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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Development of Laser Powder Bed Fusion NASA HR-2 for Hydrogen Sensitive Liquid Rocket Engine 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 2000s. AM has provided new design and manufacturing opportunities to reduce cost and schedule, consolidate parts, and optimize performance. Laser Powder Bed Fusion (L-PBF) is one of the most commonly used AM processes to fabricate components of complex shape requiring fine feature resolution. Due to exposure to high-pressure gaseous hydrogen, mechanical property degradation caused by hydrogen environment embrittlement (HEE) is a critical concern for many materials in liquid hydrogen propulsion systems. NASA has identified the need to develop and advance new materials in unique engine applications using liquid hydrogen as a propellant. One such material being developed at NASA Marshall Space Flight Center is L-PBF NASA HR-2 (Hydrogen Resistant-2), a high-strength Fe-Ni-based superalloy resistant to HEE. The chemistry of NASA HR-2 was formulated to meet requirements for key liquid rocket engine (LRE) components that operate in high-pressure hydrogen environments. Initial development and material characterization found that NASA HR-2 has excellent L-PBF printability, and its microstructure evolves well after heat treatment. This new alloy has undergone fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing across a range of temperatures. Tensile testing was performed in a pressurized gaseous hydrogen (GH2) environment to assess its resistance to HEE. L-PBF NASA HR-2 has an average yield stress of 95 ksi, an ultimate tensile stress of 165 ksi, and a very high fracture elongation of 34 - 36% when tested in a high-pressure (5 ksi) hydrogen environment. The tensile property data confirms hydrogen has little influence on HR-2’s ductility, strength, and fracture behavior. L-PBF NASA HR-2 is a promising option for many hydrogen-sensitive LRE components that require exceptional resistance to HEE. This paper will provide an overview of the L-PBF process development, material characterization, mechanical and thermophysical properties, and LRE hardware development for NASA HR-2.

Po S Chen↗
NASA NTRS1995

Theoretical and Observational Studies of the Central Engines of AGN

In Active Galactic Nuclei (AGN) the luminosity is so intense that the effect of radiation pressure on a particle may exceed the gravitational attraction. It was shown that when such luminosities are reached, relatively cold (not completely ionized) thermal matter clouds may form in the central engines of AGN, where most of the luminosity originates. We show that the spectrum of emission from cold clouds embedded in hot relativistic matter is similar to the observed spectrum. We also show that within the hot relativistic matter, cold matter moves faster than the speed of sound or the Alfven speed, and shocks form. The shocks provide a mechanism by which a localized perturbation can propagate throughout the central engine. The shocked matter can emit the observed luminosity, and can explain the flux and spectral variability. It may also provide an efficient mechanism for the outward transfer of angular momentum and provide the outward flow of winds. With observations from X-ray satellites, emission features from the cold and hot matter may be revealed. Our analysis of X-ray data from the Seyfert 1 galaxy MCG - 6-30-15 over five years using detectors on the Ginga and Rosat satellites, revealed some interesting variable features. A source with hot matter emits non-thermal radiation which is Compton reflected from cold matter and then absorbed by warm (partially ionized) absorbing matter in the first model, which can be fit to the data if both the cold and warm absorbers are near the central engine. An alternative model in which the emission from the hot matter is partially covered by very warm matter (in which all elements except Iron are mostly ionized) is also successful. In this model the cold and warm matter may be at distances of up to 100 times the size of the central engine, well within the region where broad optical lines are produced. The flux variability is more naturally explained by the second model. Our results support the existence of cold matter in, or near, the central engine of MCG -6-30-15. Cold matter in the central engine, and evidence of the effects of shocks, is probably forthcoming with future X-ray satellites.

