. A final goal of the RAMPT project is to design and test a 40,000 lbf (40k) thrust chamber assembly. The40k chamber presented the team several new challenges including an integral inlet port in the main body of the composite overwrap. Through multiple iterations of manufacturing techniques, varied materials, and Non-Destructive Evaluations (NDE), many lessons were learned to obtain a final design solution that would not only allow for the interrupted port inlet but also allow for sufficient material margins for the most critically stressed part of the chamber. This paper will cover the manufacturing techniques exploring fabric designs to help subsidize the coverage in the areas left bare by the inlet port during the filament winding process and custom tooling needed for the final full chamber processing. The original material choice of bismaleimide (BMI) 5250-4 from the 7k chamber performed well for the extreme environment of hot fire testing but proved to be difficult with the increased scale and interrupted port design of the 40kchamber. Discussion in this paper will cover these changes, including evaluation of the design, comparison to the prior 2k and 7k designs, and show the final hardware that will be tested. One primary goal of this work and RAMPT project is to provide this development process and data to industry for infusion into future engine designs.

Filament Wound↗

DOE OSTI2024

Challenging Common Assumptions of Thick-Wall Chamber Dynamics in Inertial Fusion Systems using MOOSE

As an increasing number of companies look toward commercial Inertial Fusion Energy (IFE) designs, there is a pressing need to understand the physics of thick-wall chamber gas dynamics. The thick liquid wall approach implements a renewable wall to mitigate the fusion target emissions, thereby reducing the radiation damage rate and significantly extending the lifetime of chamber structures, leading to increased plant availability and reduced waste streams in comparison to dry wall chamber designs. It is necessary, however, to assess the critical performance and safety aspects of these systems. For example, it is crucial to predict (1) where the mass ablated from the liquid walls will vent, which determines the placement of condensing surfaces; (2) debris propagation up the beam lines, which provides essential information for design and protection requirements; (3) peak pressures and impulse on chamber walls, which affect chamber structural design; and (4) momentum transfer to the liquid jets, which constrains the shape and positioning of the jets. In turn, the chamber design and its liquid walls affect shielding requirements, material activation, and tritium fuel cycle. Currently available simulation tools, however, are unable to accurately capture key thick-wall chamber dynamics. Significant assumptions are often made to simplify the system and reduce computational cost and modeling capability needs, but the impact of these assumptions on simulation predictions has not been evaluated. For example, no three-dimensional simulations can be found in the open literature to evaluate gas venting and momentum transfer to the jets with simulations using two-dimensional domains to represent complex three-dimensional geometries. Moreover, limited studies have been dedicated to jet breakup due to both turbulence and neutron heating, and no studies have been found that evaluate how jet breakup can impact shock-jet interaction. Furthermore, effects of radiative heat transfer have rarely been included for the hydrodynamic phase of shock propagation, and integration of proper equations of state in shock dynamics codes has been mostly exploratory. In this study, we use the flexible, high-fidelity Multiphysics Object-Oriented Simulation Environment (MOOSE) to model these complex phenomena and inform design and safety studies. Capabilities to model thick-wall chamber gas dynamics are being developed, and the impact of the assumptions listed above (i.e., two-dimensional vs three-dimensional, absence of jet breakout, no radiative heat transfer, and ideal gas behavior) are being quantified.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2024

Challenging Common Assumptions of Thick-Wall Chamber Dynamics in Inertial Fusion Systems Using MOOSE-based Multiphysics Simulations

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Numerical simulation of compressible fluid-dynamics in the chamber of inertial fusion energy systems

Here, this paper aims to establish new and innovative modeling capabilities for analyzing chambers in Inertial Fusion Energy (IFE) systems. IFE is emerging as a promising method to achieve fusion power production, but several challenges must be overcome to develop an IFE pilot plant or deploy commercial IFE systems. These challenges are both theoretical and technical, encompassing a deeper understanding of the underlying physical phenomena and the development of new technologies and materials. One of the needs is to develop mathematical models to describe IFE systems and numerical tools to simulate them. This paper contributes to this endeavor by presenting a new OpenFOAM solver for IFE systems, focusing on gas dynamics in their chambers. The analysis and development of chamber designs will play a significant role in the transition from single-shot experiments to high-repetition rates, as there is a need to protect the chamber walls from the intense radiation fields produced by fusion reactions. A promising design option, normally referred to as thick wall chamber design, consists in using lithium or molten salt jet arrays within the chamber. A critical phenomenon is the venting of high-pressure gases from the center to the external part of the chamber, passing through the blanket array. This process involves the propagation and attenuation of strong pressure waves, requiring suitable modeling approaches for compressible fluid-dynamics. The solver proposed in this work implements a multi-material hydrodynamics model tailored to accurately describe the non-linear propagation of pressure waves while avoiding numerical oscillation issues typical of high-velocity compressible simulation. This solver is verified against numerical test cases, validated against experimental data, and applied to the analysis of the High-Yield Lithium-Injection Fusion-Energy (HYLIFE-I) concept. The relevance of this paper is threefold. Firstly, it contributes to developing and testing modeling approaches for compressible fluid-dynamics phenomena, with specific focus on the new and unexplored topic of IFE thick-liquid-wall blanket modeling. Secondly, it marks one of the first applications of the OpenFOAM library in the research field of IFE systems. Finally, the investigated problem is of practical interest for IFE developers, as it provides useful indications about relevant phenomena in pressure wave propagation in the chamber of these systems.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1976

