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NASA NTRS2019

Additive Manufacturing and Hot-Fire Testing of Bimetallic GRCop-84 and C-18150 Channel-Cooled Combustion Chambers Using Powder Bed Fusion and Inconel 625 Hybrid Directed Energy Deposition

Additive manufacturing (AM) is an advanced fabrication technique that is demonstrating tremendous potential to reduce fabrication lead times and costs for liquid rocket engine components. The additive manufacturing technology lends itself to fabricate components with complex features such as internal coolant channels in combustion chambers that would otherwise require complex manufacturing operations. A requirement for high performance engines is to use high conductivity, high strength materials such as copper-alloys for combustion chamber liners to provide adequate wall temperatures and meet subsequent structural margins. A further requirement of this configuration is to minimize weight by defining and fabricating material in discrete locations as required. NASA and Industry partner, Virgin Orbit, have been working to advance these technologies through development of bimetallic additive manufacturing techniques under a public-private partnership through NASA’s Announcement of Collaborative Opportunity (ACO). This partnership is advancing a bimetallic hybrid additively manufactured combustion chamber that integrates Powder Bed Fusion (PBF), specifically Selective Laser Melting (SLM), and Directed Energy Deposition (DED) blown powder techniques to optimize the chamber materials and subsequent assembly. The SLM process is being developed for the combustion chamber liner to use copper-alloys GRCop-84 (Copper-Chrome-Niobium) or C-18150 (Copper-Chrome-Zirconium). The hybrid DED blown powder technology is used to apply an integrated structural jacket and manifolds using an Inconel 625 superalloy on the outer surface of the SLM copper liner. The hybrid DED technology being used on this program is a DMG Mori Seiki AM machining center which integrates the DED blown powder with an integral subtractive (traditional) machining to minimize overall setups. A series of chambers were fabricated using these techniques with GRCop-84/Inconel 625 and C-18150/Inconel and hot-fire tested at NASA Marshall Space Flight Center (MSFC) in LOX/Kerosene (RP-1). This paper describes the process development to integrate these AM technologies into an integrated bimetallic assembly, the design of the chamber, results from hot-fire testing, and further development.

Gradl, Paul R.↗

NASA NTRS2019

Additive Manufacturing and Hot-fire Testing of Bimetallic GRCop-84 and C-18150 Channel-Cooled Combustion Chambers using Powder Bed Fusion and Inconel 625 Hybrid Directed Energy Deposition

Gradl, Paul↗

NASA NTRS1999

Diode Laser Measurements of Concentration and Temperature in Microgravity Combustion

Diode laser absorption spectroscopy provides a direct method of determinating species concentration and local gas temperature in combustion flames. Under microgravity conditions, diode lasers are particularly suitable, given their compact size, low mass and low power requirements. The development of diode laser-based sensors for gas detection in microgravity is presented, detailing measurements of molecular oxygen. Current progress of this work and future application possibilities for these methods on the International Space Station are discussed.

Silver, Joel A.↗

NASA NTRS1982

Pulsed multiwavelength laser ranging system

A pulsed multiwavelength laser ranging system for measuring atmospheric delay was built and tested, and its theoretical performance limits were calculated. The system uses a dye modelocked ND:YAG laser, which transmits 70 psec wide pulses simultaneously at 1064, 532, and 355 nm. The differential delay of the 1064 and 355 nm pulses is measured by a specially calibrated waveform digitizer to estimate the dry atmospheric delay. The delay time of the 532 nm pulse is used to measure the target distance. Static crossed field photomultipliers are used as detectors for all wavelengths. Theoretical analysis shows that path curvature and atmospheric turbulence are fundamental limits to the ranging accuracy of both single and multicolor systems operating over horizontal paths. For two color systems, an additional error is caused by the uncertainty in the path averaged water vapor. The standard deviation of the multicolor instrument's timing measurements is directly proportional to the laser pulse width plus photomultiplier jitter divided by the square root of the received photoelectron number. The prototype system's maximum range is km, which is limited by atmospheric and system transmission losses at 355 nm. System signal detection and false alarm calculations are also presented.

