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All sourcesNASA NTRSDOE OSTI
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 NTRSDate not supplied

Advanced Materials Development under NASA’s Hybrid Thermally Efficient Core (HyTEC) Project

The Hybrid Thermally Efficient Core (HyTEC) project aims to develop small core turbofan engine technologies that will enable fuel burn reductions, additional use of electric airplane systems through power extraction, and to advance engine operability and compatibility with sustainable aviation fuels. As such, a portfolio of technologies that contribute to raising the pressure, temperature and efficiency of turbofan engine cores needs developed. Included in HyTEC’s technology portfolio to enable these advancements are enhanced combustor liner materials and higher temperature capable turbine blades and vanes manufactured using ceramic matrix composites (CMCs) and environmental barrier coatings (EBCs). These technologies are being developed and tested in laboratory-scale relevant environments to advance the technology readiness level (TRL) to 4 or 5, before moving into an engine core demonstrator to raise the TRL to 6. A new natural gas/oxygen burner rig facility will be used to simulate turbine engine relevant environments at the laboratory/coupon scale. In addition, improvements to enable sub-element, and more complex component testing in NASA Glenn’s combustor facility (CE-5) will be presented.

Ceramic Matrix Composites (CMCs)↗
NASA NTRSDate not supplied

Maturation of Additive Manufactured Aerospace Alloys and Development of Mechanical and Thermophysical Properties for Space 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 have focused on the understanding of AM processes through design optimization, component fabrication, material characterization, testing, standards development, and infusion into propulsion development for flight applications. NASA and partners have matured commonly used aerospace alloys from various alloy families (Nickel, Steel, Iron, Aluminum, and Titanium) and AM processes. An extensive effort has been ongoing between NASA, industry partners, and academia to complete detailed AM process and heat treatment characterization, in addition to generating temperature-dependent mechanical and thermophysical properties. This presentation highlights the characterization and property results using laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes among various alloys. In addition to commonly used alloys, 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 launch vehicles, liquid rocket engines, advanced propulsion systems, advanced power systems, and in-space propulsion with high heat fluxes, high pressure, and that utilize propellants such as hydrogen, which can degrade alloys. This presentation will also discuss 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, and C-103. The results from these processes have demonstrated that AM can enable rapid development and new AM optimized alloys can yield higher performance. These alloys have undergone modeling, fundamental metallurgical evaluations, heat treatment studies, and microstructure characterization and mechanical testing campaigns. This, combined with direct application-specific component fabrication and hot-fire testing, can enable the increase of the Technology Readiness Level (TRL) through high duty-cycle testing. This presentation provides a background and overview of these various common and AM-enabled alloys and processing developments including the initial effort related to metallurgical, mechanical, and thermophysical property studies. It also covers the latest advancement in the parallel component development, hot-fire testing, and future developments for these alloys.

Additive Manufacturing↗
NASA NTRSDate not supplied

Hybrid-Electric Aero-Propulsion Controls Testbed Results

NASA is supporting the development of Electrified Aircraft Propulsion (EAP) technology due to its potential to reduce aircraft fuel burn, emissions, and noise as well as improving safety and performance. One focus of this research is the electrification of conventional turbomachinery propulsion systems, which offers ways to improve the performance and operability of turbine-engine powered aircraft through the addition of electro-mechanical systems. These hybrid-electric turbine engines provide additional actuation and energy management control opportunities for improving stability and transient response behavior. This paper summarizes the results of a Hardware-in-the-Loop (HIL) test performed at the NASA Electric Aircraft Testbed (NEAT) during the summer of 2022. The test demonstrates the feasibility and performance of an advanced energy management control strategy by integrating a simulated turbofan engine with scaled electro-mechanical hardware. A full-scale real-time reference model of a geared turbofan was run alongside a scaled electro-mechanical system representing the electrified turbofan components operating at a megawatt-scale power level. The model was interfaced with the hardware through a novel closed-loop control and scaling algorithm that emulated the dynamic speed and torque response of the turbofan shafts. The control strategy was implemented on the electrical machines connected to the emulated turbomachinery shafts. The results from the testbed are compared against simulations that predict the testbed and geared turbofan model operation. The energy management control strategy successfully changed the operating point of the engine model and improved its stability during throttle transients. These results also demonstrate the success of the novel closed loop control and scaling approach for emulating turbomachinery and elevate the Technology Readiness Level (TRL) of the energy management control strategy.

