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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
NASA NTRS2011

Monitoring Delamination of Thermal Barrier Coatings During Interrupted High-Heat-Flux Laser Testing using Luminescence Imaging

This presentation showed progress made in extending luminescence-base delamination monitoring to TBCs exposed to high heat fluxes, which is an environment that much better simulates actual turbine engine conditions. This was done by performing upconversion luminescence imaging during interruptions in laser testing, where a high-power CO2 laser was employed to create the desired heat flux. Upconverison luminescence refers to luminescence where the emission is at a higher energy (shorter wavelength) than the excitation. Since there will be negligible background emission at higher energies than the excitation, this methods produces superb contrast. Delamination contrast is produced because both the excitation and emission wavelengths are reflected at delamination cracks so that substantially higher luminescence intensity is observed in regions containing delamination cracks. Erbium was selected as the dopant for luminescence specifically because it exhibits upconversion luminescence. The high power CO2 10.6 micron wavelength laser facility at NASA GRC was used to produce the heat flux in combination with forced air backside cooling. Testing was performed at a lower (95 W/sq cm) and higher (125 W/sq cm) heat flux as well as furnace cycling at 1163C for comparison. The lower heat flux showed the same general behavior as furnace cycling, a gradual, "spotty" increase in luminescence associated with debond progression; however, a significant difference was a pronounced incubation period followed by acceleration delamination progression. These results indicate that extrapolating behavior from furnace cycling measurements will grossly overestimate remaining life under high heat flux conditions. The higher heat flux results were not only accelerated, but much different in character. Extreme bond coat rumpling occurred, and delamination propagation extended over much larger areas before precipitating macroscopic TBC failure. This indicates that under the higher heat flux (and surface & interface temperatures), the TBC was more tolerant of damage. The main conclusions were that high heat flux conditions can not only accelerate TBC debond progression but can also grossly alter the pathway of delamination.

Eldridge, Jeffrey I.↗
NASA NTRS2005

Simulation of Laser Cooling and Trapping in Engineering Applications

An advanced computer code is undergoing development for numerically simulating laser cooling and trapping of large numbers of atoms. The code is expected to be useful in practical engineering applications and to contribute to understanding of the roles that light, atomic collisions, background pressure, and numbers of particles play in experiments using laser-cooled and -trapped atoms. The code is based on semiclassical theories of the forces exerted on atoms by magnetic and optical fields. Whereas computer codes developed previously for the same purpose account for only a few physical mechanisms, this code incorporates many more physical mechanisms (including atomic collisions, sub-Doppler cooling mechanisms, Stark and Zeeman energy shifts, gravitation, and evanescent-wave phenomena) that affect laser-matter interactions and the cooling of atoms to submillikelvin temperatures. Moreover, whereas the prior codes can simulate the interactions of at most a few atoms with a resonant light field, the number of atoms that can be included in a simulation by the present code is limited only by computer memory. Hence, the present code represents more nearly completely the complex physics involved when using laser-cooled and -trapped atoms in engineering applications. Another advantage that the code incorporates is the possibility to analyze the interaction between cold atoms of different atomic number. Some properties that cold atoms of different atomic species have, like cross sections and the particular excited states they can occupy when interacting with each other and light fields, play important roles not yet completely understood in the new experiments that are under way in laboratories worldwide to form ultracold molecules. Other research efforts use cold atoms as holders of quantum information, and more recent developments in cavity quantum electrodynamics also use ultracold atoms to explore and expand new information-technology ideas. These experiments give a hint on the wide range of applications and technology developments that can be tackled using cold atoms and light fields. From more precise atomic clocks and gravity sensors to the development of quantum computers, there will be a need to completely understand the whole ensemble of physical mechanisms that play a role in the development of such technologies. The code also permits the study of the dynamic and steady-state operations of technologies that use cold atoms. The physical characteristics of lasers and fields can be time-controlled to give a realistic simulation of the processes involved such that the design process can determine the best control features to use. It is expected that with the features incorporated into the code it will become a tool for the useful application of ultracold atoms in engineering applications. Currently, the software is being used for the analysis and understanding of simple experiments using cold atoms, and for the design of a modular compact source of cold atoms to be used in future research and development projects. The results so far indicate that the code is a useful design instrument that shows good agreement with experimental measurements (see figure), and a Windows-based user-friendly interface is also under development.