Abshire, J. B.↗

NASA NTRS2015

Space Optical Communications Using Laser Beam Amplification

The Space Optical Communications Using Laser Beam Amplification (SOCLBA) project will provide a capability to amplify a laser beam that is received in a modulating retro-reflector (MRR) located in a satellite in low Earth orbit. It will also improve the pointing procedure between Earth and spacecraft terminals. The technology uses laser arrays to strengthen the reflected laser beam from the spacecraft. The results of first year's work (2014) show amplification factors of 60 times the power of the signal beam. MMRs are mirrors that reflect light beams back to the source. In space optical communications, a high-powered laser interrogator beam is directed from the ground to a satellite. Within the satellite, the beam is redirected back to ground using the MMR. In the MMR, the beam passes through modulators, which encode a data signal onto the returning beam. MMRs can be used in small spacecraft for optical communications. The SOCLBA project is significant to NASA and small spacecraft due to its application to CubeSats for optical data transmission to ground stations, as well as possible application to spacecraft for optical data transmission.

Laser↗

NASA NTRS1986

Recording Interferograms Holographically

Images of experiments stored for later analysis Classical interferometer modified for holography by removing entrance semireflecting mirror and inserting holographic recording in one of legs. Collimated laser beam projected through hologram and directed to remaining semitransparent mirror. Combines with reference beam from same laser to form virtual image of original experiment. Developed for experiments on crystal growth during space flights. Images recorded rapidly under constraints of experiments and later examined on ground.

Comeens, E. R.↗

NASA NTRS2010

Mode Tracker for Mode-Hop-Free Operation of a Laser

A mode-tracking system that includes a mode-controlling subsystem has been incorporated into an external-cavity (EC) quantum cascade laser that operates in a mid-infrared wavelength range. The mode-tracking system makes it possible to perform mode-hop-free wavelength scans, as needed for high-resolution spectroscopy and detection of trace gases. The laser includes a gain chip, a beam-collimating lens, and a diffraction grating. The grating is mounted on a platform, the position of which can be varied to effect independent control of the EC length and the grating angle. The position actuators include a piezoelectric stage for translation control and a motorized stage for coarse rotation control equipped with a piezoelectric actuator for fine rotation control. Together, these actuators enable control of the EC length over a range of about 90 m with a resolution of 0.9 nm, and control of the grating angle over a coarse-tuning range of +/-6.3deg and a fine-tuning range of +/-520 microrad with a resolution of 10 nrad. A mirror mounted on the platform with the grating assures always the same direction of the output laser beam.

Wysocki, Gerard↗

DOE OSTI2024

Melting and solidification dynamics during laser melting of reaction-based metal matrix composites uncovered by in-situ synchrotron X-ray diffraction

Laser additive manufacturing (AM) of reaction-based metal matrix composites (MMCs) involves highly complex and non-equilibrium material transformation behavior, including melting, dissolution, precipitation, and solidification. Yet, the dynamics and interplay of these phase transformation processes remain poorly understood, posing substantial challenges in identifying the microstructure formation mechanism, and predicting and controlling the microstructure in the printed parts. Here, in this study, we performed the in-situ X-ray diffraction experiment to characterize the phase evolution dynamics of the 316L + 10 vol.%TiC system during laser melting, which provides direct and quantitative insights of the complex phase reaction and evolution dynamics under rapid heating and cooling conditions relevant to additive manufacturing of reaction-based MMCs. Further in-depth thermodynamic and kinetic calculations revealed that most of the phase evolution behavior observed in the in-situ X-ray diffraction experiment cannot be solely explained by widely used equilibrium thermodynamic models, and diffusion-controlled nonequilibrium dissolution and precipitation kinetics must be considered to elucidate the complex phase evolution behavior, including incomplete TiC dissolution, and three-step TiC precipitation. The three distinct types of precipitates generate unique hierarchical TiC micro- and nanostructures, which enhances the yield strength from 513 MPa to 877 MPa by 71 %, tensile strength from 628 MPa to 1054 MPa by 68 %, and Young's modulus from 193 GPa to 221 GPa by 14 %. The findings of our research provide the knowledge foundation for the design of unique microstructures and advanced MMC materials through laser AM.

36 MATERIALS SCIENCE↗

NASA NTRS2010

Study of Fabry-Perot Etalon Stability and Tuning for Spectroscopic Rayleigh Scattering