Sivron, Ran↗
NASA NTRSDate not supplied

Development of Laser Powder Bed Fusion NASA HR-2 for Hydrogen Sensitive Liquid Rocket Engine 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. AM has provided new design and manufacturing opportunities to reduce cost and schedule, consolidate parts, and optimize performance. Laser Powder Bed Fusion (L-PBF) is one of the most commonly used AM processes to fabricate components that have complex shape and need fine feature resolution. Due to exposure to high pressure gaseous hydrogen, mechanical property degradation caused by hydrogen environment embrittlement (HEE) is a critical concern for many materials in liquid hydrogen propulsion systems. NASA has identified the need to develop and advance new materials in unique engine applications using liquid hydrogen as a propellant. One such material being developed at NASA Marshall Space Flight Center is L-PBF NASA HR-2 (Hydrogen Resistant-2), a high-strength Fe-Ni-based superalloy resistant to HEE. The chemistry of NASA HR-2 was formulated to meet requirements for key liquid rocket engine (LRE) components that operate in high-pressure hydrogen environments. Initial development and material characterization found NASA HR-2 has excellent L-PBF printability and its microstructure evolves well after heat treatment. This new alloy has undergone fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing across a range of temperatures. Tensile testing was performed in pressurized gaseous hydrogen (GH2) environment to assess its resistance to HEE. L-PBF NASA HR-2 has an average yield stress of 95 ksi, ultimate tensile stress of 165 ksi, and very high fracture elongation at 34 - 36% when tested in a 5 ksi high pressure hydrogen environment. The tensile property data confirms hydrogen has little influence on its ductility, strength, and fracture behavior. L-PBF NASA HR-2 is a promising option for many hydrogen sensitive LRE components that require exceptional resistance to HEE. The development of L-PBF NASA HR-2 is funded under the grants provided by Jacobs TIPI program and the Liquid Engine Office at NASA Marshall Space Flight Center. This paper will provide an overview of the L-PBF process development, material characterization, mechanical and thermophysical properties, and LRE hardware development for NASA HR-2.

NASA HR-2↗
NASA NTRSDate not supplied

Development of Laser Powder Bed Fusion NASA HR-2 for Hydrogen Sensitive Liquid Rocket Engine 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. AM has provided new design and manufacturing opportunities to reduce cost and schedule, consolidate parts, and optimize performance. Laser Powder Bed Fusion (L-PBF) is one of the most commonly used AM processes to fabricate components that have complex shape and need fine feature resolution. Due to exposure to high pressure gaseous hydrogen, mechanical property degradation caused by hydrogen environment embrittlement (HEE) is a critical concern for many materials in liquid hydrogen propulsion systems. NASA has identified the need to develop and advance new materials in unique engine applications using liquid hydrogen as a propellant. One such material being developed at NASA Marshall Space Flight Center is L-PBF NASA HR-2 (Hydrogen Resistant-2), a high-strength Fe-Ni-based superalloy resistant to HEE. The chemistry of NASA HR-2 was formulated to meet requirements for key liquid rocket engine (LRE) components that operate in high-pressure hydrogen environments. Initial development and material characterization found NASA HR-2 has excellent L-PBF printability and its microstructure evolves well after heat treatment. This new alloy has undergone fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing across a range of temperatures. Tensile testing was performed in pressurized gaseous hydrogen (GH2) environment to assess its resistance to HEE. L-PBF NASA HR-2 has an average yield stress of 95 ksi, ultimate tensile stress of 165 ksi, and very high fracture elongation at 34 - 36% when tested in a 5 ksi high pressure hydrogen environment. The tensile property data confirms hydrogen has little influence on its ductility, strength, and fracture behavior. L-PBF NASA HR-2 is a promising option for many hydrogen sensitive LRE components that require exceptional resistance to HEE. The development of L-PBF NASA HR-2 is funded under the grants provided by Jacobs TIPI program and the Liquid Engine Office at NASA Marshall Space Flight Center. This paper will provide an overview of the L-PBF process development, material characterization, mechanical and thermophysical properties, and LRE hardware development for NASA HR-2.

NASA HR-2↗
NASA NTRS2018

Additive Manufacturing of Liquid Rocket Engine Combustion Devices: A Summary of Process Developments and Hot-Fire Testing Results

Additive Manufacturing (AM) is an emerging technology with a focus on complex metallic component fabrication: Enables complex shapes and internal features that were not possibly with traditional manufacturing techniques, and significant schedule and overall lifecycle cost reductions. To date at the NASA Marshall Space Flight Center (MSFC), combustion devices component hardware ranging in size from 100 - 35,000 lbf has been designed and manufactured using AM and many of these pieces have been hot-fire tested.

