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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 NTRS1983

Limitations of laser transmission measurements due to correlated atmospheric effects

An evaluation is made of results of recent experimental work concerning the effects that atmospherically induced fluctuations and temporal correlations have on the accuracy of atmospheric laser transmission experiments. These experiments directly measured the limitations of signal averaging as a means to the reduction of the standard deviation of laser signals which are backscattered from either a specular or a diffusely reflecting target, by means of both heterodyne and direct detection systems. These limitations are shown to agree with a theory in which the observed, atmospherically induced temporal correlation is taken into account.

Menyuk, N.↗

NASA NTRS1975

Experimental results of a continuous wave laser radar system

A 1.06 micron CW laser radar system was used to establish the feasibility of remotely measuring sea surface wind magnitude and direction. Simultaneous correlation of collected laser data with the environment was established by using meteorological instruments. The experimental system and methods of analysis are summarized. Results of the experiments, including wind magnitude and direction correlation, are reported. Results are compared with theoretical predictions.

Petri, K. J.↗

NASA NTRS1988

Space-based laser-powered orbital transfer vehicle (Project SLICK)

A conceptual design study of a laser-powered orbital transfer vehicle (LOTV) is presented. The LOTV, nicknamed SLICK (Space Laser Interorbital Cargo Kite), will be utilized for the transfer of 16000 kg of cargo between Low Earth Orbit (LEO) and either Geosynchronous Earth Orbit (GEO) or Low Lunar Orbit (LLO). This design concentrates primarily on the LEO/GEO scenario, which will have typical LEO-to-GEO trip time of 6 days and two return versions. One version uses an all propulsive return while the other utilizes a ballute aerobrake for the return trip. Furthermore, three return cargo options of 16000 kg, 5000 kg (standard option), and 1600 kg are considered for this scenario. The LEO/LLO scenario uses only a standard, aerobraked version. The basic concept behind the LOTV is that the power for the propulsion system is supplied by a source separate from the LOTV itself. For the LEO/GEO scenario the LOTV utilizes a direct solar-pumped iodide laser and possibly two relay stations, all orbiting at an altitude of one Earth radius and zero inclination. An additional nuclear-powered laser is placed on the Moon for the LEO/LLO scenario. The propulsion system of the LOTV consists of a single engine fueled with liquid hydrogen. The laser beam is captured and directed by a four mirror optical system through a window in the thrust chamber of the engine. There, seven plasmas are created to convert the laser beam energy into thermal energy at an efficiency of at least 50 percent. For the LEO/LLO scenario the laser propulsion is supplemented by LH2/LOX chemical thrusters.

Source record↗

NASA NTRSDate not supplied

Overview of Space Technology developed during 1980s ~ present

Early 1980s, a science team of NASA Langley Research has developed various space power systems, especially directly solar-pumped iodine laser (DSPIL), wireless power transmission technology, concepts of solar thermal propulsion, pulse-power for direct-energy weapons (DEW) applications, soft X-ray lithography and to name a few. This presentation will briefly overview these NASA-Langley developed space technology for future applications.

plasma devices↗

DOE OSTI2023

Multi-shock design tools in double shell models

The essence of the project was to implement a program in python that demonstrated certain models put forth by fusion physicists. Across the time spent at Los Alamos National Laboratory, much was spent programming. Though fundamentally programmatical in nature, the task contained considerable difficulty hid within mathematically deriving and manipulating the models while maintaining data discretization. The result of solving these complications gave invaluable experience in applied mathematics. The final product, a piece of lengthy code, ended up having the full range of desired capabilities, with plans for more. Given the laser power history from a pulse shot on NIF, Omega, or any other Inertial Confinement Fusion facility, the code maps the terrain of radiation temperature inside the hohlraum throughout the period of the shot. Additionally, shock wave convergence prediction was implemented as additional capability. As the name of the project suggests, this tool acts as a compass of direction for researchers designing laser power profiles. Further development of this tool will undoubtedly assist in the research conducted on single and double-shell indirect ICF, consequently expanding the capabilities of operating stewardship over the national nuclear stockpile.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1997

