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NASA NTRS1974

Turbulent measurements in supersonic boundary layer flows using laser velocimetry

Laser velocimetry has been applied successfully in the measurement of mean velocities and Reynolds stresses in a zero pressure gradient, Mach 2.9 boundary layer, and upstream and downstream of a two-dimensional, shock-wave boundary layer interaction for the same Mach number. The Reynolds stresses were obtained using a one-component, dual-scatter laser velocimeter operated in a manner analogous to the 'slanted hot-wire' technique. Signal processing was of the single-particle counting type which permitted measurements to be made using only the naturally occurring particles in the tunnel air stream for light scattering. The results for the shock-wave boundary layer interaction are presented along with hot-wire anemometer and pitot-static pressure measurements obtained in the same flow. Also, a data acquisition scheme for use with a two-component laser velocimeter is presented which should provide even better accuracies in future studies.

Johnson, D. A.↗

NASA NTRSDate not supplied

Al6061-RAM2 Development and Hot-Fire Testing using Additive Manufacturing Laser Powder Directed Energy Deposition for Liquid Rocket Engine Channel-Cooled Nozzles

Aluminum 6061-RAM2 is a high-strength aluminum feedstock developed for additive manufacturing (AM)processes. This alloy leverages Reactive Additive Manufacturing (RAM) technology. The RAM aluminum alloys were developed to be weldable—therefore printable—while equaling or exceeding strength properties of high strength wrought aluminum alloys. NASA and industry partners developed Laser Powder Directed Energy Deposition (LP-DED)additive manufacturing of Al6061-RAM2 for use in aerospace applications. Efforts included establishing build parameters, characterizing the alloy, fabricating components, and completing hot-fire testing of complex internal channel-cooled nozzles. These efforts are to address the growing need for large-scale parts using high-performance light-weight materials. Two rocket engine nozzles were fabricated using LP-DED Al6061-RAM2 that included integral cooling channels. The Al6061-RAM2 has completed process development and initial properties were established. This paper provides an overview of the LP-DED process development, material characterization and properties, component manufacturing, supplemental development, and hot-fire testing. Results from hot-fire testing are provided for a lander-class 31kN (7,000lbf)thrust engine using Liquid Oxygen (LOX)/Liquid Hydrogen(LH2) and LOX/Methane(LCH4).

Al6061-RAM2↗

NASA NTRSDate not supplied

Al6061-RAM2 Development and Hot-Fire Testing using Additive Manufacturing Laser Powder Directed Energy Deposition for Liquid Rocket Engine Channel-Cooled Nozzles

Al6061-RAM2↗

NASA NTRSDate not supplied

Al6061-RAM2 Development and Hot-Fire Testing using Additive Manufacturing Laser Powder Directed Energy Deposition for Liquid Rocket Engine Channel-Cooled Nozzles

Aluminum 6061-RAM2 is a high-strength aluminum feedstock developed for additive manufacturing (AM)processes. This alloy leverages Reactive Additive Manufacturing (RAM) technology. The RAM aluminum alloys were developed to be weldable—therefore printable—while equaling or exceeding strength properties of high strength wrought aluminum alloys. NASA and industry partners developed Laser Powder Directed Energy Deposition (LP-DED)additive manufacturing of Al6061-RAM2 for use in aerospace applications. Efforts included establishing build parameters, characterizing the alloy, fabricating components, and completing hot-fire testing of complex internal channel-cooled nozzles. These efforts are to address the growing need for large-scale parts using high-performance light-weight materials. Two rocket engine nozzles were fabricated using LP-DED Al6061-RAM2 that included integral cooling channels. The Al6061-RAM2 has completed process development and initial properties were established. This paper provides an overview of the LP-DED process development, material characterization and properties, component manufacturing, supplemental development, and hot-fire testing. Results from hot-fire testing are provided for a lander-class 31kN (7,000lbf) thrust engine using Liquid Oxygen (LOX)/Liquid Hydrogen (LH2) and LOX/Methane (LCH4).

Al6061-RAM2↗

NASA NTRS1989

Growth and patterning of laser ablated superconducting YBa2Cu3O7 films on LaAlO3 substrates

A high quality superconducting film on a substrate with a low dielectric constant is desired for passive microwave circuit applications. In addition, it is essential that the patterning process does not effect the superconducting properties of the thin films to achieve the highest circuit operating temperatures. YBa2Cu3O7 superconducting films were grown on lanthanum aluminate substrates using laser ablation with resulting maximum transition temperature (T sub c) of 90 K. The films were grown on a LaAlO3 which was at 775 C and in 170 mtorr of oxygen and slowly cooled to room temperature in 1 atm of oxygen. These films were then processed using photolithography and a negative photoresist with an etch solution of bromine and ethanol. Results are presented on the effect of the processing on T(sub c) of the film and the microwave properties of the patterned films.