Gradl, Paul↗
NASA NTRS1986

De-icing of the altitude wind tunnel turning vanes by electro-magnetic impulse

The Altitude Wind Tunnel at the NASA-Lewis facility is being proposed for a refurbishment and moderization. Two major changes are: (1) the increasing of the test section Mach number to 0.90, and (2) the addition of spray nozzles to provide simulation of flight in icing clouds. Features to be retained are the simulation of atmospheric temperature and pressure to 50,000 foot altitude and provision for full-scale aircraft engine operation by the exhausting of the aircraft combustion gases and ingestion of air to replace that used in combustion. The first change required a re-design of the turning vanes in the two corners downstream of the test section due to the higher Mach number at the corners. The second change threatens the operation of the turning vanes by the expected ice build-up, particulary on the first-corner vanes. De-icing by heat has two drawbacks: (1) an extremely large amount of heat is required, and (2) the melted ice would tend to collect as ice on some other surfaces in the tunnel, namely, the tunnel propellers and the cooling coils. An alternate de-icing method had been under development for three years under NASA-Lewis grants to the Wichita State University. This report describes the electro-impulse de-icing (EIDI) method and the testing work done to assess its applicability to wind tunnel turning vane de-icing. Tests were conducted in the structural dynamics laboratory and in the NASA Icing Research Tunnel. Good ice protection was achieved at lower power consumption and at a wide range of tunnel operations conditions. Recommendations for design and construction of the system for this application of the EIDI method are given.

Zumwalt, G. W.↗
NASA NTRS1989

Involute composite design evaluation using global design sensitivity derivatives

An optimization capability for involute structures has been developed. Its key feature is the use of global material geometry variables which are so chosen that all combinations of design variables within a set of lower and upper bounds correspond to manufacturable designs. A further advantage of global variables is that their number does not increase with increasing mesh density. The accuracy of the sensitivity derivatives has been verified both through finite difference tests and through the successful use of the derivatives by an optimizer. The state of the art in composite design today is still marked by point design algorithms linked together using ad hoc methods not directly related to a manufacturing procedure. The global design sensitivity approach presented here for involutes can be applied to filament wound shells and other composite constructions using material form features peculiar to each construction. The present involute optimization technology is being applied to the Space Shuttle SRM nozzle boot ring redesigns by PDA Engineering.

Hart, J. K.↗
NASA NTRS1989

A high efficiency motor/generator for magnetically suspended flywheel energy storage system

The authors discuss the theory and design of a brushless direct current motor for use in a flywheel energy storage system. The motor design is optimized for a nominal 4.5-in outside diameter operating within a speed range of 33,000-66,000 revolutions per minute with a 140-V maximum supply voltage. The equations which govern the motor's operation are used to compute a series of acceptable design parameter combinations for ideal operation. Engineering tradeoffs are then performed to minimize the irrecoverable energy loss while remaining within the design constraint boundaries. A final integrated structural design whose features allow it to be incorporated with the 500-Wh magnetically suspended flywheel is presented.

Niemeyer, W. L.↗
NASA NTRS1994

Knowledge-based processing for aircraft flight control

This Contractor Report documents research in Intelligent Control using knowledge-based processing in a manner dual to methods found in the classic stochastic decision, estimation, and control discipline. Such knowledge-based control has also been called Declarative, and Hybid. Software architectures were sought, employing the parallelism inherent in modern object-oriented modeling and programming. The viewpoint adopted was that Intelligent Control employs a class of domain-specific software architectures having features common over a broad variety of implementations, such as management of aircraft flight, power distribution, etc. As much attention was paid to software engineering issues as to artificial intelligence and control issues. This research considered that particular processing methods from the stochastic and knowledge-based worlds are duals, that is, similar in a broad context. They provide architectural design concepts which serve as bridges between the disparate disciplines of decision, estimation, control, and artificial intelligence. This research was applied to the control of a subsonic transport aircraft in the airport terminal area.