Aeronautics↗
NASA NTRSDate not supplied

ENABLING ARCHITECTURE TRADES AND DESIGN EXPLORATION FOR NUCLEAR ELECTRIC PROPULSION

Recent renewed interest in Nuclear Electric Propulsion (NEP) at NASA has driven the need for design space exploration and analysis of alternative architectures to evaluate performance and feasibility of NEP concepts. It has been over a decade since NASA last invested in Nuclear Electric Propulsion development efforts, and the landscape has shifted in both mission objectives and technology readiness levels. This also means that many of the engineering analyses and design frameworks tailored to NEP date back to the Jupiter Icy Moons Orbiter (JIMO) days of the early 2000s. Thus, a need was identified for updating and modernizing the modeling and simulation toolsets for NEP. This paper will detail the development efforts in the Marshall Space Flight Center’s Advanced Concepts Office, with a particular focus on the development of the NEP stage of the NEP-Chem vehicle. The paper will cover the various models used, and their current development status, as well as provide an overview of the integrated vehicle model and plans for further development.

Nuclear↗
NASA NTRSDate not supplied

Enabling Architecture Trades and Design Exploration for Nuclear Electric Propulsion

Recent renewed interest in Nuclear Electric Propulsion (NEP) at NASA has driven the need for design space exploration and analysis of alternative architectures to evaluate performance and feasibility of NEP concepts. It has been over a decade since NASA last invested in Nuclear Electric Propulsion development efforts, and the landscape has shifted in both mission objectives and technology readiness levels. This also means that many of the engineering analyses and design frameworks tailored to NEP date back to the Jupiter Icy Moons Orbiter (JIMO) days of the early 2000s. Thus, a need was identified for updating and modernizing the modeling and simulation toolsets for NEP. This paper will detail the development efforts in the Marshall Space Flight Center’s Advanced Concepts Office, with a particular focus on the development of the NEP stage of the NEP-Chem vehicle. The paper will cover the various models used, and their current development status, as well as provide an overview of the integrated vehicle model and plans for further development.

Nuclear↗
NASA NTRSDate not supplied

Current State of NASA Continuously Rotating Detonation Cycle Engine Development

NASA is currently investigating continuous detonation cycle engines for the application of lander and interplanetary space exploration missions. The performance benefits of a detonation cycle engine may allow for a broader design trade space and more compact geometry required for future missions to the Moon and onwards towards Mars. However, the technology readiness level (TRL) within the US was found to be low with several major risk factors that require understanding prior to full engine system development. One area of uncertainty is the extreme heat loads expected during thermal steady state conditions. To achieve this, an announcement for collaborative opportunity (ACO) partnership between IN Space LLC and NASA Marshall Space Flight Center (MSFC) was established to explore integration of additive manufacturing (AM) processes and the high conductance copper-based alloys, GRCop-42 and GRCop-84. This work outlines the hot fire testing of a 7K lbf thrust class fully AM GRCop-alloy rotating detonation rocket engine (RDRE). Two annular thrust chamber configurations emulating a lander engine system were tested with LOx/GH2 and LOx/LCH4. In both configurations, select hardware was actively cooled using de-ionized water and regeneratively cooled using LCH4. All primary hardware survived long duration tests to thermal steady state up to 133 seconds in a single burn. In total, 18 starts and 802 seconds of duration were achieved with and without visual confirmation of waves present. The proportion of burned propellant, or level of complete combustion, was found to be high compared to the theoretically achievable mean chamber pressure in all cases.

