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At least 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
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.↗
NASA NTRS2018

Creating the Required Deep Space Environments for Testing the James Webb Space Telescope (JWST) at NASA Johnson Space Center's Chamber A

NASA is the mission lead for the James Webb Space Telescope (JWST), the next of the "Great Observatories", scheduled for launch in 2021. NASA was directly responsible for the integration and test (I&T) program that culminated in an end-to-end cryo vacuum optical test of the flight telescope and instrument module in Chamber A at NASA Johnson Space Center. Historic Chamber A is the largest thermal vacuum chamber at Johnson Space Center and one of the largest space simulation chambers in the world. Chamber A has undergone a major modernization effort to support the deep cryogenic, vacuum and cleanliness requirements for testing the JWST. This paper will discuss the thermal vacuum test of the Optical Telescope Element (OTE) plus Integrated Science Instrument Module (ISIM) (OTIS) as well as the extensive series of tests that were performed to incrementally validate the operations and performance of the Chamber and Ground Support Equipment (GSE). Each test required a unique thermal vacuum profile for cool down and warm up, steady state operations, GSE testing and contamination control. Select results will be presented on Facility Functional Testing, Chamber Bake-out, GSE Cryo-Proof Testing, Chamber Commissioning, the Optical Ground Support Equipment (OGSE) Test series and the final thermal vacuum test of the OTIS with respect to facility operations to meet JWST program test requirements.

Francis, Andrew↗
DOE OSTI2026

Hybrid combustion modeling approach for turbulent jet ignition in natural-gas pre-chamber spark-ignition engines at high EGR

Here, this study presented a hybrid modeling approach for simulating turbulent jet ignition and combustion processes in a natural-gas pre-chamber spark-ignition engine operating under exhaust gas recirculation (EGR) diluted conditions. In-depth analyses of experimental data and simulation results from previous work [Chinnathambi et al., ICEF2021-67836; Kim et al., Fuel 409: 137815, 2026] revealed two key findings: (i) the magnitude of pressure difference between the pre-chamber and main chamber ($∆P_{PC-MC}$) was positively correlated with the combustion duration from the moment of $∆P_{PC-MC}=0$ to the point of 5% mass fraction burned, with larger $∆P_{PC-MC}$ associated with longer duration; and (ii) the turbulent combustion regime in the main chamber transitioned from the broken reaction zone to the corrugated flamelet regime, with the Karlovitz number exceeding 100 immediately after turbulent hot jets were ejected from nozzles, coinciding with observed local extinction events. To accurately simulate the entire combustion process, a hybrid approach was developed under Reynolds-Averaged Navier Stokes framework, combining the G-equation model for pre-chamber combustion with the multi-zone well-stirred reactor approach and a turbulence-chemistry interaction (TCI) submodel for main chamber combustion. The TCI submodel accounted for the attenuation of reaction rates due to turbulent strain and modeled local extinction by suppressing reaction rates under certain flow and flame conditions. When applied to three EGR rate conditions toward the dilution limit, the hybrid modeling approach accurately reproduced experimental data in terms of cylinder pressure, apparent heat release rate, and the observed positive correlation, including the delayed onset of main chamber combustion—a feature not captured by existing combustion models.

computational fluid dynamics simulation↗
NASA NTRSDate not supplied

Operating and Maintaining the JWST Cleanroom attached to JSC's Chamber A during preparations for the OTIS Cryogenic Thermal Vacuum Test

In order to maintain cleanliness during preparations for JWST’s OTIS (Optical Telescope Element-Integrated Science Instrument Module) Cryogenic Thermal Vacuum Test, a cleanroom was built that attached directly to the 60-year-old Chamber A. The cleanroom and chamber were outfitted with independent environmental control systems each providing ISO Class 71 air cleanliness. To maintain balanced, positive pressure in both the cleanroom and chamber volumes, a special control protocol was developed and successfully implemented. Dual back-up environmental control units (one each for the chamber and cleanroom) were installed just outside the building to provide environmental control redundancy due to a single source chilled water supply and weather threats. In addition, lack of a dedicated cleanroom airlock facilitating clean ingress and egress made it necessary to perform additional cleaning and packaging, as well as augment the uncontrolled truck lock space with small clean tents for pre-cleaning. Special procedures were developed to allow ingress of extra-large support equipment required for load testing of the cleanroom crane, installation of optical equipment in Chamber A and accommodation of the OTIS shipping container. A thorough bake-out and cleaning of Chamber A was also necessary to reduce volatiles from the shroud’s black thermal paint and to reduce particle fallout. Acrylic adhesive fracture discovered during early cryo-testing represented a significant challenge that was successfully mitigated prior to OTIS testing. A dedicated team of Contamination Control (CC) Technicians was specifically trained to clean support equipment and screen materials entering the cleanroom and chamber to ensure cleanliness and vacuum compatibility.