Ramirez-Serrano, Jaime↗
NASA NTRS2019

Additive Manufacturing of NASA HR-1 Material for Liquid Rocket Engine Component Applications

NASA HR-1 is a high-strength Fe-Ni superalloy designed to resist high pressure, hydrogen environment embrittlement, oxidation, and corrosion. NASA HR-1 was originally developed at NASA in the 1990’s and derived from JBK-75 to increase strength and ductility in high-pressure hydrogen environments. The NASA HR-1 chemistry was formulated to meet requirements for liquid rocket engine applications, specifically components used in a high-pressure hydrogen environment. Recent developments using additive manufacturing (AM) have made this material an attractive option for channel-cooled nozzles under the Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) program and other liquid rocket engine component applications. The RAMPT program has baselined to fully evolve and characterize NASA HR-1 material. NASA HR-1 meets materials requirements for liquid rocket engine components, including good hydrogen resistance, high conductivity, good low cycle fatigue performance, and high elongation and strength for channel-cooled nozzles in high heat flux environments. Initial development and characterization has been completed using blown powder Directed Energy Deposition (DED) and Laser Powder Bed Fusion (L-PBF) additive manufacturing techniques to develop material test samples and nozzle hardware. NASA HR-1 powder has been sourced and characterized from several powder suppliers, and a series of development and hardware samples completed fabrication using DED and L-PBF. Characterization of the material has included heat treatment development, metallography, chemistry evaluations, mechanical testing, measurement of thermophysical properties, and fabrication of relevant nozzle hardware to demonstrate feasibility. This paper presents results from the process and early materials development and provide future development work including hardware fabrication.

Katsarelis, Colton↗
NASA NTRS2023

Reactive Additive Manufacturing for Fourth Industrial Revolution Exploration Systems (Ramfire) Aluminum 6061-Ram2 Nozzle Testing

The NASA Marshall Space Flight Center (MSFC) has applied various forms of metallic additive manufacturing (AM) in liquid rocket engine component design, development, and testing since 2010. These AM techniques reduce hardware cost, shorten fabrication schedules, increase reliability by reducing the number of joints, and improve hardware performance by allowing unconventional design. The RAMFIRE project, funded under Space Technology Mission Directorate (STMD) Game Changing Development (GCD) Program, has furthered the use of novel AM liquid rocket nozzles in collaboration with Elementum 3D. The project advanced novel large-scale AM aluminum material technology for significant weight savings in rocket engines and launch vehicles. Previously, aluminum alloys were difficult to weld and print using additive manufacturing. Elementum 3D’s patented Aluminum 6061-RAM2 alloy allows for aluminum alloys to be printed using various AM techniques and at various scales. The alloy can be leveraged for welding wire, showing drastic improvements in aluminum weldability. The RAMFIRE project focuses on five key areas: 1) Laser Powder Directed Energy Deposition (LP-DED) AL6061-RAM2 feedstock specification and verification, 2) LP-DED process development and validation, 3) LP-DED printed AL6061-RAM2 microstructural and mechanical property characterization, 4) Hot-fire test a 7k-lbf thrust class regeneratively cooled nozzle, 5) Print large scale regeneratively cooled nozzle. Hot-fire testing demonstrates potential of advanced space technologies to NASA and potential users by providing the relevant environments to advance TRL levels to the 5/6 range.

Al6061-RAM2↗
NASA NTRS2018

Gradient Field Imploding Liner Fusion Propulsion System: NASA Innovative Advanced Concepts Phase I Final Report

The advancement of human deep space exploration requires the continued development of energetic in-space propulsion systems, from current chemical engines to nuclear thermal rockets to future high energy concepts such as nuclear fusion. As NASA embarks on a program to develop near-term nuclear thermal propulsion, this NASA Innovative Advanced Concepts (NIAC) Phase I activity was funded to investigate the feasibility of an innovative approach toward highly energetic pulsed fusion propulsion. Previous concept studies have proposed the conversion of fusion energy for in-space propulsion, ranging from laser-ignited fusion systems such as Gevaltig and VISTA, to the British Interplanetary Society's Daedalus concept and its more recent incarnation under Project Icarus, to steady-state spherical torus fusion systems. Recent NIAC studies have also evaluated several innovative fusion concepts, including the acceleration and compression of field reversed configuration plasmas in time-changing magnetic fields, magnetically driven liners imploding onto plasma targets, and high current z-pinch compression of material liners onto fission-fusion fuel targets. While each of these studies firmly established the potential benefits of fusion systems for interplanetary travel, they also identified significant challenges in successfully engineering such systems for spacecraft propulsion. The concept outlined in this Technical Publication (TP) builds on the lessons learned from these prior activities, approaching the quest for fusion-powered propulsion through an innovative variation of magneto-inertial fusion concepts developed for terrestrial power applications.