Experimental and theoretical investigation of fatigue life in reusable rocket thrust chambers

During a test program to investigate low-cycle thermal fatigue, 13 rocket combustion chambers were fabricated and cyclically test fired to failure. Six oxygen-free, high-conductivity (OFHC) copper and seven Amzirc chambers were tested. The chamber liners were fabricated of copper or copper alloy and contained milled coolant channels. The chambers were completed by means of an electroformed nickel closeout. The oxidant/fuel ratio for the liquid oxygen and gaseous hydrogen propellants was 6.0. The failures in the OFHC copper chambers were not typical fatigue failures but are described as creep rupture enhanced by ratcheting. The coolant channels bulged toward the chamber centerline, resulting in progressive thinning of the wall during each cycle. The failures in the Amzirc alloy chambers were caused by low-cycle thermal fatigue. The lives were much shorter than were predicted by an analytical structural analysis computer program used in conjunction with fatigue life data from isothermal test specimens, due to the uneven distribution of Zr in the chamber material.

Hannum, N. P.↗

NASA NTRS1986

Liquid oxygen cooling of high pressure LOX/hydrocarbon rocket thrust chambers

An experimental program using liquid oxygen (LOX) and RP-1 as the propellants and supercritical LOX as the coolant was conducted at 4.14, 8.27, and 13.79 MN/sq m (600, 1200, and 2000 psia) chamber pressure. The objectives of this program were to evaluate the cooling characteristics of LOX with the LOX/RP-1 propellants, the buildup of the soot on the hot-gas-side chamber wall, and the effect of an internal LOX leak on the structural integrity of the combustor. Five thrust chambers with throat diameters of 6.6 cm (2.5 in.) were tested successfully. The first three were tested at 4.14 MN/sq m (600 psia) chamber pressure over a mixture ratio range of 2.25 to 2.92. One of these three was tested for over 22 cyclic tests after the first through crack from the coolant channel to the combustion zone was observed with no apparent metal burning or distress. The fourth chamber was tested at 8.27 MN/sq m (1200 psia) chamber pressure over a mixture range of 1.93 to 2.98. The fourth and fifth chambers were tested at 13.79 MN/sq m (2000 psia) chamber pressure over a mixture ratio range of 1.79 to 2.68.

Price, H. G.↗

NASA NTRS1991

Deployment and testing of a second prototype expandable surgical chamber in microgravity

During microgravity exposure, two separate expandable surgical chambers were tested. Both chambers had been modified to fit the microgravity work station without extending over the sides of the table. Both chambers were attached to a portable laminar flow generator which served two purposes: to keep the chambers expanded during use; and to provide an operative area environment free of contamination. During the tests, the chambers were placed on various parts of a total body moulage to simulate management of several types of trauma. The tests consisted of cleansing contusions, debridement of burns, and suturing of lacerations. Also, indigo carmine dye was deliberately injected into the chamber during the tests to determine the ease of cleansing the chamber walls after contamination by escaping fluids. Upon completion of the tests, the expandable surgical chambers were deflated, folded, and placed in a flattened state back into their original containers for storage and later disposal. Results are briefly discussed.