First Single-Crystal Mullite Fibers

Ceramic-matrix composites strengthened by suitable fiber additions are being developed for high-temperature use, particularly for aerospace applications. New oxide-based fibers, such as mullite, are particularly desirable because of their resistance to high-temperature oxidative environments. Mullite is a candidate material in both fiber and matrix form. The primary objective of this work was to determine the growth characteristics of single-crystal mullite fibers produced by the laser-heated floating zone method. Directionally solidified fibers with nominal mullite compositions of 3Al2O3 2SiO2 were grown by the laser-heated floating zone method at the NASA Lewis Research Center. SEM analysis revealed that the single-crystal fibers grown in this study were strongly faceted and that the facets act as critical flaws, limiting fiber strength. The average fiber tensile strength is 1.15 GPa at room temperature. The mullite fibers exhibit superior strength retention (80 percent of their room temperature tensile strength at 1450 C). Examined by transmission electron microscopy, these mullite single crystals are free of dislocations, low-angle boundaries, and voids. In addition, they show a high degree of oxygen vacancy ordering. High-resolution digital images from an optical microscope furnish evidence of the formation of a liquid-liquid miscibility gap during crystal growth. These images represent the first experimental evidence of liquid immiscibility for these compositions and temperatures. Continuing investigation with controlled seeding of mullite single crystals is planned.

Source record↗

NASA NTRS1981

Direct nuclear excitation of a He-3 - CO2 gas mixture

Probe measurements using a continuous wave CO2 laser have been carried out on a He-3 - CO2 gas mixture directly excited by the He-3(n,p)H-3 reaction. At a gas pressure of 1 atm and thermal neutron flux up to 10 to the 17th n/sq cm sec, total extinction of the probe beam was observed. Addition of N2 to the gas mixture (up to 20%) produced a media such as is used in electric discharge CO2 lasers. However, this mixture produced the same results as the He-3 - CO2 mixture. Absorption of the laser beam indicates that with direct nuclear excitation, it is the lower laser level which is excited. Therefore direct nuclear pumping of a CO2 laser does not appear feasible.

Jalufka, N. W.↗

NASA NTRS1990

Laser-boosted lightcraft technology demonstrator

The detailed description and performance analysis of a 1.4 meter diameter Lightcraft Technology Demonstator (LTD) is presented. The launch system employs a 100 MW-class ground-based laser to transmit power directly to an advanced combined-cycle engine that propels the 120 kg LTD to orbit - with a mass ratio of two. The single-stage-to-orbit (SSTO) LTD machine then becomes an autonomous sensor satellite that can deliver precise, high quality information typical of today's large orbital platforms. The dominant motivation behind this study is to provide an example of how laser propulsion and its low launch costs can induce a comparable order-of-magnitude reduction in sensor satellite packaging costs. The issue is simply one of production technology for future, survivable SSTO aerospace vehicles that intimately share both laser propulsion engine and satellite functional hardware.

Richard, J. C.↗

DOE OSTI2026

Reduction of baseplate distortion during directed energy deposition using compliant features

Distortion in additive manufacturing (AM) remains a barrier to its adoption in precision industries. Baseplate warpage is one such issue which compromises the feasibility of post-process precision machining. The restriction to thermal contraction of the deposited part, imposed by the baseplate, generates bending moments, that in turn causes warpage. A novel distortion mitigation strategy using baseplates with integrated compliant features, which enables thermal contraction of the build is presented. Six unique design concepts are evaluated, including a solid reference, using two deposition geometries. A laser, hot-wire, directed energy deposition (DED) process is used to deposit a symmetric cylindrical part (C-part) and a T-shaped asymmetric part (T-part). Flatness deviation of baseplates is measured using structured light 3D scanning. Measurements reveal a reduction in net flatness deviation of 58.8% for the C-part and 40.9% for the T-part, compared to the solid reference. While most designs yielded reductions exceeding 30% and 20% for the C- and T-parts, respectively, one configuration resulted in increased deviation. Finite element (FE) simulations are performed to elucidate the underlying mechanisms affecting distortion of compliant baseplates during DED. Despite variations between predictions and measurements, agreement in the general trend is observed. It also revealed that initial flatness errors in baseplates significantly affect its deviation during deposition. Predictions indicate that compliant features significantly affect the thermal distribution as well as the evolution of flatness deviation in the baseplate during deposition. Notably, one design exhibited a reduction in distortion during cooling, following its initial increase during deposition. FE predictions show a maximum reduction of 60.9% and 38.8% in net flatness deviation for the C- and T-parts, respectively. The performance of compliant baseplates is found to be governed by both its the thermal and mechanical characteristics, which are crucial factors to be considered during design.