The Fabry-Perot interferometer is a commonly employed instrument for resolving the spectrum of molecular Rayleigh scattered light for the purpose of evaluating flow properties such as gas velocity and temperature. Rayleigh scattered light from a focused laser beam can be directly imaged through a solid Fabry-Perot etalon onto a CCD detector to provide the spectral content of the scattered light. The spatial resolution of the measurements is governed by the locations of interference fringes. The location of the fringes can be changed by altering the etalon?s physical characteristics, such as thickness and index of refraction. For a fused silica solid etalon the physical properties can be adjusted by changing the etalon temperature; hence changing the order of the interference pattern and the physical fringe locations. Controlling the temperature of the etalon can provide for a slow time-response spatial scanning method for this type of etalon system. A custom designed liquid crystal Fabry-Perot (LCFP) can provide for a fast time-response method of scanning the etalon system. Voltage applied to the liquid crystal interface sets the etalon?s properties allowing Rayleigh measurements to be acquired at varying spatial locations across the image of the laser beam over a very short time period. A standard fused silica etalon and a tunable LCFP etalon are characterized to select the system that is best suited for Rayleigh scattering measurements in subsonic and supersonic flow regimes. A frequency-stabilized laser is used to investigate the apparent frequency stability and temperature sensitivity of the etalon systems. Frequency stability and temperature sensitivity data of the fused silica and LCFP etalon systems are presented in this paper, along with measurements of the LCFP etalon?s tuning capabilities. Rayleigh scattering velocity measurements with both etalon systems are presented, in an effort to determine which etalon is better suited to provide optical flow measurements of velocity, temperature, and density.

Clem, Michelle M.↗

DOE OSTI2020

Innovative accident tolerant fuel concept enabled through direct manufacturing technology

Nuclear energy is one of the largest sources of carbon-free electricity in the world. Some countries are looking at new ways to support and revitalize the nuclear sector since the Fukushima disaster. The accident tolerant fuel program is geared toward improving the safety of nuclear energy by investigating materials that can replace or modify the current uranium-dioxide nuclear fuel and zirconium-based cladding. This research program is being supported by all major nuclear countries since 2011. The practical limitations on allowable uranium enrichment has taken the focus away from the most promising fuels with high radioactivity retention such as tristructural isotropic particle fuel. To overcome such enrichment limitation, a new fuel concept is proposed using advanced ceramic direct manufacturing with laser-induced chemical vapor deposition. The fuel-as-fiber concept is an accident-tolerant fuel design that features high thermal conductivity, strong capability of radioactivity retention and most importantly requires reasonable enrichment levels with uranium nitride as the fuel. In this work, the initial fabrication of uranium-based fuel with laser-induced chemical vapor deposition technology is demonstrated. Then an advanced multi-physics guided modeling approach based on finite element analysis codes and informed by the manufacturing capabilities is developed to accelerate the advancement of fuel-as-fiber concept for use in current light-water reactor technology. The detailed thermomechanical analysis showed promising results for viability of the innovative fuel-as-fiber concept. The predicted stresses in the fuel structural materials were similar to the case of tristructural isotropic particle fuel experience base that has shown excellent reliability in retention of fuel radioactivity at high temperatures.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS2017

Development and Hotfire Testing of Additively Manufactured Copper Combustion Chambers for Liquid Rocket Engine Applications

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), commonly referred to as additive manufacturing (AM). The NASA Low Cost Upper Stage Propulsion (LCUSP) program was designed to develop processes and material characterization for GRCop-84 (a NASA Glenn Research Center-developed copper, chrome, niobium alloy) commensurate with powder bed AM, 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. To advance the processes further and allow for optimization with multiple materials, NASA is also investigating the feasibility of bimetallic AM chambers. In addition to the LCUSP program, NASA’s Marshall Space Flight Center (MSFC) has completed a series of development programs and hot-fire tests to demonstrate SLM GRCop-84 and other AM techniques. MSFC’s efforts include a 4,000 pounds-force thrust liquid oxygen/methane (LOX/CH4) combustion chamber. Small thrust chambers for 1,200 pounds-force LOX/hydrogen (H2) applications have also been designed and fabricated with SLM GRCop-84. Similar chambers have also completed development with an Inconel 625 jacket bonded to the GRCop-84 material, evaluating direct metal deposition (DMD) laser- and arc-based techniques. The same technologies for these lower thrust applications are being applied to 25,000-35,000 pounds-force main combustion chamber (MCC) designs. This paper describes the design, development, manufacturing and testing of these numerous combustion chambers, and the associated lessons learned throughout their design and development processes.