Painter, John H.↗
NASA NTRS1995

Flow Distribution Around the SSME Main Injector Assembly Using Porosity Formulation

Hot gas turbulent flow distribution around the main injector assembly of the Space Shuttle Main Engine (SSME) and Liquid Oxidizer (LOX) flow distribution through the LOX posts have a great effect on the combustion phenomena inside the main combustion chamber. In order to design a CFD model to be an effective engineering analysis tool with good computational turn- around time (especially for 3-D flow problems) and still maintain good accuracy in describing the flow features, the concept of porosity was employed to describe the effects of blockage and drag force due to the presence of the LOX posts in the turbulent flow field around the main injector assembly of the SSME. 2-D numerical studies were conducted to identify the drag coefficients of the flows both through tube banks and around the shielded posts over a wide range of Reynolds numbers. Empirical, analytical expressions of the drag coefficient as a function of local flow Reynolds number were then deduced. The porosity model was applied to the turbulent flow around the main injector assembly of the SSME, and analyses were performed. The 3-D CFD analysis was divided into three parts, LOX dome, hot gas injector assembly, and hydrogen cavity. The numerical results indicate that the mixture ratio at the downstream of injector face was close to stoichiometric around baffle elements.

Cheng, Gary C.↗
NASA NTRS1990

Project LASER

NASA formally launched Project LASER (Learning About Science, Engineering and Research) in March 1990, a program designed to help teachers improve science and mathematics education and to provide 'hands on' experiences. It featured the first LASER Mobile Teacher Resource Center (MTRC), is designed to reach educators all over the nation. NASA hopes to operate several MTRCs with funds provided by private industry. The mobile unit is a 22-ton tractor-trailer stocked with NASA educational publications and outfitted with six work stations. Each work station, which can accommodate two teachers at a time, has a computer providing access to NASA Spacelink. Each also has video recorders and photocopy/photographic equipment for the teacher's use. MTRC is only one of the five major elements within LASER. The others are: a Space Technology Course, to promote integration of space science studies with traditional courses; the Volunteer Databank, in which NASA employees are encouraged to volunteer as tutors, instructors, etc; Mobile Discovery Laboratories that will carry simple laboratory equipment and computers to provide hands-on activities for students and demonstrations of classroom activities for teachers; and the Public Library Science Program which will present library based science and math programs.

Source record↗
NASA NTRS2006

NASA High Temperature Turbine Seal Rig Development

This viewgraph presentation describes a turbine seal rig concept to meet next generation engine speed and temperatures requirements. The contents include: 1) Turbomachinery Seal Development Objectives; 2) High Temperature Turbomachinery Seal Test Rig; 3) Test Parameters; 4) Highlights of Engineering Calculations; 5) Seal Rig Global Thermal Analysis; 6) Test Rig Status; 7) Seal Rig Schematic; 8) Test Chamber Enlarged View; and 9) Rig Features Unique Measurement Systems.

Steinetz, Bruce M.↗
NASA NTRS2005

Thermoelectric Air/Soil Energy-Harvesting Device

A proposed thermoelectric device would exploit natural temperature differences between air and soil to harvest small amounts of electric energy. Because the air/soil temperature difference fluctuates between nighttime and daytime, it is almost never zero, and so there is almost always some energy available for harvesting. Unlike photovoltaic cells, the proposed device could operate in the absence of sunlight. Unlike a Stirling engine, which could be designed to extract energy from the air/soil temperature difference, the proposed device would contain no moving parts. The main attractive feature of the proposed device would be high reliability. In a typical application, this device would be used for low-power charging of a battery that would, in turn, supply high power at brief, infrequent intervals for operating an instrumentation package containing sensors and communication circuits. The device (see figure) would include a heat exchanger buried in soil and connected to a heat pipe extending up to a short distance above the ground surface. A thermoelectric microgenerator (TEMG) would be mounted on top of the heat pipe. The TEMG could be of an advanced type, now under development, that could maintain high (relative to prior thermoelectric generators) power densities at small temperature differentials. A heat exchanger exposed to the air would be mounted on top of the TEMG. It would not matter whether the air was warmer than the soil or the soil warmer than the air: as long as there was a nonzero temperature difference, heat would flow through the device and electricity would be generated. A study of factors that could affect the design and operation of the device has been performed. These factors include the thermal conductances of the soil, the components of the device, the contacts between the components of the device, and the interfaces between the heat exchangers and their environments. The study included experiments that were performed on a model of the device to demonstrate feasibility. Because a TEMG suitable for this device was not available, a brass dummy component having a known thermal conductance of 1.68 W/K was substituted for the TEMG in the models to enable measurement of heat flows. The model included a water-based heat pipe 30 in. (76.2 cm) long and 1 in. (2.54 cm) in diameter, wrapped with polyethylene insulation to reduce radial heat flow. Several different side heat exchangers were tested. On the basis of the measurements, it was predicted that if a prototype of the device were equipped with a TEMG, daily temperature fluctuations would cause its output power to fluctuate between 0 and about 0.1 mW, peaking to 0.35 mW during early afternoon.