Lapointe, M. R.↗
NASA NTRS2004

Semiconductor lasers beyond the fiber optics telecommunication wavelength

Semiconductor lasers emitting at 1.55 microns are the cornerstone of the high bandwidth optical communications industry. Semiconductor lasers operating at this and other wavelengths are also used in the engineering, biology, chemistry and medical fields. The light emission in most semiconductor lasers is due to the optical transition between the valence and conduction bands of the semiconductor active material. This means that the intrinsic properties of the semiconductor active material i.e., the bandgap energy dictates the emission wavelength. This limits the efficient operation of these lasers at wavelengths above 3 microns. In the mid 1990s this limitation was overcome with the emergence of new laser architectures, such as the intersubband and interband Quantum Cascade (QC) lasers

Forouhar, Siamak↗
NASA NTRS1987

High intensity 5 eV atomic oxygen source and Low Earth Orbit (LEO) simulation facility

An atomic oxygen exposure facility has been developed for studies of material degradation. The goal of these studies is to provide design criteria and information for the manufacture of long life (20 to 30 years) construction materials for use in LEO. The studies that are being undertaken using the facility will provide: absolute reaction cross sections for use in engineering design problems; formulations of reaction mechanisms; and calibration of flight hardware (mass spectrometers, etc.) in order to directly relate experiments performed in LEO to ground based investigations. The facility consists of: (1) a CW laser sustained discharge source of O atoms having a variable energy up to 5 eV and an intensity between 10(15) and 10(17) O atoms s(-1) cm(-2); (2) an atomic beam formation and diagnostics system consisting of various stages of differential pumping, a mass spectrometer detector, and a time of flight analyzer; (3) a spinning rotor viscometer for absolute O atom flux measurements; and (4) provision for using the system for calibration of actual flight instruments. Surface analysis equipment is available for the characterization of material surfaces before and after exposure to O atoms.

Cross, J. B.↗
NASA NTRSDate not supplied

Lightweight Thrust Chamber Assemblies using Multi-Alloy Additive Manufacturing and Composite Overwrap

Additive Manufacturing (AM) has brought significant design and fabrication opportunities for complex components with internal features such as liquid rocket engine thrust chambers not previously possible. This technology allows for significant cost savings and schedule reductions in addition to new performance optimization through weight reduction and increased margins. Specific to regeneratively-cooled combustion chambers and nozzles for liquid rocket engines, additive manufacturing offers the ability to form the complex internal coolant channels and the closeout of the channels to contain the high pressure liquid propellants with a single operation. Much of additive manufacturing development has focused on monolithic alloys using Laser Powder Bed Fusion (L-PBF), which do not allow for complete optimization of the structure. The National Aeronautics and Space Administration (NASA) completed feasibility of an AM bimetallic L-PBF GRCop-84 copper-alloy combustion chamber with an AM electron beam freeform Inconel 625 structural jacket under the Low Cost Upper Stage Propulsion (LCUSP) Project. A follow-on project called Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) is under development to further expand large-scale multi-alloy thrust chambers while maturing composite overwrap technology for significant weight savings opportunities. The RAMPT project has three primary objectives: 1) Advancing blown powder Directed Energy Deposition (DED) to fabricate integral-channel large scale nozzles, 2) Develop composite overwrap technology to reduce weight and provide structural capability for thrust chamber assemblies, and 3) Develop bimetallic and multi-metallic additively manufactured radial and axial joints to optimize material performance. In addition to these primary manufacturing developments, analytical modeling efforts compliment the process development to simulate the AM processes to reduce build failures and distortions. The RAMPT project is also maturing the supply chain for various manufacturing processes described above in addition to L-PBF of GRCop-42. This paper will present an overview of the RAMPT project, the process development and hardware progress to date, material and hot-fire testing results, along with future developments.