James Webb Space Telescope↗
NASA NTRSDate not supplied

Development of Large-Scale Thrust Chambers using Laser Powder Directed Energy Deposition

Historical manufacturing methods for liquid propulsion combustion chambers have relied on series of tube-walls or slotted channel walls (subsequently brazed or plated) for regenerative cooling paths. Large-scale additive manufacturing techniques offer strong potential to minimize manufacturing lead times and cost for developing liquid propulsion chambers, while maintaining performance metrics of traditionally manufactured hardware. The benefits expand beyond traditional combustion chambers to lesser considered nuclear thermal propulsion chambers where radiation energizes the singular incoming propellant stream instead of an exothermic chemical reaction. While each subset of liquid propulsion chambers reaps similar benefit, the geometric challenges in each design can vary substantially. This manuscript discusses the challenges of large contraction ratio propulsion chambers, bimetallic liners and closeout jackets, and material selection when considering laser powder directed energy deposition. LP-DED presently offers build volumes unattainable by L-PBF systems, required for large diameter thrust chambers. LP-DED typically has faster deposition time and is capable of overhang angles without support material (due to the ability to tilt the build plate and minimize the actual build angle). These benefits come at the cost of feature resolution. Designers and manufacturers should consider the effects of thick-wall features printed parallel to the primary surface versus perpendicular due to distortion. Thick-wall and thin-wall features printed in the same plane can substantially increase build time. Where large-scale L-PBF overlaps in size, there may be limited benefit in the quantity of powder required for the build due to the low capture rate of LP-DED and a case-by-case examination is required.

LP-DED↗
DOE OSTI2024

Scintillating Bubble Chambers for Direct Dark Matter Detection, and an Update on SBC-LAr10

The Scintillating Bubble Chamber (SBC) Collaboration aims to use the liquid-noble bubble chamber technology as a low-threshold detector for dark matter particles of 1-10 GeV/c2. The detector combines the remarkable electron recoil (ER) discrimination of the bubble chamber with the event-by-event energy resolution provided by liquid argon (LAr) scintillation, with the crucial added benefit that ER discrimination in liquid-noble bubble chambers extends to much lower thresholds than in past freon-filled bubble chambers, with the potential for quasi-background-free operation at thresholds of 100 eV in nuclear recoil (NR) energy. SBC has developed two functionally identical 10 kg detectors: SBC-LAr10 at Fermilab will calibrate low-threshold performance, while the radio-pure SBC-SNOLAB chamber will execute SBC s first deep-underground dark matter search. SBC-LAr10 at Fermilab was recently installed in the MINOS tunnel 100 meters underground, and the first bubbles are expected this fall. I will present the current status of SBC-LAr10 and describe the suite of gamma and neutron calibrations we will execute. The calibrations will confirm the physics reach of this new technology, motivating not just the SBC-SNOLAB chamber now being assembled but also future searches into the solar neutrino fog at 1 GeV/c2.

Sheng, Zhiheng↗
NASA NTRS1977

Studies with the Arapahoe smoke chamber

Samples of polymethyl methacrylate, polyvinyl chloride, polyester, and polystyrene were evaluated using the Arapahoe smoke chamber. These same materials had been previously evaluated using the National Bureau of Standards (NBS) smoke chamber. The percent smoke based on initial weight as determined using the Arapahoe smoke chamber appeared to correlate with the maximum specific optical density under flaming conditions as determined using the NBS smoke chamber. In addition, the percent smoke based on weight loss as determined using the Arapahoe smoke chamber appeared to correlate with the maximum specific optical density under nonflaming conditions as determined using the NBS smoke chamber. The Arapahoe smoke chamber also offers the advantage of high sample throughput and the possibility of related studies of smoke particulates.

Hilado, C. J.↗
NASA NTRS1984

Preparation and cleanliness verifications of a space simulation chamber for contamination sensitive test specimens

Contamination sensitive optical devices were to be evaluated under thermal vacuum conditions. Test specifications called for an extremely clean chamber environment, ambient temperature chamber walls, and optical surface temperatures at approximately - 30 C. Chamber preparation included the replacement of diffusion pumps with cryopumps and the cleaning of the chamber walls to reduce contamination levels. Chamber cleaning using vacuum bake was tried and abandoned as time consuming and ineffective. Chemical cleaning and cleanliness verification methods were developed. Gas chromatograph analysis techniques were used extensively throughout the cleaning process to verify cleanliness levels prior to evacuating the chamber. A chamber cleanliness verification test using a thermoelectric quartz crystal microbalance and witness samples was performed to demonstrate that an appropriate cleanliness level was achieved.