Warner, J. D.↗

NASA NTRS1977

Review of experimental work on transonic flow in turbomachinery

The review is primarily concerned with modern experimental techniques of high response and laser supported instrumentation. The considered techniques make it possible to obtain detailed data of steady and unsteady processes occurring inside transonic blade rows and in the vicinity of the rows. Such data are needed for the verification of computer codes used for the study of the operational characteristics of turbomachinery. Attention is given to high response transducers, hot wire probes, hot film gages, laser Doppler velocimeter systems, laser fluorescence, and laser holography.

Mcnally, W. D.↗

NASA NTRS1992

Velocity measurement in rocket exhaust and general aerodynamic flows by photolysis of H2O and laser induced fluorescence of OH

A 'tagging' approach in which the photolysis of H2O by an excimer laser creates a zone of enhanced OH concentration, while a second, pulsed-UV laser detects tagged-zone convection via time-delayed excitation of OH fluorescence, depends on the photodissociation process and the kinetics of OH decay (relative to velocity). For application to the fuel-rich, high supersonic Mach number exhaust flow of the SSME, the detection of OH is being accomplished with either a pulsed narrowband UV dye laser or a tunable XeCl excimer laser for excitation of an OH 0-0 band transition, while the two-photon photolysis of H2O is conducted by focusing an injection-locked KrF excimer laser into the flow.

Boedeker, Laurence R.↗

NASA NTRS2018

Channel Wall Nozzle Manufacturing and Hot-Fire Testing using a Laser Wire Deposition Closeout Technique for Liquid Rocket Engines

A regeneratively-cooled nozzle for liquid rocket engine applications is a significant cost of the overall engine due to the complexities of manufacturing a large thin-walled structure that must operate in extreme temperature and pressure environments. NASA has been investigating and advancing methods for fabrication of liquid rocket engine channel wall nozzles to realize further cost and schedule improvements. The methods being evaluated are targeting increased scale required for current NASA and commercial space programs. Several advanced rapid fabrication methods are being investigated for forming of the inner liner, producing the coolant channels, closeout of the coolant channels, and fabrication of the manifolds. NASA Marshall Space Flight Center (MSFC) completed process development and subscale hot-fire testing of a series of these advanced fabrication channel wall nozzle technologies to gather performance data in a relevant environment. The primary fabrication technique being discussed in this paper is Laser Wire Deposition Closeout (LWDC). This process has been developed to significantly reduce time required for closeouts of regeneratively-cooled slotted liners. It allows for channel closeout to be formed in place in addition to the structural jacket without the need for channel fillers or complex tooling. Additional technologies were also tested as part of this program including water jet milling and arc-based additive manufacturing deposition. Each nozzle included different fabrication features, materials, and methods to demonstrate durability in a hot-fire environment. The results of design, fabrication and hot-fire testing performance is discussed in this paper.

Gradl, Paul R.↗

NASA NTRS1998

Stable Isotope Laser Spectrometer for Exploration of Mars

On Earth, measurements of the ratios of stable carbon isotopes have providet much information about geological and biological processes. For example, fractionation of carbon occur in biotic processes and the retention of a distinctive 2-4% contrast in C-13/C-12 between organic carbon and carbonates in rocks as old as 3.8 billion years constitutes some of the firmest evidence for the antiquity of life on the Earth. We have developed a prototype tunable diode laser spectrometer which demonstrates the feasibility of making accurate in situ isotopic ratio measurements on Mars. This miniaturized instrument, with an optical path length of 10 cm should be capable of making accurate C-13/C-12 and N-15/N-14 measurements. Gas samples for measurement are to be produced by pyrolysis using soil samples as small as 50 mg. Measurements of C-13/C-12, O-18/O-16 and N-15/N-14 have been made to a precision of better than 0.1%, and various other isotopes are feasible. This laser technique, which relies on the extremely narrow emission linewidth of tunable diode lasers (less than 0.001/ cm),has favorable features in comparison to mass spectrometry, the standard method of accurate isotopic ratio measurement. The miniature instrument could be ready to deploy c 2003 or other Mars lander missions.