Additive Manufacturing↗
NASA NTRSDate not supplied

Hot-Fire Testing Results of Additively Manufactured NASA HR-1 towards Large Scale Implementation of Channel Wall Nozzles

Additive manufacturing (AM) has provided new design and manufacturing opportunities to reduce cost and schedules, consolidate parts, and optimize performance. One technique being evaluated is Laser Powder Directed Energy Deposition (LP-DED), which provides a significant increase in scale compared to Laser Powder Bed Fusion (L-PBF). NASA along with industry partners have been developing the LP-DED process to demonstrate internal channel geometry and development components for use in liquid rocket engine channel cooled nozzles. One material that has been the focus of this development is NASA HR-1, an Iron-Nickel based superalloy optimized for use in high pressure hydrogen environments. Material properties and process characterization has been completed on the high density thin-wall material in addition to advancements of the supply chain. NASA has also completed fabrication of several subscale and full scale channel wall nozzles in LP-DED NASA HR-1 and completed hot-fire testing. This includes refinement of the process to produce thin-walls and various channel geometries to meet the requirements for channel wall nozzle applications. This paper will provide an overview of the LP-DED process development, material characterization and properties, component manufacturing, and hot-fire testing. Hot-fire testing was completed for a lander-class 7K-lbf thrust chamber using Liquid Oxygen (LOX)/Methane. The design overview and results from hot-fire testing will be presented in addition to hardware development for future testing on 2K-lbf and 35k-lbf thrust chambers and large-scale manufacturing technology demonstrators.

Paul Gradl↗
NASA NTRSDate not supplied

Advancement of Extreme Environment Additively Manufactured Alloys for Next Generation Space Propulsion Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into propulsion development and flight applications. NASA matured commonly used aerospace alloys from various alloy families (Nickel, Copper, Stainless and Steel, Aluminum, and Titanium-based) through detailed AM process and heat treatment characterization, in addition to mechanical and thermophysical testing. While these alloys are actively used in many propulsion applications, there is a need for ongoing AM optimized alloys using integrated computational materials engineering (ICME) and process development for high performance applications. The applications targeted are liquid rocket engines; advanced propulsion systems; and in-space propulsion with high heat fluxes, high pressure, and/or that use propellants that can degrade alloys (e.g., hydrogen). This paper highlights the characterization and physical properties of the more common AM alloys using laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Additionally, this paper discusses some of the ongoing novel alloy development and maturation using AM for use in these harsh environments, such as GRCop42, GRCop-84, NASA HR-1, GRX-810, and C-103. The results from these processes demonstrated that AM could enable rapid development and ongoing efforts for optimized alloys using ICME, yielding higher performances. These alloys have undergone modeling, fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing campaigns. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL) through high duty-cycle testing. A background and overview of these novel AM-enabled alloys and AM processing developments including metallurgical and mechanical property studies is presented here. The latest advancement in the parallel component development and hot-fire testing and future developments for these alloys is also discussed.

Additive Manufacturing↗
NASA NTRSDate not supplied

Advancement of Extreme Environment Additively Manufactured Alloys for Next Generation Space Propulsion Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into propulsion development and flight applications. NASA matured commonly used aerospace alloys from various alloy families (Nickel, Copper, Stainless and Steel, Aluminum, and Titanium-based) through detailed AM process and heat treatment characterization, in addition to mechanical and thermophysical testing. While these alloys are actively used in many propulsion applications, there is a need for ongoing AM optimized alloys using integrated computational materials engineering (ICME) and process development for high performance applications. The applications targeted are liquid rocket engines; advanced propulsion systems; and in-space propulsion with high heat fluxes, high pressure, and/or that use propellants that can degrade alloys (e.g., hydrogen). This paper highlights the characterization and physical properties of the more common AM alloys using laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Additionally, this paper discusses some of the ongoing novel alloy development and maturation using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, GRX-810, and C-103. The results from these processes demonstrated that AM could enable rapid development and ongoing efforts for optimized alloys using ICME, yielding higher performances. These alloys have undergone modeling, fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing campaigns. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL) through high duty-cycle testing. A background and overview of these novel AM-enabled alloys and AM processing developments including metallurgical and mechanical property studies is presented here. The latest advancement in the parallel component development and hot-fire testing and future developments for these alloys is also discussed.

Additive Manufacturing↗
NASA NTRS1994

High energy lasers as a stability rating device

A very cursory test program was performed to evaluate the feasibility of using a 100W CO2 laser to initiate resonant oscillations in a test combustor. GOX/RP-1 were selected as propellants due to the absorption characteristics of RP-1 and due to test facility capabilities. Very low amplitude oscillations were initiated during laser pulsing that correspond to the first longitudinal mode of the test engine.