Markham, Sanford M.↗

NASA NTRS1991

Subscale LOX/hydrogen testing with a modular chamber and a swirl coaxial injector

To support basic injector and chamber technology, the response of a modular calorimeter chamber to an injector with swirl coaxial elements was investigated. The tests supported both the Advanced Launch System (ALS) and the Space Shuttle Main Engine programs. Original test plans included chamber pressures up to 2250 psia, the current ALS engine criteria, but hardware limitations forced conditions to be reduced. With four different chamber configurations, a variety of data was obtained with chamber pressures ranging from 1483 psia to 1679 psia and mixture ratios from 5.24 to 6.90. The swirl coaxial injector showed good chamber wall compatibility, despite misaligned elements, and its high performance was independent of fuel. Heating rates and wall temperatures were acceptable and close to predict profiles, and after scaling to a chamber pressure of 2250 psia, heating rates remained acceptable. In addition, a chamber spool made with the vacuum plasma spray process survived hot-fire testing with no detrimental effects.

Elam, Sandra K.↗

NASA NTRS1992

A two dimensional finite difference time domain analysis of the quiet zone fields of an anechoic chamber

Prediction of anechoic chamber performance is a difficult problem. Electromagnetic anechoic chambers exist for a wide range of frequencies but are typically very large when measured in wavelengths. Three dimensional finite difference time domain (FDTD) modeling of anechoic chambers is possible with current computers but at frequencies lower than most chamber design frequencies. However, two dimensional FDTD (2D-FTD) modeling enables much greater detail at higher frequencies and offers significant insight into compact anechoic chamber design and performance. A major subsystem of an anechoic chamber for which computational electromagnetic analyses exist is the reflector. First, an analysis of the quiet zone fields of a low frequency anechoic chamber produced by a uniform source and a reflector in two dimensions using the FDTD method is presented. The 2D-FDTD results are compared with results from a three dimensional corrected physical optics calculation and show good agreement. Next, a directional source is substituted for the uniform radiator. Finally, a two dimensional anechoic chamber geometry, including absorbing materials, is considered, and the 2D-FDTD results for these geometries appear reasonable.

Ryan, Deirdre A.↗

NASA NTRS1947

Determination of ram-jet combustion-chamber temperatures by means of total-pressure surveys

A method is described by which the total temperature of the gases at the combustion-chamber outlet of a ram-jet engine may be determined from the loss in total pressure measured across the combustion chamber. A working chart is presented by means of which the ratio of the total temperature of the gases at the combustion-chamber outlet to the total temperature of the gases at the combustion-chamber inlet may be determined from the measured loss of total pressure across the combustion chamber and the known values of air flow, total pressure, and total temperature at the combustion-chamber inlet. Values of total-temperature ratio across the combustion chamber of a 20-inch ram jet were obtained in the Cleveland altitude wind tunnel over a range of pressure altitudes from 6000 to 15,000 feet. The difference between the temperature ratio across the combustion chamber determined from the chart and that obtained from the thermocouple measurement was within 6.2 percent of the thermocouple-temperature ratio and was within the accuracy of the thermocouple measurements.

Pinkel, I Irving↗

NASA NTRS1993

Small rocket flowfield diagnostic chambers

Instrumented and optically-accessible rocket chambers are being developed to be used for diagnostics of small rocket (less than 440 N thrust level) flowfields. These chambers are being tested to gather local fluid dynamic and thermodynamic flowfield data over a range of test conditions. This flowfield database is being used to better understand mixing and heat transfer phenomena in small rockets, influence the numerical modeling of small rocket flowfields, and characterize small rocket components. The diagnostic chamber designs include: a chamber design for gathering wall temperature profiles to be used as boundary conditions in a finite element heat flux model; a chamber design for gathering inner wall temperature and static pressure profiles; and optically-accessible chamber designs, to be used with a suite of laser-based diagnostics for gathering local species concentration, temperature, density, and velocity profiles. These chambers were run with gaseous hydrogen/gaseous oxygen (GH2/GO2) propellants, while subsequent versions will be run on liquid oxygen/hydrocarbon (LOX/HC) propellants. The purpose, design, and initial test results of these small rocket flowfield diagnostic chambers are summarized.