Gradl, Paul R.↗

DOE OSTI2025

An Investigation of Thermal Properties of 2D Materials [Dissertation]

Studying the thermal conductivity of 2D materials is important due to the applications of 2D materials in fields such as thermal management, thermoelectricity, renewable energy, and sensors. As such, measurements of the thermal conductivity of these 2D materials become important to measure. Thermal conductivity is often difficult to measure for 2D materials due to their atomically thin nature and many experimental methods for doing so requiring contact with the sample, which can alter the thermal properties. A non-contact method for calculating the thermal conductivity of 2D materials supported on substrates in order to model the thermal conductivity of 2D materials for devices, is proposed and experimentally performed in this dissertation. The optothermal Raman technique is a useful non-contact diagnostic technique useful in determining the thermal conductivity of 2D materials. The optothermal Raman typically does not account for heat losses due to convection or radiation or substrate resistance, which are shown to be important factors to consider when developing an optothermal Raman model. Additionally, the calculation of the interfacial thermal conductance between the bottom surface of the sample and the top surface of the substrate, plays an important role in determining the final value of the thermal conductivity of a supported sample, and will yield differing results based on whether or not the conductance is calculated using an approach such as the Diffuse Mismatch Model (DMM) or calculated directly by varying the laser heating profile (usually done by changing the laser objective). This is shown to be the case for both graphene on Ni, graphene on Cu, and SnSe 2 on Cu. In addition to experimentally calculating the thermal conductivity of a 2D material with the optothermal Raman technique, the thermal conductivity of 2D materials can also be calculated using computational methods. The three-phonon method is a method which can be used to simulate phonon scattering processes and determine the thermal conductivity of semiconductors, wherein phonon scattering is the dominant mechanism which determines the thermal conductivity. The three-phonon method uses relaxation times for phonon scattering with other phonons, electrons, and other material system elements, such as isotopes or material defects, in order to create a single-mode relaxation time approximation (SMRTA), which is used to calculate the final value of the thermal conductivity. An important consideration when determining the thermal conductivity of a 2D material using this method is the device geometry, which is reflected in this work as the phonon-boundary scattering relaxation time. This inclusion is important along with the inclusion of phonon-electron scattering in accurately determining the thermal conductivity of a 2D material. In both the optothermal Raman experiments and the three-phonon method computations, strain is shown to have a demonstrable effect on the thermal conductivity of 2D materials. When a 1.1% strain was applied to the mechanical properties of SnSe, the three-phonon processes yielded a lower thermal conductivity than the no-strain case. For the optothermal Raman experiments, the strain induced in the Cu substrate and transferred to a single-layer graphene (SLG) sample yields a trend where the thermal conductivity of the SLG decreases with respect to strain applied. In the case where the interfacial thermal conductance was calculated directly, the conductance increased with respect to strain applied. This presents strain as a reliable and viable method for tuning the thermal properties of 2D materials for device applications.

36 MATERIALS SCIENCE↗

NASA NTRS1987

High repetition rate sealed CO2 TEA lasers using heterogeneous catalysts

The significant operational advantages offered by CO2 lasers, operating in the 10.6 micron region of the spectrum, over current solid state lasers, emitting in the near IR region, have prompted increased interest in the development of compact, reliable, rugged CO2 laser sources. Perhaps the most critical aspect associated with achieving a laser compatible with military use is the development of lasers which require no gas replenishment. Sealed, single shot, CO2 TEA lasers have been available for a number of years. Stark et al were first to demonstrate reliable sealed operation in single shot CO2 TEA lasers in 1975 using gas catalysis. GEC Avionics reported the compact, environmentally qualified, MKIII CO2 TEA laser with a pulse life of greater than 10 to the 6th power pulses in 1980. A sealed laser lifetime of greater than 10 to the 6th power pulses is acceptable for single shot cases, such as direct detection rangefinders for tank laser sights. However, in many other applications, such as tracking of fast moving targets, it is essential that a repetition rate of typically 30Hz to 100Hz is employed. In such cases, a pulse lifetime of 10 to the 6th power pulses is no longer sufficient and a minimum pulse lifetime 10 to the 7th power pulses is essential to ensure a useful service life. In 1983 Stark el al described a sealed, 100Hz CO2 TEA laser, with a life of greater than 2.6 x 10 to the 6th power, which employed heterogeneous catalysis. Following this pioneering work, GEC Avionics has been engaged in the development of sealed high repetition rate lasers with a pulse lifetime of 20 million pulses.

Price, H. T.↗

DOE OSTI2023

Three-dimensional broadband nonlinear phased array imaging

System include an ultrasonic transducer configured to couple to a nondestructive testing (NDT) sample and configured to produce and direct an ultrasonic probe wave at a selected frequency into a subsurface region of the NDT sample, a 3D laser scanning vibrometer configured to direct a detection beam in a scan area on a surface of the NDT sample and to receive a return beam from the scan area, and to detect, based on the return beam, a 3D motion of the surface across a wideband frequency range, and a processor, and a memory configured with instructions that, when executed by the processor, cause the processor to produce sub-surface image data of the NDT sample at multiple harmonics of the selected frequency in the wideband frequency range based on the detected 3D surface motion, wherein the sub-surface image data describes a nonlinear defect response produced in the NDT sample by interaction of the ultrasonic probe wave with the subsurface region.