Breisacher, Kevin J.↗
NASA NTRS2003

Evaluation and Characterization Study of Dual Pulse Laser-Induced Spark (DPLIS) for Rocket Engine Ignition System Application

This paper addresses the progress of technology development of a laser ignition system at NASA Marshall Space Flight Center (MSFC). Laser ignition has been used at MSFC in recent test series to successfully ignite RP1/GOX propellants in a subscale rocket chamber, and other past studies by NASA GRC have demonstrated the use of laser ignition for rocket engines. Despite the progress made in the study of this ignition method, the logistics of depositing laser sparks inside a rocket chamber have prohibited its use. However, recent advances in laser designs, the use of fiber optics, and studies of multi-pulse laser formats3 have renewed the interest of rocket designers in this state-of the-art technology which offers the potential elimination of torch igniter systems and their associated mechanical parts, as well as toxic hypergolic ignition systems. In support of this interest to develop an alternative ignition system that meets the risk-reduction demands of Next Generation Launch Technology (NGLT), characterization studies of a dual pulse laser format for laser-induced spark ignition are underway at MSFC. Results obtained at MSFC indicate that a dual pulse format can produce plasmas that absorb the laser energy as efficiently as a single pulse format, yet provide a longer plasma lifetime. In an experiments with lean H2/air propellants, the dual pulse laser format, containing the same total energy of a single laser pulse, produced a spark that was superior in its ability to provide sustained ignition of fuel-lean H2/air propellants. The results from these experiments are being used to optimize a dual pulse laser format for future subscale rocket chamber tests. Besides the ignition enhancement, the dual pulse technique provides a practical way to distribute and deliver laser light to the combustion chamber, an important consideration given the limitation of peak power that can be delivered through optical fibers. With this knowledge, scientists and engineers at Los Alamos National Laboratory and CFD Research Corporation have designed and fabricated a miniaturized, first-generation optical prototype of a laser ignition system that could be the basis for a laser ignition system for rocket applications. This prototype will be tested at MSFC in future subscale rocket ignition tests.

Osborne, Robin↗
NASA NTRS1999

Instellar Exploration: Propulsion Options for Precursors and Beyond

NASA is considering a mission to explore near-interstellar space early in the next decade as the first step toward a vigorous interstellar exploration program. A key enabling technology for such an ambitious science and exploration effort is the development of propulsion systems capable of providing fast trip times; mission duration should not exceed the professional lifetime of the investigative team. Advanced propulsion technologies that might support an interstellar precursor mission early in the next century include some combination of solar sails, nuclear electric propulsion systems, and aerogravity assists. Follow-on missions to far beyond the heliopause will require the development of propulsion technologies that are only at the conceptual stage today. These include 1) matter-antimatter annihilation, 2) beamed-energy sails, and 3) fusion systems. For years, the scientific community has been interested in the development of solar sail technology to support exploration of the inner and outer planets. Progress in thin-film technology and the development of technologies that may enable the remote assembly of large sails in space are only now maturing to the point where ambitious interstellar precursor missions can be considered. Electric propulsion is now being demonstrated for planetary exploration by the Deep Space 1 mission. The primary issues for it's adaptation to interstellar precursor applications include the nuclear reactor that would be required and the engine lifetime. For further term interstellar missions, matter-antimatter annihilation propulsion system concepts have the highest energy density of any propulsion systems using onboard propellants. However, there are numerous challenges to production and storage of antimatter that must be overcome before it can be seriously considered for interstellar flight. Off-board energy systems (laser sails) are candidates for long-distance interstellar flight but development of component technologies and necessary infrastructure have not begun.. Fusion propulsion has been studied extensively. However, fusion technology is still considered immature, even after many decades of well-funded research. Furthermore, fusion alone does not offer high enough energy density to make it a viable candidate for interstellar propulsion unless propellant can be collected in situ, as was considered by R. Bussard for his interstellar ramjet concept. The current research in investigating these propulsion systems will be described, and the range of application of each technology will be explored.

Johnson, Charles Les↗
NASA NTRS2004

The Use of Laser-Induced Fluorescence to Characterize Discharge Cathode Erosion in a 30 cm Ring-Cusp Ion Thruster

Relative erosion rates and impingement ion production mechanisms have been identified for the discharge cathode of a 30 cm ion engine using laser-induced fluorescence (LIF). Mo and W erosion products as well as neutral and singly ionized xenon were interrogated. The erosion increased with both discharge current and voltage and spatially resolved measurements agreed with observed erosion patters. Ion velocity mapping identified back-flowing ions near the regions of erosion with energies potentially sufficient to generate the level of observed erosion. Ion production regions downstream of the cathode were indicated and were suggested as possible sources of the erosion causing ions.