Koch, W. R.↗
NASA NTRS1985

Observation of super high energy big family with large scale Fe emulsion chambers

In order to get higher efficiencies for detecting hadrons and to make technical improvements in the chamber structure, the Mt. Kambala Emulsion Chamber Collaboration constructed 57 sq. m. of Fe chamber, with thickness 29 c.u.(1c.u.=17.6 mm Fe), using 300 tons of Fe plates and made the first exposure from Sept., 1982 to May, 1984. The photosensitive layers consist of X-ray films of Sakura N type, Fuji No. 100 type and Tianjin III type, some of them contain also emulsion plates of Fuji ET7B type. They are inserted between the Fe plates at 2 c.u., beginning at 5 c.u. from the chamber top. In a number of blocks, 3 mm spacings are provided at every 2 c.u. of Fe plates to facilitate the replacement of photosensitive layers, without disassembling the chamber. On the bottom of the chamber Fe plates of thickness 9 mm are placed in order to shield the chamber from the radioactivities of the ground. An event, numbered K2 58 of visible energy sigma E sub gamma = 7345 TeV was found in this exposure. No obvious halo is seen in the event and all the showers are clearly separated and easy to measure. A brief report of the preliminary results is presented.

Source record↗
NASA NTRS1988

Orbital transfer vehicle 3000 LBF thrust chamber assembly hot fire test program

The Aerojet Orbital Transfer Vehicle (OTV) Thrust Chamber Assembly (TCA) concept consists of a hydrogen cooled chamber, and annular injector, and an oxygen cooled centerbody. The hot fire testing of a heat sink version of the chamber with only the throat section using hydrogen cooling is documented. Hydraulic performance of the injector and cooled throat were verified by water flow testing prior to TCA assembly. The cooled throat was proof tested to 3000 psia to verify the integrity of the codeposited EF nickel-cobalt closeout. The first set of hot fire tests were conducted with a heat sink throat to obtain heat flux information. After demonstration of acceptable heat fluxes, the heat sink throat was replaced with the LH2 cooled throat section. Fourteen tests were conducted with a heat sink chamber and throat at chamber pressures of 85 to 359 psia. The injector face was modified at this time to add more face coolant flow. Ten tests were then conducted at chamber pressures of 197 to 620 psia. Actual heat fluxes at the higher chamber pressure range were 23 percent higher than the average of 10 Btu/in 2 predicted.

Schneider, Judy↗
NASA NTRS1989

Characterization of hollow cathode, ring cusp discharge chambers

An experimental study into the effects of changes in such physical design parameters as hollow cathode position, anode position and ring cusp magnetic field configuration and strength on discharge chamber performance, is described. The results are presented in terms of comparative plasma ion energy cost, extracted ion fraction and ion beam profile data. Such comparisons are used to demonstrate specific means by which changes in these design parameters induce changes in performance, i.e., through changes in the loss rates of primary electrons to the anode, of ions to discharge chamber walls or of ions to cathode and anode surfaces. Results show: (1) the rate of primary electron loss to the anode decreases as the anode is moved downstream of the ring cusp toward the screen grid, (2) the loss rate of ions to hollow cathode surfaces are excessive if the cathode is located upstream of a point of peak magnetic flux density on the discharge chamber centerline, and (3) the fraction of the ions produced that are lost to discharge chamber walls and ring magnet surfaces is reduced by positioning the magnet rings so the plasma density is uniform over the grid surface and so there are no steep magnetic flux density gradients near the walls through which ions can be lost by Bohm diffusion. The uniformity of the plasma density at the grids can also be improved by moving the point of primary electron injection into the discharge chamber off of the chamber centerline. Other results show the discharge chamber losses decrease when a filament cathode is substituted for a hollow cathode to the extent of the hollow cathode operating power. When plasma ion energy cost is determined in such a way that the cost of operating the hollow cathode is subtracted out, the performance using either electron source is similar.

Vaughn, Jason A.↗
NASA NTRS1991

Trade study comparing specimen chamber servicing methods for the Space Station Centrifuge Facility

The Specimen Chamber Service Unit, a component of the Space Station Centrifuge Facility, must provide a clean enclosure on a continuing basis for the facility's plant, rodent and primate specimens. The specimen chambers can become soiled and can require periodic servicing to maintain a clean environment for the specimens. Two methods of servicing the specimen chambers are discussed: washing the chambers with an on-board washer, or disposing of the soiled chambers and replacing them with clean ones. Many of these issues are addressed by developing several servicing options, using either cleaning or replacement as the method of providing clean specimen chambers, and then evaluating each option according to a set of established quantitative and qualitative criteria. Disposing and replacing the Specimen Chambers is preferable to washing them.