Mathews, Ritin [ORNL] (ORCID:0000000301440828)↗

NASA NTRS1989

Laser-boosted lightcraft technology demonstrator

The ultimate goal for this NASA/USRA-sponsored 'Apollo Lightcraft Project' is to develop a revolutionary manned launch vehicle technology that can potentially reduce payload transport costs by a factor of 1000 below the space shuttle orbiter. The Rensellaer design team proposes to utilize advanced, highly energetic, beamed-energy sources (laser, microwave) and innovative combined-cycle (airbreathing/rocket) engines to accomplish this goal. This year's effort, the detailed description and performance analysis of an unmanned 1.4-m Lightcraft Technology Demonstrator (LTD) drone, is presented. The novel launch system employs a 100-MW-class ground-based laser to transmit power directly to an advanced combined-cycle engine that propels the 120-kg LTD to orbit, with a mass ratio of two. The single-stage-to-orbit (SSTO) LTD machine then becomes an autonomous sensor satellite that can deliver precise, high-quality information typical of today's large orbital platforms. The dominant motivation behind this study is to provide an example of how laser propulsion and its low launch costs can induce a comparable order-of-magnitude reduction in sensor satellite packaging costs. The issue is simply one of production technology for future, survivable SSTO aerospace vehicles that intimately share both laser propulsion engine and satellite functional hardware. A mass production cost goal of 10(exp 3)/kg for the LTD vehicle is probably realizable.

Antonison, M.↗

NASA NTRS1980

Line spread instrumentation for propagation measurements

A line spread device capable of yielding direct measure of a laser beam's line spread function (LSF) was developed and employed in propagation tests conducted in a wind tunnel to examine optimal acoustical suppression techniques for laser cavities exposed to simulated aircraft aerodynamic environments. Measurements were made on various aerodynamic fences and cavity air injection techniques that effect the LSF of a propagating laser. Using the quiescent tunnel as a control, the relative effect of each technique on laser beam quality was determined. The optical instrument employed enabled the comparison of relative beam intensity for each fence or mass injection. It was found that fence height had little effect on beam quality but fence porosity had a marked effect, i.e., 58% porosity alleviated cavity resonance and degraded the beam the least. Mass injection had little effect on the beam LSF. The use of a direct LSF measuring device proved to be a viable means of determining aerodynamic seeing qualities of flow fields.

Bailey, W. H., Jr.↗

DOE OSTI2021

Proton beam quality enhancement by spectral phase control of a PW-class laser system

We report on experimental investigations of proton acceleration from solid foils irradiated with PW-class laser-pulses, where highest proton cut-off energies were achieved for temporal pulse parameters that varied significantly from those of an ideally Fourier transform limited (FTL) pulse. Controlled spectral phase modulation of the driver laser by means of an acousto-optic programmable dispersive filter enabled us to manipulate the temporal shape of the last picoseconds around the main pulse and to study the effect on proton acceleration from thin foil targets. The results show that applying positive third order dispersion values to short pulses is favourable for proton acceleration and can lead to maximum energies of 70 MeV in target normal direction at 18 J laser energy for thin plastic foils, significantly enhancing the maximum energy compared to ideally compressed FTL pulses. The paper further proves the robustness and applicability of this enhancement effect for the use of different target materials and thicknesses as well as laser energy and temporal intensity contrast settings. We demonstrate that application relevant proton beam quality was reliably achieved over many months of operation with appropriate control of spectral phase and temporal contrast conditions using a state-of-the-art high-repetition rate PW laser system.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

NASA NTRS2004

Solar Pumped High Power Solid State Laser for Space Applications

Highly coherent laser light provides a nearly optimal means of transmitting power in space. The simplest most direct means of converting sunlight to coherent laser light is a solar pumped laser oscillator. A key need for broadly useful space solar power is a robust solid state laser oscillator capable of operating efficiently in near Earth space at output powers in the multi hundred kilowatt range. The principal challenges in realizing such solar pumped laser oscillators are: (1) the need to remove heat from the solid state laser material without introducing unacceptable thermal shock, thermal lensing, or thermal stress induced birefringence to a degree that improves on current removal rates by several orders of magnitude and (2) to introduce sunlight at an effective concentration (kW/sq cm of laser cross sectional area) that is several orders of magnitude higher than currently available while tolerating a pointing error of the spacecraft of several degrees. We discuss strategies for addressing these challenges. The need to remove the high densities of heat, e.g., 30 kW/cu cm, while keeping the thermal shock, thermal lensing and thermal stress induced birefringence loss sufficiently low is addressed in terms of a novel use of diamond integrated with the laser material, such as Ti:sapphire in a manner such that the waste heat is removed from the laser medium in an axial direction and in the diamond in a radial direction. We discuss means for concentrating sunlight to an effective areal density of the order of 30 kW/sq cm. The method integrates conventional imaging optics, non-imaging optics and nonlinear optics. In effect we use a method that combines some of the methods of optical pumping solid state materials and optical fiber, but also address laser media having areas sufficiently large, e.g., 1 cm diameter to handle the multi-hundred kilowatt level powers needed for space solar power.