Thomas Teasley↗
NASA NTRSDate not supplied

Independent Reliability Assessment of the Laser Transmitter for the ESA-NASA Laser Interferometer Space Antenna (LISA) Program

As part of the laser development process, NASA’s Goddard Space Flight Center (GSFC) requested support from the NASA Engineering and Safety Center (NESC) to independently assess the Technology Readiness Level (TRL) of the LISA Laser System (LS). The independent assessment included the following tasks: (a) assess the design for weaknesses and suggest improvements to mitigate risks, (b) assess the laser reliability plan for weaknesses and suggest improvements to mitigate risks and improve effectiveness, and (c) assess the current redundancy plan on laser subsystems for weaknesses and suggest improvements to mitigate risks and improve effectiveness. The presentation will focus on the assessment findings and the current development progress of the LISA laser to meet the mission requirements with a delivery of a form, fit, and functional TRL6 laser to the LISA mission by late 2023.

Laser Interferometry↗
NASA NTRSDate not supplied

Development of Stirling Convertors for Radioisotope and Fission Power Systems

NASA has been developing free-piston Stirling-cycle power convertors over the past 22 years for use in nuclear power systems that would provide electricity for space science missions to dark, dusty, or distant destinations where solar power is not practical. These nuclear power systems would generate heat from either the radioactive decay of isotopes or fission nuclear reactors. That heat would be converted to usable electricity using highly efficient Stirling convertors for a wide range of power needs needing 10s of watts to 50 kWe. NASA’s Radioisotope Power Systems (RPS) Program is maturing advanced thermoelectric and dynamic conversion technologies that would increase the system efficiency beyond what is currently possible using heritage systems to enable a larger number of robotic missions or higher power missions to solar system bodies of interest. The Dynamic Radioisotope Power Systems (DRPS) Project has matured prototype Stirling convertors to sufficiently increase the technology readiness level for infusion into flight development. Flexure and gas-bearing free-piston Stirling convertors were developed under contract by commercial partners and delivered to enable government evaluation. Gas-bearing designs have met performance and robustness requirements and were selected for flight development. This paper provides the status of SRSC test campaign and maturity level.

Dynamic↗
NASA NTRSDate not supplied

The P-Band Space Exploration Synthetic Aperture Radar (SESAR)

The Space Exploration Synthetic Aperture Radar (SESAR) is a P-band (435 MHz) radar instrument for planetary applications capable of measuring the surface and subsurface of planetary bodies at full polarimetry and at meter-scale resolution. These measurements can reveal important information about the surface evolution and geologic history of the planetary bodies, and help identify buried resources for future explorers. SESAR’s architecture is based on a low power, lightweight, beamforming design, specifically developed to meet stringent requirements of planetary instruments. The SESAR developmental effort, carried out at NASA/GSFC, designed and built a prototype SAR instrument, and environmentally tested it, with the goal of maturing the SESAR technology readiness level for upcoming planetary mission opportunities.

Rafael F Rincon↗
NASA NTRSDate not supplied

Simulated Ice Shapes on the High Lift Common Research Model Using LEWICE3D

Computational icing tools consist of predicting two distinct problems, the dry air aerodynamics around the iced or uniced vehicle and the accretion of ice due to inclement weather. A desire exists to advance these tools such that they can be reliably used earlier in the design process to limit the need for more costly flight and wind tunnel testing. To achieve these goals the computational tools need to be benchmarked and validated against high quality experimental data sets to raise the software’s Technology Readiness Level. An ongoing collaborative effort between NASA and Boeing Commercial Airplanes is focused on obtaining this required experimental data and subsequently benchmarking and/or validating the tools that predict the aerodynamics around the iced and uniced vehicle. Currently the scope of this effort is focused on the usage of simulated ice shapes to be representative of the iced vehicle. This presentation discusses the generation of those simulated ice shapes.

Icing↗
NASA NTRSDate not supplied

Vertical Lunar Regolith Conveying as A Flight Experiment in Simulated Lunar-Gravity

Regolith conveying will be an essential task for supplying regolith feedstock to In-Situ Resource Utilization (ISRU) reactor systems for regolith processing on the Moon and Mars. The Vertical Lunar Regolith Conveyor (VLRC) is a technology being developed at NASA Kennedy Space Center (KSC) as a regolith transport task for the GCD ISRU FLEET project led by NASA Glenn Research Center (GRC). Single test loop versions of the VLRC are being developed at NASA KSC as a technology demonstration for a flight experiment. The NASA Flight Opportunities program selected the VLRC for a technology demonstration opportunity on a future Blue Origin New Shepard suborbital launch vehicle to study regolith transport physics in a relevant environment in a vacuum chamber under simulated lunar gravity conditions in order to advance its technology readiness level (TRL) for future space applications. This presentation will discuss the objectives and current status of the VLRC lunar-gravity flight experiment, including the types of granular mineral materials that will be conveyed.