Snyder, Jeffrey↗
NASA NTRS2004

Improved Electrohydraulic Linear Actuators

A product line of improved electrohydraulic linear actuators has been developed. These actuators are designed especially for use in actuating valves in rocket-engine test facilities. They are also adaptable to many industrial uses, such as steam turbines, process control valves, dampers, motion control, etc. The advantageous features of the improved electrohydraulic linear actuators are best described with respect to shortcomings of prior electrohydraulic linear actuators that the improved ones are intended to supplant. The flow of hydraulic fluid to the two ports of the actuator cylinder is controlled by a servo valve that is controlled by a signal from a servo amplifier that, in turn, receives an analog position-command signal (a current having a value between 4 and 20 mA) from a supervisory control system of the facility. As the position command changes, the servo valve shifts, causing a greater flow of hydraulic fluid to one side of the cylinder and thereby causing the actuator piston to move to extend or retract a piston rod from the actuator body. A linear variable differential transformer (LVDT) directly linked to the piston provides a position-feedback signal, which is compared with the position-command signal in the servo amplifier. When the position-feedback and position-command signals match, the servo valve moves to its null position, in which it holds the actuator piston at a steady position.

Hamtil, James↗
NASA NTRS2013

Compendium of Directors Colloquia 1999-2012

The Director s colloquium series was established primarily to provide a mechanism to bring high profile individuals to the Center to present new and innovative ideas to the entire Ames staff. More focused lecture series are arranged by specific divisions or departments. Before the year 1999, there is only a fragmentary record of who spoke in this series. Announcements to the staff were sent via land mail, and tickets were required to attend the colloquium. In 1999, the notification to attend colloquia became electronic and the entire resident staff was invited to attend. The centerwide announcement archive established in this timeframe created a lasting record of the Director s colloquia. The "Office of the Chief Scientist" at Ames had the responsibility for administering the colloquium series. When I became Chief Scientist on June 29, 1998, the program was not being used extensively and this continued to be the case through the years 1999-2002 of Harry McDonald s tenure as Director (see graph below). During Scott Hubbard s tenure as Director (September 19, 2002- February 15, 2006), the Director's colloquium series was used exclusively for high profile speakers from outside Ames whom he selected, such as lab directors from other research organizations around the Bay Area. During Pete Worden s tenure as Ames Director (May 4, 2006 -present) the colloquium series gained far greater use. First, I had greater discretion to select speakers for the colloquium series. Secondly, beginning in 2007, we established a 10-week Director's Colloquium Summer Series focused on enriching the experience of our many summer interns, and giving our top researchers within Ames Research Center an opportunity to present their work to the Center. The summer program has received rave reviews. This compendium contains a compilation of one-page descriptions (title, abstract and speaker biographies) for all of the 171 colloquia presented from the beginning of 1999 to October of 2012. The list of speakers includes four Nobel Laureates, six astronauts, three current or former Ames Center Directors, as well as many CEOs and other lab directors. Other featured speakers include famous mountain climbers, historians, movie stars, and former FBI agents and directors. Finally, the list includes world-class scientists and engineers representing a wide range of disciplines. It has been my privilege to host almost all of the colloquia presented in this compendium.