Sauke, Todd B.↗

NASA NTRS1992

Doppler global velocimetry - The next generation?

A new measurement technique is being developed by NASA to measure off-surface flow fields. This method, Doppler global velocimetry, will allow quantification of complex three-dimensional flow fields at video camera rates. The entire flow field structure within a selected plane is measured simultaneously rather than by scanned, point-by-point measurements using conventional laser velocimetry. To assess the capability of this new technique, velocity measurements of the vortical flow field above a thin 75-degree delta wing were made in the NASA Langley Basic Aerodynamics Research Tunnel. The operation of the system is described along with the techniques developed to process the output images. The results are then compared with similar measurements obtained using a three component laser velocimeter.

Meyers, James F.↗

NASA NTRS1991

Doppler Global Velocimetry: The Next Generation?

Meyers, James F.↗

NASA NTRS2004

A Novel Biomedical Device Utilizing Light Emitting Nano-Structures

This paper will discuss the development of a novel biomedical detection device that will be used to detect microorganisms with the use of infrared fluorochrome polymers attached to antibodies in fluids such as water. The fluorochrome polymers emit light in the near inferred region (NIR), approximately 805 nm, when excited by an NIR laser at 778 nm. The device could remarkably change the way laboratory testing is done today. The testing process is usually performed on a time scale of days while our device will be able to detect microorganisms in minutes. This type of time efficient analysis is ideal for use aboard the International Space Station and the Space Shuttle (ISS/SS) and has many useful commercial applications, for instance at a water treatment plant and food processing plants. With more research and experimentation the testing might also one day be used to detect bacteria and viruses in complex fluids such as blood, which would revolutionize blood analysis as it is performed today. My contribution to the project has been to develop a process which will allow an antibody/fluorescent dye pair to be conjugated to a specific bacteria or virus and than to to be separated from a sample body of water for detection. The antibody being used in this experiment is anti beta galactosidase and its complement enzyme is beta galactosidase, a non harmful derivative of E. Coli. The anti beta galactosidase has been conjugated to the fluorochrome polymer, IRDye800, which emits at approximately 806 nm. The dye when excited by the NIR laser emits a signal which is detected by a spectrometer and then is read by state of the art computer software. The state-of-the-art process includes incubating the anti beta galactosidase and beta galactosidase in a phosphate buffer solution in a test tube, allowing the antibody to bind to specific sites on the enzyme. After the antibody is bound to the enzyme, it is centrifuged in specific filters that will allow free antibody to wash away and leave the antibody-enzyme complexes on top in solution for testing and analysis. This solution is pipetted into a cuvette, a special plastic test tube, which will then be excited by the laser. The signal read will tell US that an antibody is present and since it is bound to the enzyme, that the bacteria is also present.

Varaljay, Vanessa A.↗

NASA NTRS2016

Evaluation of the Effect of Surface Finish on High-Cycle Fatigue of SLM-IN718

The surface finish of parts produced by additive manufacturing processes is much rougher than the surface finish generated by machining processes, and a rougher surface can reduce the fatigue strength of a part. This paper discusses an effort to quantify that reduction of strength in high-cycle fatigue for selective laser melt (SLM) coupons. A high-cycle fatigue (HCF) knockdown factor was estimated for Inconel 718, manufactured with the SLM process. This factor is the percentage reduction from the maximum stress in fatigue for low-stress ground (LSG) specimens to the maximum stress of those left with the original surface condition at the same fatigue life. Specimens were provided by a number of vendors, free to use their "best practice"; only one heat treat condition was considered; and several test temperatures were characterized, including room temperature, 800F, 1000F, and 1200F. The 1000F data had a large variance, and was omitted from consideration in this document. A first method used linear approximations extracted from the graphs, and only where data was available for both. A recommended knockdown factor of the as-built surface condition (average roughness of approximately 245 micro-inches/inch) versus low-stress ground condition (roughness no more than 4 micro-inches/inch) was established at approximately 1/3 or 33%. This is to say that for the as-built surface condition, a maximum stress of 2/3 of the stress for LSG can be expected to produce a similar life in the as-built surface condition. In this first evaluation, the knockdown factor did not appear to be a function of temperature. A second approach, the "KP method", incorporated the surface finish measure into a new parameter termed the pseudo-stress intensity factor, Kp, which was formulated to be similar to the fracture mechanics stress intensity factor. Using Kp, the variance seemed to be reduced across all sources, and knockdown factors were estimated using Kp over the range where data occurred. A plot of the results suggests that the knockdown factor is a function of temperature, and that for low lives the knockdown might be lower than the knockdown observed above about one million cycles, where it tended to stabilize. This was not universal for all temperatures tested. The higher temperature tests are thought to be influenced by the test temperature, which perhaps continued the aging process. Further evaluation of the method is suggested.