regolith↗
NASA NTRSDate not supplied

Development of the Advanced Regolith Ground Operations (ARGO) Test Bed – A Robotic Excavation and Construction Test Facility with Simulated Lunar Environments

NASA’s Artemis Program is working towards developing a sustained presence on the Moon and eventually Mars. To achieve this goal, robotic excavation, site preparation and construction technologies are under development to establish the capability to construct infrastructure such as launch/landing pads and radiation protection shelters. Technologies must be proven in simulated Lunar conditions prior to surface demonstration missions. To that end, the Relevant Additive Construction Technology (REACT) Announcement of Collaboration Opportunities (ACO) project with AI Space Factory and the NASA Kennedy Space Center’s (KSC) Granular Mechanics and Regolith Operations Laboratory (a.k.a. Swamp Works) has developed the Advanced Regolith Ground Operations (ARGO) Test Bed. ARGO includes a ~1.5m x 1.5m x 1.2m (~5x5x4ft) vacuum chamber, cryogenically cooled thermal shroud, 3-axis robotic positioning system, and regolith bin. For the REACT project, a pellet extruder, feed hopper, and heated 600mm x 600mm (23.6x23.6in) build plate have been installed on ARGO to advance the Technology Readiness Level (TRL) of regolith-polymer composite Fused Deposition Modeling (FDM) additive construction systems, processes, and materials. This paper will focus on the design and operational characteristics of the ARGO Test Bed with pellet extruder.

regolith↗
NASA NTRS2023

Development of Stirling Convertors for Radioisotope and Fission Power Systems

NASA has been developing free-piston Stirling-cycle power convertors over the past 22 years for use in nuclear power systems that would provide electricity for space science missions to dark, dusty, or distant destinations where solar power is not practical. These nuclear power systems would generate heat from either the radioactive decay of isotopes or fission nuclear reactors. That heat would be converted to usable electricity using highly efficient Stirling convertors for a wide range of power needs needing 10s of watts to 50 kWe. NASA’s Radioisotope Power Systems (RPS) Program is maturing advanced thermoelectric and dynamic conversion technologies that would increase the system efficiency beyond what is currently possible using heritage systems to enable a larger number of robotic missions or higher power missions to solar system bodies of interest. The Dynamic Radioisotope Power Systems (DRPS) Project has matured prototype Stirling convertors to sufficiently increase the technology readiness level for infusion into flight development. Flexure and gas-bearing free-piston Stirling convertors were developed under contract by commercial partners and delivered to enable government evaluation. Gas-bearing designs have met performance and robustness requirements and were selected for flight development. This paper provides the status of SRSC test campaign and maturity level.

Dynamic↗
NASA NTRSDate not supplied

Parametric Analysis of Entry Vehicles for Giant Planet Missions

The Planetary Science Decadal Survey has identified Uranus and Saturn as high priori-ty destinations for a flagship and New Frontier missions respectively in the decade 2023-2032. The pro-posed presentation will focus on the entry and descent aspects of the entry vehicles design, considered as part of Giant Planet probe mission concepts, and associated trades for viable trajectory options. Giant Planet Entry Vehicle Parametric Study: Launch vehicle capabilities are evolving and provide an opportunity to increase instrumented probe dimensions. To assess the impact of larger aeroshell designs, a parametric study was conducted to understand the impact on aerothermal environments, TPS options, and TPS mass over a range of 1.0m to 2.0m aeroshell diameters for Uranus and Saturn probe concept missions. The 45° sphere-cone geometry is a legacy configuration that has demonstrated static stability and been used successfully in missions to Venus (Pioneer-Venus) and Jupiter (Galileo). A nose radius of 0.4 m was considered primarily to reduce the heat flux at the stagnation point compared to the smaller radii used in the Venus and Jupiter missions. Representative inertial velocities are chosen from a prior NASA Ames study. Viable entry trajectories to meet concept mission and science objectives were developed using the tool POST2. The newly developed thermal protection material called HEEET (Heatshield for Extreme Entry Environment Technology) was considered in the study. This material, which is at a technology readiness level (TRL) of 6, is highly customizable and available in two varieties: (i) a dual-layer version consisting of recession layer on top of an insulative layer, and (ii) a single-layer version consisting of the insulative layer alone, termed 3- dimensional Mid-Density Carbon Phenolic (3MDCP). Both options were considered for the forward heatshield (the sphere-cone part) in the pre-sent study.