Remillieux, Marcel↗

NASA NTRS1983

A laser interferometer for measuring skin friction in three-dimensional flows

A new, nonintrusive method is described for measuring skin friction in three-dimensional flows with unknown direction. The method uses a laser interferometer to measure the changing slope of a thin oil film applied to a surface experiencing shear stress. The details of the method are described, and skin friction measurements taken in a swirling three-dimensional boundary-layer flow are presented. Comparisons between analytical results and experimental values from the laser interferometer method and from a bidirectional surface-fence gauge are made.

Monson, D. J.↗

NASA NTRS1993

Combinatorial pulse position modulation for power-efficient free-space laser communications

A new modulation technique called combinatorial pulse position modulation (CPPM) is presented as a power-efficient alternative to quaternary pulse position modulation (QPPM) for direct-detection, free-space laser communications. The special case of 16C4PPM is compared to QPPM in terms of data throughput and bit error rate (BER) performance for similar laser power and pulse duty cycle requirements. The increased throughput from CPPM enables the use of forward error corrective (FEC) encoding for a net decrease in the amount of laser power required for a given data throughput compared to uncoded QPPM. A specific, practical case of coded CPPM is shown to reduce the amount of power required to transmit and receive a given data sequence by at least 4.7 dB. Hardware techniques for maximum likelihood detection and symbol timing recovery are presented.

Budinger, James M.↗

DOE OSTI2021

Synergistic foam stabilization and transport improvement in simulated fractures with polyelectrolyte complex nanoparticles: Microscale observation using laser etched glass micromodels

Inaccessibility to direct pore scale observation in hydrocarbon recovery of tight shale formations poses a great challenge to water-energy nexus initiatives and necessitates the use of high throughput technologies to emulate environmentally friendly processes. Herein, we employ a precise glass micromodel fabrication and visualization method to isolate the supercritical CO 2 bubbles surrounded by CO 2 -water lamella prepared in saline produced water stabilized with molecular complexation of zwitterionic surfactants (ZS) and polyelectrolyte complex nanoparticles (PECNP). The Selective Laser Enhanced Etching (SLE) technique was selected for micromodel simulation of high-pressure flow. Two representative designs, (1) fracture/micro-crack network 28 and (2) fracture/matrix were etched on fused silica glass with a laser printing machine and scCO 2 foam was injected to study the foamability, propagation, stability, and fluid loss properties. The highly monodispersed and uniformly distributed array of scCO 2 bubbles were detected in flow of scCO 2 foam in highly saline brine containing ionic complexes of positively charged PECNPs and ZS, whereas foam flow with the lamella containing ZS in fractures offered a noticeably large and polydisperse array of scCO 2 bubbles. scCO 2 bubble motion and deformation were traced, and local description of foam flow was visually examined. The confined array of scCO 2 bubbles stabilized by ZS in microcracks was affected by bubble growth and coalescence, whereas the super-populated array of monodispersed scC O2 bubbles with lamella containing complexes of PECNP and ZS were able to fill the channels with stable configurations within the timeframe of comparative stability measurements. The ability of complex fluid to prevent the formation damage was evaluated through fluid loss visualization in micromodels. Probing scCO 2 foam transport in homogenous porous media revealed smaller volume leak-off for scCO 2 foam containing PECNP-ZS ionic complexes.

04 OIL SHALES AND TAR SANDS↗

NASA NTRS1987

Designing transonic wind-tunnel test sections for flow diagnostics and laser velocimeter applications

The design, fabrication, and validation of the Basic Aerodynamic Facility (BARF), developed for the direct comparison of three-dimensional laser velocimetry (LV) and hot-wire techniques at transonic speeds, are discussed. To accommodate the installation of the three-dimensional orthogonal LV system in the BARF, the transonic slots were redesigned to house windows, and the test section mounting was redesigned to facilitate LV transversing. Two-dimensional and three-dimensional code validation tests of the LV test section showed uniform mean flow through the test section to sonic speeds, and fluctuating pressure measurements at subsonic speeds which are consistent with facilities with good flow quality.

Jones, G. S.↗