Morren, Sybil↗

NASA NTRS1994

Evaluation of oxide-coated iridium-rhenium chambers

Iridium-coated rhenium (Ir-Re) provides long life operation of radiation-cooled rockets at temperatures up to 2200 C. Ceramic oxide coatings could be used to increase Ir-Re rocket lifetimes and allow operation in highly oxidizing environments. Ceramic oxide coatings promise to serve as both thermal and diffusion barriers for the iridium layer. Seven ceramic oxide-coated Ir-Re, 22-N rocket chambers were tested with gaseous hydrogen/gaseous oxygen (GHz/G02) propellants. Five chambers had thick (over 10 mils), monolithic coatings of either hafnia (HfO2) or zirconia (ZrO2). Two chambers had coatings with thicknesses less than 5 mils. One of these chambers had a thin-walled coating of ZrO2 infiltrated with sol gel HfO2. The other chamber had a coating composed of an Ir-oxide composite. The purpose of this test program was to assess the ability of the oxide coatings to withstand the thermal shock of combustion initiation, adhere under repeated thermal cycling, and operate in aggressively oxidizing environments. All of the coatings survived the thermal shock of combustion and demonstrated operation at mixture ratios up to 11. Testing the Ir-oxide composite-coated chamber included over 29 min at mixture ratio 16. The thicker walled coatings provided the larger temperature drops across the oxide layer (up to 570 C), but were susceptible to macrocracking and eventual chipping at a stress concentrator. The cracks apparently resealed during firing, under compression of the oxide layer. The thinner walled coatings did not experience the macrocracking and chipping of the chambers that was seen with the thick, monolithic coatings. However, burn-throughs in the throat region did occur in both of the thin-walled chambers at mixture ratios well above stoichiometric. The burn-throughs were probably the result of oxygen diffusion through the oxide coating that allowed the underlying Ir and Re layers to be oxidized. The results of this test program indicated that the thin-walled oxide coatings are better suited for repeated thermal cycling than the thick-walled coating, while thicker coatings may be required for operation in aggressively oxidizing environments.

Reed, Brian D.↗

NASA NTRS1993

Testing and evaluation of oxide-coated iridium/rhenium chambers

Iridium-coated rhenium provides long life operation of radiation-cooled rockets at temperatures up to 2200 C. Ceramic oxide coatings could be used to increase iridium/rhenium rocket lifetimes and allow operation in highly oxidizing environments. Ceramic oxide coatings promise to serve as both thermal and diffusion barriers for the iridium layer. Seven ceramic oxide-coated iridium/rhenium, 22 N rocket chambers were tested on gaseous hydrogen/gaseous oxygen propellants. Five chambers had thick (over 10 mils), monolithic coatings of either hafnia or zirconia. Two chambers had coatings with thicknesses less than 5 mils. One of these chambers had a thin-walled coating of zirconia infiltrated with sol gel hafnia. The other chamber had a coating composed of an iridium/oxide composite. The purpose of this test program was to assess the ability of the oxide coatings to withstand the thermal shock of combustion initiation, adhere under repeated thermal cycling, and operate in aggressively oxidizing environments. All of the coatings survived the thermal shock of combustion and demonstrated operation at mixture ratios up to 11. The iridium/oxide composite coated chamber included testing for over 29 minutes at mixture ratio 16. The thicker-walled coatings provided the larger temperature drops across the oxide layer (up to 570 C), but were susceptible to macrocracking and eventual chipping at a stress concentrator. The cracks apparently resealed during firing, under compression of the oxide layer. The thinner-walled coatings did not experience the macrocracking and chipping of the chambers seen with the thick, monolithic coatings. However, burnthroughs in the throat region did occur in both of the thin-walled chambers at mixture ratios well above stochiometric. The burn-throughs were probably the result of oxygen-diffusion through the oxide coating that allowed the underlying iridium and rhenium layers to be oxidized. The results of this test program indicated that the thin-walled oxide coatings are better suited for repeated thermal cycling than the thick-walled coating, while thicker coatings may be required for operation in aggressively oxidizing environments.

Reed, Brian D.↗

NASA NTRS2004

On Orbit Daytime Solar Heating Effects: A Comparison of Ground Chamber Arcing Results

The purpose of the current experiment is to make direct comparisons between the arcing results obtained from the diffusion pumped vertical chamber and our newly renovated Teney vacuum chamber which is equipped with a cryogenic pump. Recall that the prior reported results obtained for the Vertical chamber were nominal at best, showing only a slight reduction in the arc rate after 5 heating cycles at the lower bias potentials and virtually no changes at high potential biases. It was concluded that the vertical chamber was unable to remove enough water vapor from the chamber to adequately test the arcing criterion. Because the cryo-pumped Teney chamber has a ten times better pumping speed, (40,000 liters per sec compared to 4,000 liters per sec for the diffusion pumped vertical chamber), a decision was made to retest that experiment in both the Teney and Vertical vacuum chambers. A comparison of the various data is presented with encouraging results.