Sovey, James S.↗
NASA NTRS1978

A new concept for solar pumped lasers

A new approach is proposed in which an intermediate body heated by sunlight is used as the pumping source for IR systems, i.e., concentration solar radiation is absorbed and reradiated via an intermediate blackbody. This body is heated by focused sunlight to a high temperature and its heat losses are engineered to be small. The cooled laser tube (or tubes) is placed within the cavity and is pumped by it. The advantage is that the radiation spectrum is like a blackbody at the intermediate temperature and the laser medium selectively absorbs this light. Focusing requirements, heat losses, and absorption bandwidths of laser media are examined, along with energy balance and potential efficiency. The results indicate that for lasers pumped through an IR absorption spectrum, the use of an intermediate blackbody offers substantial and important advantages. The loss in radiative intensity for optical pumping by a lower-temperature body is partly compensated by the increased solid angle of exposure to the radiative environment.

Christiansen, W. H.↗
NASA NTRS2019

Additive Manufacturing Development and Hot-Fire Testing of Liquid Rocket Channel Wall Nozzles Using Blown Powder Directed Energy Deposition Inconel 625 and JBK-75 Alloys

Additive manufacturing (AM) is being investigated at NASA and across much of the rocket propulsion industry as an alternate fabrication technique to create complex geometries for liquid engine components that offers schedule and cost saving opportunities. The geometries that can be created using AM offer a significant advantage over traditional techniques. Internal complexities, such as internal coolant channels for combustion chambers and nozzles that would typically require several operations to manufacture traditionally can be fabricated in one process. Additionally, the coolant channels are closed out as a part of the AM build process, eliminating the complexities of a traditional process like brazing or plating. The primary additive manufacturing technique that has been evaluated is powder bed fusion (PBF), or selective laser melting (SLM), but there is a scale limitation for this technique. There are several alternate additive manufacturing techniques that are being investigated for large-scale nozzles and chambers including directed energy deposition (DED) processes. A significant advantage of the DED processes is the ability to adapt to a robotic or gantry CNC system with a localized purge or purge chamber, allowing unlimited build volume. This paper will discuss the development and hot-fire testing of channel-cooled nozzles fabricated utilizing one form of DED called blown powder deposition. This initial development work using blown powder DED is being explored to form the entire channel wall nozzle with integral coolant channels within a single AM build. Much of this development is focused on the design and DED-fabrication of complex and thin-walled features and on characterization of the materials properties produced with this techniques in order to evolve this process. Subscale nozzles were fabricated using this DED technique and hot-fire tested in Liquid Oxygen/Hydrogen (LOX/GH2) and LOX/Kerosene (LOX/RP-1) environments accumulating significant development time and cycles. The initial materials that were evaluated during this testing were high-strength nickel-based Inconel 625 and JBK-75. Further process development is being completed to increase the scale of this technology for large-scale nozzles. This paper will summarize the general design considerations for DED, specific channel-cooled nozzle design, manufacturing process development, property development, initial hot-fire testing and future developments to mature this technology for regeneratively-cooled nozzles. An overview of future development at NASA will also be discussed.

Gradl, Paul R.↗
NASA NTRS1979

Symposium /International/ on Combustion, 17th, Leeds University, Leeds, England, August 20-25, 1978, Proceedings

The Symposium focused on deflagration to detonation transition, coal combustion, turbulent-combustion interactions, kinetics, furnace combustion, inhibition and ignition, flame structure and chemistry, combustion studies, measurement techniques, fire and explosion, engine combustion, soot, and propellants and explosives. Papers were presented on numerical modeling of the deflagration-to-detonation transition, the interaction between turbulence and combustion, turbulent flame propagation in premixed gases, spray evaporation in recirculating flow, dissociation of nitric oxide in shock waves, pollutant emissions from partially mixed turbulent flames, energy transfer and quenching rates of laser-pumped electronically excited alkalis in flames, a study of flammability limits using counterflow flames, the unified theory of explosions with fuel consumption, and the dynamics and radiant intensity of large hydrogen flames.

Source record↗