Lambert, D. M.↗

NASA NTRS1996

Flame Characterization Using a Tunable Solid-State Laser with Direct UV Pumping

Tunable solid-state lasers with direct UV pumping, based on d-f transitions of rare earth ions incorporated in wide band-gap dielectric crystals, are reliable sources of laser radiation that are suitable for excitation of combustion-related free radicals. We have employed such a laser for analytical flame characterization utilizing Laser-Induced Fluorescence (LIF) techniques. LIF spectra of alkane-air flames (used for studying combustion processes under normal and microgravity conditions) excited in the region of the A-X (0,0) OH-absorption band have been recorded and found to be both temperature-sensitive and positionally-sensitive. In addition, also clearly noticeable was the sensitivity of the spectra to the specific wavelength used for data registration. The LiCAF:Ce laser shows good prospects for being able to cover the spectral region between 280 and 340 nm and therefore be used excitation of combustion-intermediates such as the hydroxyl OH, methoxy CH30 and methylthio CH3S radicals.

Kamal, Mohammed M.↗

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

Channel Wall Nozzle Manufacturing and Hot-Fire Testing Using a Laser Wire Direct Closeout Technique for Liquid Rocket Engines

A regeneratively-cooled nozzle for liquid rocket engine applications is a significant cost of the overall engine due to the complexities of manufacturing a large thin-walled structure that must operate in extreme temperature and pressure environments. The National Aeronautics and Space Administration (NASA) has been investigating and advancing methods for fabrication of liquid rocket engine channel wall nozzles to realize further cost and schedule improvements over traditional techniques. The methods being evaluated are targeting increased scale required for current NASA and commercial space programs. Several advanced rapid fabrication methods are being investigated for forming of the inner liner, producing the coolant channels, closeout of the coolant channels, and fabrication of the manifolds. NASA's Marshall Space Flight Center (MSFC) has completed process development and subscale hot-fire testing of a series of these advanced fabrication channel wall nozzle technologies to gather performance data in a relevant environment. The primary fabrication technique being discussed in this paper is Laser Wire Direct Closeout (LWDC). This process has been developed to significantly reduce the time required for closeouts of regeneratively-cooled slotted liners. It allows for channel closeout to be formed in place in addition to the structural jacket without the need for channel fillers or complex tooling. Additional technologies were also tested as part of this program including water jet milling and arc-based additive manufacturing deposition. Each nozzle included different fabrication features, materials, and methods to demonstrate durability in a hot-fire environment. The results of design, fabrication, and hot-fire testing are discussed in this paper.

Gradl, Paul R.↗

NASA NTRS1985

Process research of non-Cz material

Efforts were aimed at achieving a simultaneous front and back junction. Lasers and other heat sources were tried. Successful results were gained by two different methods: laser and flash lamp. Polymer dopants were applied to both sides of dendritic web cells. Rapid heating and cooling avoided any cross contamination between two junctions after removal of the dendrites. Both methods required subsequent thermal annealing in an oven to produce maximum efficiency cells.

Campbell, R. B.↗

NASA NTRS1990

Laser annealing of amorphous/poly: Silicon solar cell material flight experiment

The preliminary design proposed for the microelectronics materials processing equipment is presented. An overall mission profile, description of all processing steps, analysis methods and measurement techniques, data acquisition and storage, and a preview of the experimental hardware are included. The goal of the project is to investigate the viability of material processing of semiconductor microelectronics materials in a micro-gravity environment. The two key processes are examined: (1) Rapid Thermal Annealing (RTA) of semiconductor thin films and damaged solar cells, and (2) thin film deposition using a filament evaporator. The RTA process will be used to obtain higher quality crystalline properties from amorphous/poly-silicon films. RTA methods can also be used to repair radiation-damaged solar cells. On earth this technique is commonly used to anneal semiconductor films after ion-implantation. The damage to the crystal lattice is similar to the defects found in solar cells which have been exposed to high-energy particle bombardment.

Cole, Eric E.↗