Galofaro, J.↗

NASA NTRS2004

On-Orbit Daytime Solar Heating Effects: A Comparison of Ground Chamber Arcing Results

The purpose of the current experiment is to make direct comparisons between the arcing results obtained from the diffusion pumped vertical chamber and our newly renovated Teney vacuum chamber which is equipped with a cryogenic pump. Recall that the prior reported results obtained for the Vertical chamber were nominal at best, showing only a slight reduction in the arc rate after five heating cycles at the lower bias potentials and virtually no changes at high potential biases. It was concluded that the vertical chamber was unable to remove enough water vapor from the chamber to adequately test the arcing criterion. Because the cryo-pumped Teney chamber has a ten times better pumping speed, (40,000 liters per sec compared to 4,000 liters per sec for the diffusion pumped vertical chamber), a decision was made to retest that experiment in both the Teney and Vertical vacuum chambers. A comparison of the various data is presented with encouraging results.

Galofaro, J.↗

NASA NTRS2012

The Mobile Chamber

A document discusses a simulation chamber that represents a shift from the thermal-vacuum chamber stereotype. This innovation, currently in development, combines the capabilities of space simulation chambers, the user-friendliness of modern-day electronics, and the modularity of plug-and-play computing. The Mobile Chamber is a customized test chamber that can be deployed with great ease, and is capable of bringing payloads at temperatures down to 20 K, in high vacuum, and with the desired metrology instruments integrated to the systems control. Flexure plans to lease Mobile Chambers, making them affordable for smaller budgets and available to a larger customer base. A key feature of this design will be an Apple iPad-like user interface that allows someone with minimal training to control the environment inside the chamber, and to simulate the required extreme environments. The feedback of thermal, pressure, and other measurements is delivered in a 3D CAD model of the chamber's payload and support hardware. This GUI will provide the user with a better understanding of the payload than any existing thermal-vacuum system.

Scharfstein, Gregory↗

NASA NTRS2012

Utilizing Chamber Data for Developing and Validating Climate Change Models

Controlled environment chambers (e.g. growth chambers, SPAR chambers, or open-top chambers) are useful for measuring plant ecosystem responses to climatic variables and CO2 that affect plant water relations. However, data from chambers was found to overestimate responses of C fluxes to CO2 enrichment. Chamber data may be confounded by numerous artifacts (e.g. sidelighting, edge effects, increased temperature and VPD, etc) and this limits what can be measured accurately. Chambers can be used to measure canopy level energy balance under controlled conditions and plant transpiration responses to CO2 concentration can be elucidated. However, these measurements cannot be used directly in model development or validation. The response of stomatal conductance to CO2 will be the same as in the field, but the measured response must be recalculated in such a manner to account for differences in aerodynamic conductance, temperature and VPD between the chamber and the field.

Monje, Oscar↗

NASA NTRS2017

Application of Molecular Adsorber Coatings in Chamber A for the James Webb Space Telescope

As a coating made of highly porous zeolite materials, the Molecular Adsorber Coating (MAC) was developed to capture outgassed molecular contaminants, such as hydrocarbons and silicones. For spaceflight applications, the adsorptive capabilities of the coating can alleviate on-orbit outgassing concerns on or near sensitive surfaces and instruments within the spacecraft. Similarly, this sprayable paint technology has proven to be significantly beneficial for ground-based space applications, in particular, for vacuum chamber environments. This presentation describes the application of the MAC technology for the James Webb Space Telescope (JWST) at NASA Johnson Space Center (JSC). The coating was used as a mitigation tool to entrap outgassed contaminants, specifically silicone-based diffusion pump oil, from within JSCs cryogenic optical vacuum chamber test facility called Chamber A. This presentation summarizes the background, fabrication, installation, chemical analysis test results, and future plans for the MAC technology, which was effectively used to protect the JWST test equipment from vacuum chamber contamination. As a coating made of highly porous zeolite materials, the Molecular Adsorber Coating (MAC) was developed to capture outgassed molecular contaminants, such as hydrocarbons and silicones. For spaceflight applications, the adsorptive capabilities of the coating can alleviate on-orbit outgassing concerns on or near sensitive surfaces and instruments within the spacecraft. Similarly, this sprayable paint technology has proven to be significantly beneficial for ground-based space applications, in particular, for vacuum chamber environments. This presentation describes the application of the MAC technology for the James Webb Space Telescope (JWST) at NASA Johnson Space Center (JSC). The coating was used as a mitigation tool to entrap outgassed contaminants, specifically silicone-based diffusion pump oil, from within JSCs cryogenic optical vacuum chamber test facility called Chamber A. This presentation summarizes the background, fabrication, installation, chemical analysis test results, and future plans for the MAC technology, which was effectively used to protect the JWST test equipment from vacuum chamber contamination.

molecular contamination↗