Calvisi, Michael L.↗
NASA NTRS1928

Performance of Several Combustion Chambers Designed for Aircraft Oil Engines

Several investigations have been made on single-cylinder test engines to determine the performance characteristics of four types of combustion chambers designed for aircraft oil engines. Two of the combustion chambers studied were bulb-type precombustion chambers, the connecting orifice of one having been designed to produce high turbulence by tangential air flow in both the precombustion chamber and the cylinder. The other two were integral combustion chambers, one being dome-shaped and the other pent-roof shaped. The injection systems used included cam and eccentric driven fuel pumps, and diaphragm and spring-loaded fuel-injection valves. A diaphragm type maximum cylinder pressure indicator was used in part of these investigations with which the cylinder pressures were controlled to definite valves. The performance of the engines when equipped with each of the combustion chambers is discussed. The best performance for the tests reported was obtained with a bulb-type combustion chamber designed to give a high degree of turbulence within the bulb and cylinder. (author)

Joachim, William F↗
NASA NTRS1993

Design, analysis, and fabrication of oxide-coated iridium/rhenium combustion chambers

Iridium-coated rhenium (Ir/Re) combustion chambers provide high temperature, oxidation-resistant operation for radiation-cooled liquid-fueled rocket engines. A 22-N (5-lb(sub f)) chamber has been operated for 15 hours at 2200 C (4000 F) using nitrogen tetroxide/monomethyl hydrazine (NTO/MMH) propellant, with negligible internal erosion. The oxidation resistance of these chambers could be further increased by the addition of refractory oxide coatings, providing longer life and/or operation in more oxidizing and higher temperature environments. The oxide coatings would serve as a thermal and diffusion barrier for the iridium coating, lowering the temperature of the iridium layer while also preventing the ingress of oxygen and egress of iridium oxides. This would serve to slow the failure mechanisms of Ir/Re chambers, namely the diffusion of rhenium to the inner surface and the oxidation of iridium. Such protection could extend chamber lifetimes by tens or perhaps hundreds of hours, and allow chamber operation on stoichiometric or higher mixture ratio oxygen/hydrogen (O2/H2) propellant. Extensive thermomechanical, thermochemical, and mass transport modeling was performed as a key material/structure design tool. Based on the results of these analyses, several 22-N oxide-coated Ir/Re chambers were fabricated and delivered to NASA Lewis Research Center for hot-fire testing.

Jang, Q.↗
NASA NTRS2000

Vacuum Plasma Spray of CuCrNb Alloy for Advanced Liquid - Fuel Combustion Chambers

The copper-8 atomic percent chromium-4 atomic percent niobium (CuCrNb) alloy was developed by Glenn Research Center (formally Lewis Research Center) as an improved alloy for combustion chamber liners. In comparison to NARloy-Z, the baseline (as in Space Shuttle Main Engine) alloy for such liners, CuCrNb demonstrates mechanical and thermophysical properties equivalent to NARloy-Z, but at temperatures 100 C to 150 C (180 F to 270 F) higher. Anticipated materials related benefits include decreasing the thrust cell liner weight 5% to 20%, increasing the service life at least two fold over current combustion chamber design, and increasing the safety margins available to designers. By adding an oxidation and thermal barrier coating to the liner, the combustion chamber can operate at even higher temperatures. For all these benefits, however, this alloy cannot be formed using conventional casting and forging methods because of the levels of chromium and niobium, which exceed their solubility limit in copper. Until recently, the only forming process that maintains the required microstructure of CrNb intermetallics is powder metallurgy formation of a billet from powder stock, followed by extrusion. This severely limits its usefulness in structural applications, particularly the complex shapes required for combustion chamber liners. Vacuum plasma spray (VPS) has been demonstrated as a method to form structural articles including small combustion chambers from the CuCrNb alloy. In addition, an oxidation and thermal barrier layer can be formed integrally on the hot wall of the liner that improve performance and extend service life. This paper discusses the metallurgy and thermomechanical properties of VPS formed CuCrNb versus the baseline powder metallurgy process, and the manufacturing of small combustion chamber liners at Marshall Space Flight Center using the VPS process. The benefits to advanced propulsion initiatives of using VPS to fabricate combustion chamber liners while maintaining the superior CuCrNb properties are also presented.