Thermal Protection System↗
NASA NTRSDate not supplied

Development of the Advanced Regolith Ground Operations (ARGO) Test Bed: A Robotic Excavation and Construction Test Facility with Simulated Lunar Environments

NASA’s Artemis Program is working towards developing a sustained presence on the Moon and eventually Mars. To achieve this goal, robotic excavation, site preparation and construction technologies are under development to establish the capability to construct infrastructure such as launch/landing pads and radiation protection shelters. Technologies must be proven in simulated Lunar conditions prior to surface demonstration missions. To that end, the Relevant Additive Construction Technology (REACT) Announcement of Collaboration Opportunities (ACO) project with AI Space Factory and the NASA Kennedy Space Center’s (KSC) Granular Mechanics and Regolith Operations Laboratory (a.k.a. Swamp Works) has developed the Advanced Regolith Ground Operations (ARGO) Test Bed. ARGO includes a ~1.5m x 1.5m x 1.2m (~5x5x4ft) vacuum chamber, cryogenically cooled thermal shroud, 3-axis robotic positioning system, and regolith bin. For the REACT project, a pellet extruder, feed hopper, and heated 600mm x 600mm (23.6x23.6in) build plate have been installed on ARGO to advance the Technology Readiness Level (TRL) of regolith-polymer composite Fused Deposition Modeling (FDM) additive construction systems, processes, and materials. This paper will focus on the design and operational characteristics of the ARGO Test Bed with pellet extruder.

regolith↗
NASA NTRSDate not supplied

Vertical Lunar Regolith Conveying as a Flight Experiment in Simulated Lunar-Gravity

Regolith conveying will be an essential task for supplying regolith feedstock to In-Situ Resource Utilization (ISRU) reactor systems for regolith processing on the Moon and Mars. The Vertical Lunar Regolith Conveyor (VLRC) is a technology being developed at NASA Kennedy Space Center (KSC) as a regolith transport task for the GCD ISRU FLEET project led by NASA Glenn Research Center (GRC). Single test loop versions of the VLRC are being developed at NASA KSC as a technology demonstration for a flight experiment. The NASA Flight Opportunities program selected the VLRC for a technology demonstration opportunity on a future Blue Origin New Shepard suborbital launch vehicle to study regolith transport physics in a relevant environment in a vacuum chamber under simulated lunar gravity conditions in order to advance its technology readiness level (TRL) for future space applications. The VLRC system includes four primary subsystems to achieve the objectives of the lunar gravity (Lunar-G) flight experiment. (1) An eccentric vibratory conveyor stack to convey regolith particles consisting of three single-loop helical surface conveyors with each actuated by two vibratory motors that vibrate in unison. One of the three single-loops contains a 0.8°-3.1° inclined helical path and the other two contain a 1.6°-6.2° incline. (2) A stick-slip conveyor stack to convey regolith particles consisting of three single-loop helical surface conveyors with each actuated by the same motor to move in unison in a stick-slip motion. One of the three single-loops contains a 0.8°-3.1° inclined helical path and the other two contain a 1.6°-6.2° incline. (3) A regolith containment system to contain the regolith in each single-loop track during launch before the start of the experiment using containment caps that will be lifted in unison at the start of Lunar-G. (4) COTS cameras will record the motion of regolith and tracer particles. Post-flight analysis of the videos will be used to determine convey speeds and flow rates. The VLRC experiment will use the well-known technique of Particle Image Velocimetry (PIV) image analysis to determine the velocity of tracer particles entrained in the regolith flow. This velocity will be used to calculate the mass flow rate of the regolith being conveyed.

ISRU↗