Fork, Richard L.↗

DOE OSTI2022

Keyhole-mode Microscopy Dataset for Laser Powder-bed Fusion Modeling

Laser powder-bed fusion (LPBF) is an additive manufacturing (AM) technology that uses high-power sintering lasers to precisely construct metal designs. Material is accumulated by selectively sintering regions of a metal powder layer to a growing structure underneath forming a 3D geometry. Certain conditions make fusion in this process to operate in "keyhole-mode," characterized by targeted materials evaporating as plasma. While keyhole-mode operations can produce deeper molten pools than that observed in "conduction-mode", this mode of operation is often undesirable, as its molten regions can collapse on themselves, encapsulating metal vapors and forming cavities. The formation of such cavities negatively affects strength and consistency of the fused materials. To identify and avoid these detrimental effects of keyhole-mode operation, considerable data collection and analysis regarding this mode of operation is needed. Therefore, under the support of the "Open Data Initiative," Lawrence Livermore National Lab is releasing a dataset for analysis of this keyhole effect, and the conditions which transition operation from conduction-mode to keyhole-mode melting. This dataset consists of 600+ micrographs from laser powder-bed single track runs, with differing cross-section angles and input parameters, operating under both normal and keyhole mode operations. This journal documents the collection, organization, and usage of this dataset.

36 MATERIALS SCIENCE↗

NASA NTRS1995

Automated Laser Cutting In Three Dimensions

Computer-controlled machine-tool system uses laser beam assisted by directed flow of air to cut refractory materials into complex three-dimensional shapes. Velocity, position, and angle of cut varied. In original application, materials in question were thermally insulating thick blankets and tiles used on space shuttle. System shapes tile to concave or convex contours and cuts beveled edges on blanket, without cutting through outer layer of quartz fabric part of blanket. For safety, system entirely enclosed to prevent escape of laser energy. No dust generated during cutting operation - all material vaporized; larger solid chips dislodged from workpiece easily removed later.

Bird, Lisa T.↗

NASA NTRS2016

Design, Development and Hotfire Testing of Monolithic Copper and Bimetallic Additively Manufactured Combustion Chambers

NASA and industry partners are working towards fabrication process development to reduce costs and schedules associated with manufacturing liquid rocket engine components with the goal of reducing overall mission costs. One such technique being evaluated is powder-bed fusion or selective laser melting (SLM) otherwise commonly referred to as additive manufacturing. The NASA Low Cost Upper Stage Propulsion (LCUSP) program was designed to develop processes and material characterization for the GRCop-84 copper-alloy commensurate with powder bed additive manufacturing, evaluate bimetallic deposition and complete testing of a full scale combustion chamber. As part of this development, the process has been transferred to industry partners to enable a long-term supply chain of monolithic copper combustion chambers. As a direct spin off of this program, NASA is working with industry partners to further develop the printing process for the GRCop-84 material in addition to the C-18150 (CuCrZr) material. To advance the process further and allow for optimization with multiple materials, NASA is also investigating the feasibility of bimetallic additively manufactured chambers. A 1.2k sized thrust-chamber was designed and developed to compare the printing process of the GRCop-84 and C-18150 SLM materials. A series of similar MCC liners also completed development with an Inconel 625 jacket bonded to the GRcop-84 liner evaluating direct metal deposition (DMD) laser and arc-based techniques. This paper describes the design, development, manufacturing and testing of these combustion chambers and associated lessons learned throughout the design and development process.

Gradl, Paul↗

DOE OSTI2021

Direct Measurements of DT Fuel Preheat from Hot Electrons in Direct-Drive Inertial Confinement Fusion

Hot electrons generated by laser-plasma instabilities degrade the performance of laser-fusion implosions by preheating the DT fuel and reducing core compression. The hot-electron energy deposition in the DT fuel has been directly measured for the first time by comparing the hard x-ray signals between DT-layered and mass-equivalent ablator-only implosions. The electron energy deposition profile in the fuel is inferred through dedicated experiments using Cu-doped payloads of varying thickness. The measured preheat energy accurately explains the areal-density degradation observed in many OMEGA implosions. Furthermore, this technique can be used to assess the viability of the direct-drive approach to laser fusion with respect to the scaling of hot-electron preheat with laser energy.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