Langhoff, Stephanie↗
NASA NTRS2013

A Tool for the Automated Design and Evaluation of Habitat Interior Layouts

The objective of space habitat design is to minimize mass and system size while providing adequate space for all necessary equipment and a functional layout that supports crew health and productivity. Unfortunately, development and evaluation of interior layouts is often ignored during conceptual design because of the subjectivity and long times required using current evaluation methods (e.g., human-in-the-loop mockup tests and in-depth CAD evaluations). Early, more objective assessment could prevent expensive design changes that may increase vehicle mass and compromise functionality. This paper describes a new interior design evaluation method to enable early, structured consideration of habitat interior layouts. This interior layout evaluation method features a comprehensive list of quantifiable habitat layout evaluation criteria, automatic methods to measure these criteria from a geometry model, and application of systems engineering tools and numerical methods to construct a multi-objective value function measuring the overall habitat layout performance. In addition to a detailed description of this method, a C++/OpenGL software tool which has been developed to implement this method is also discussed. This tool leverages geometry modeling coupled with collision detection techniques to identify favorable layouts subject to multiple constraints and objectives (e.g., minimize mass, maximize contiguous habitable volume, maximize task performance, and minimize crew safety risks). Finally, a few habitat layout evaluation examples are described to demonstrate the effectiveness of this method and tool to influence habitat design.

Simon, Matthew A.↗
NASA NTRS2016

Mission Analysis and Aircraft Sizing of a Hybrid-Electric Regional Aircraft

The purpose of this study was to explore advanced airframe and propulsion technologies for a small regional transport aircraft concept (approximately 50 passengers), with the goal of creating a conceptual design that delivers significant cost and performance advantages over current aircraft in that class. In turn, this could encourage airlines to open up new markets, reestablish service at smaller airports, and increase mobility and connectivity for all passengers. To meet these study goals, hybrid-electric propulsion was analyzed as the primary enabling technology. The advanced regional aircraft is analyzed with four levels of electrification, 0 percent electric with 100 percent conventional, 25 percent electric with 75 percent conventional, 50 percent electric with 50 percent conventional, and 75 percent electric with 25 percent conventional for comparison purposes. Engine models were developed to represent projected future turboprop engine performance with advanced technology and estimates of the engine weights and flowpath dimensions were developed. A low-order multi-disciplinary optimization (MDO) environment was created that could capture the unique features of parallel hybrid-electric aircraft. It is determined that at the size and range of the advanced turboprop: The battery specific energy must be 750 watt-hours per kilogram or greater for the total energy to be less than for a conventional aircraft. A hybrid vehicle would likely not be economically feasible with a battery specific energy of 500 or 750 watt-hours per kilogram based on the higher gross weight, operating empty weight, and energy costs compared to a conventional turboprop. The battery specific energy would need to reach 1000 watt-hours per kilogram by 2030 to make the electrification of its propulsion an economically feasible option. A shorter range and/or an altered propulsion-airframe integration could provide more favorable results.

Antcliff, Kevin R.↗
NASA NTRS2018

Coupling Fractional Thermal Runaway Calorimetry (FTRC) Results with Statistical Analysis Methods

Important factors to consider when optimizing Lithium-ion (Li-ion) battery thermal management systems, from a battery safety perspective, include the total energy released during a single cell thermal runaway (TR) event and the fraction of the total energy that is released through the cell casing versus through the ejecta material. A fractional thermal runaway calorimeter (FTRC) was used to examine the TR behavior of the following 18650-format Li-ion cells: (1) Molicel 18650-J, (2) LG 18650-HG2, (3) Samsung 18650-30Q, (4) 3.35 Ah LG 18650 test cell, (5) Sony 18650-VC7, and (6) LG 18650-MJ1. These cells were intentionally selected to represent a variety of manufacturers, chemistries, capacities, and safety features. Because of the large number of random and non-random variables associated with the FTRC results, a linear regression model, developed using engineering statistical methods, was utilized to provide final interpretation of the TR behavior for each cell type and design variable combination.

Walker, William↗