Zimmerman, Frank↗
NASA NTRS2003

Evaluation of Impinging Stream Vortex Chamber Concepts for Liquid Rocket Engine Applications

NASA Marshall Space Flight Center (MSFC) and the U. S. Army are jointly investigating vortex chamber concepts for cryogenic oxygen/hydrocarbon fuel rocket engine applications. One concept, the Impinging Stream Vortex Chamber Concept (ISVC), has been tested with gel propellants at AMCOM at Redstone Arsenal, Alabama. A version of this concept for the liquid oxygen (LOX)/hydrocarbon fuel (RP-1) propellant system is derived from the one for the gel propellant. An unlike impinging injector is employed to deliver the propellants to the chamber. MSFC has also designed two alternative injection schemes, called the chasing injectors, associated with this vortex chamber concept. In these injection techniques, both propellant jets and their impingement point are in the same chamber cross-sectional plane. One injector has a similar orifice size with the original unlike impinging injector. The second chasing injector has small injection orifices. The team has achieved their objectives of demonstrating the self-cooled chamber wall benefits of ISVC and of providing the test data for validating computational fluids dynamics (CFD) models. These models, in turn, will be used to design the optimum vortex chambers in the future.

Trinh, Huu↗
NASA NTRS1961

Effects of Geometric Variations on Lift Augmentation of Simple-plenum-chamber Ground-effect Models

Considerable interest has been shown during recent years in ground-effect vehicles. Of the various types proposed, the simple-plenum-chamber vehicle has indicated promise because, although the lift augmentation obtainable appears to be less than that of an annular jet, it may be somewhat less complicated structurally. The present investigation was undertaken to study the effects of some geometric variations upon lift augmentation of a simple plenum chamber within ground proximity. The variables included the ratio inlet area to exit area, plenum-chamber depth, and entrance configuration. An optimum plenum-chamber depth appeared to be between 3 and 10 percent of the plenum-chamber diameter with a ratio of inlet diameter to plenum-chamber diameter of 0.15 for the range of plenum-chamber depths investigated. The most important effect of multiple inlets was the elimination of negative lift augmentation, which was experienced with single sharp-edged inlets, at intermediate heights. Installation of a flared inlet and a turning-vane assembly improved lift augmentation of a single-inlet configuration at intermediate heights.

Davenport, Edwin E.↗
NASA NTRS1996

Higher sympathetic nerve activity during ventricular (VVI) than during dual-chamber (DDD) pacing

OBJECTIVES: We determined the short-term effects of single-chamber ventricular pacing and dual-chamber atrioventricular (AV) pacing on directly measured sympathetic nerve activity. BACKGROUND: Dual-chamber AV cardiac pacing results in greater cardiac output and lower systemic vascular resistance than does single-chamber ventricular pacing. However, it is unclear whether these hemodynamic advantages result in less sympathetic nervous system outflow. METHODS: In 13 patients with a dual-chamber pacemaker, we recorded the electrocardiogram, noninvasive arterial pressure (Finapres), respiration and muscle sympathetic nerve activity (microneurography) during 3 min of underlying basal heart rate and 3 min of ventricular and AV pacing at rates of 60 and 100 beats/min. RESULTS: Arterial pressure was lowest and muscle sympathetic nerve activity was highest at the underlying basal heart rate. Arterial pressure increased with cardiac pacing and was greater with AV than with ventricular pacing (change in mean blood pressure +/- SE: 10 +/- 3 vs. 2 +/- 2 mm Hg at 60 beats/min; 21 +/- 5 vs. 14 +/- 2 mm Hg at 100 beats/min; p < 0.05). Sympathetic nerve activity decreased with cardiac pacing and the decline was greater with AV than with ventricular pacing (60 beats/min -40 +/- 11% vs. -17 +/- 7%; 100 beats/min -60 +/- 9% vs. -48 +/- 10%; p < 0.05). Although most patients showed a strong inverse relation between arterial pressure and muscle sympathetic nerve activity, three patients with severe left ventricular dysfunction (ejection fraction < or = 30%) showed no relation between arterial pressure and sympathetic activity. CONCLUSIONS: Short-term AV pacing results in lower sympathetic nerve activity and higher arterial pressure than does ventricular pacing, indicating that cardiac pacing mode may influence sympathetic outflow simply through arterial baroreflex mechanisms. We speculate that the greater incidence of adverse outcomes in patients treated with single-chamber ventricular rather than dual-chamber pacing may be due in part to increased sympathetic nervous outflow.

NASA Discipline Cardiopulmonary↗