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

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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Large Scale and Multi-Alloy Rocket Engine Component Development using Various Metal Additive Manufacturing Techniques

The NASA Marshall Space Flight Center (MSFC) has been involved with various forms of metallic additive manufacturing (AM) for use in liquid rocket engine component design, development, and testing since 2010. These AM techniques have been demonstrated to significantly reduce hardware cost, shorten fabrication schedules, increase reliability by reducing the number of joints, and improve hardware performance by allowing fabrication of designs not feasible by conventional means. The focus at the NASA MSFC for these metal additive manufacturing techniques include laser powder-bed fusion (L-PBF), blown powder directed energy deposition (DED), arc-based deposition, and Laser Wire Direct Closeout (LWDC). A variety of components have been evaluated and tested including thrust chamber injectors, injector components such as faceplates, regeneratively-cooled combustion chambers, regeneratively-cooled nozzles, gas generator and preburner hardware, and augmented spark igniters. To support these component applications in harsh environments, NASA has advanced a variety of “standard” additive manufacturing alloys such as those in the superalloy-family and also evolved new alloys including GRCop-84, GRCop-42, NASA HR-1, and JBK-75. The purpose of this presentation is to discuss the various component programs at the NASA MSFC using AM to develop, fabricate, and test combustion devices hardware and the evolution of the new additive alloys. One of these projects that will be highlighted is Rapid Analysis and Manufacturing Propulsion Technology (RAMPT), which includes new process development for large scale AM components, multi-metallic AM components, including unique component designs using additive manufacturing. Additional information will be provided on the development of other components, hot-fire testing, post-processing of AM techniques including surface enhancements (polishing) techniques, material and process characterization, future development programs, and dissemination of data to industry partners.

Additive Manufacturing↗
DOE OSTI2016

Measuring the seeds of ion outflow: auroral sounding rocket observations of low-altitude ion heating and circulation

Here, we present an analysis of in situ measurements from the MICA (Magnetosphere-Ionosphere Coupling in the Alfvén Resonator) nightside auroral sounding rocket with comparisons to a multifluid ionospheric model. MICA made observations at altitudes below 325 km of the thermal ion kinetic particle distributions that are the origins of ion outflow. Late flight, in the vicinity of an auroral arc, we observe frictional processes controlling the ion temperature. Upflow of these cold ions is attributed to either the ambipolar field resulting from the heated electrons or possibly to ion-neutral collisions. We measure E → xB → convection away from the arc (poleward) and downflows of hundreds of m s -1 poleward of this arc, indicating small-scale low-altitude plasma circulation. In the early flight we observe DC electromagnetic Poynting flux and associated ELF wave activity influencing the thermal ion temperature in regions of Alfvénic aurora. We observe enhanced, anisotropic ion temperatures which we conjecture are caused by transverse heating by wave-particle interactions (WPI) even at these low altitudes. Throughout this region we observe several hundred m s -1 upflow of the bulk thermal ions colocated with WPI; however, the mirror force is negligible at these low energies; thus, the upflow is attributed to ambipolar fields (or possibly neutral upwelling drivers). Moreover, the low-altitude MICA observations serve to inform future ionospheric modeling and simulations of (a) the need to consider the effects of heating by WPI at altitudes lower than previously considered viable and (b) the occurrence of structured and localized upflows/downflows below where higher-altitude heating rocesses are expected.

47 OTHER INSTRUMENTATION↗
DOE OSTI2019

Study of the Effects of Materials Selection for the Closeout Structure on the Service Life of a Liquid Rocket Engine Thrust Chamber

The external structure of rocket engines thrust chambers for aerospace applications should be designed in order to provide adequate stiffness to the thrust chamber; however, it affects in a significant way the engine service life since it acts as a structural bound for the internal structure which is subjected to very high temperature values. The adoption of thin closeout structures allows to have lighter structures and to significantly increase the service life of the thrust chamber. The aim of the present work is to perform numerical investigations on the influence of the closeout geometry and materials on the number of cycles to failure of the thrust chamber. Furthermore, a study on the impact of creep phenomenon on the service life is illustrated. In particular, the present paper is focused on the thermomechanical study of the closeout structure, in terms of material choice, thickness, joining process with the inner liner, etc. Transient thermal and static structural nonlinear analyses are conducted by means of a commercial finite element code (ANSYS), in order to evaluate the number of cycles to failure for the investigated configurations. Viscoplastic models are adopted in order to simulate the highly nonlinear and rate-dependent phenomena occurring in the inner liner structure.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Influence of O 2 / N 2 oxidizer blends on soot formation and radiative heat flux in PMMA-air 2D slab burner for understanding hybrid rocket combustion

The focus of this study is to establish a correlation between the flame to fuel incident radiative heat flux (RHF) in 1D steady-state diffusion flames to non-intrusively measured RHF in 2D slab burner experiments for a range of O 2 /N 2 oxidizer blends. Slab burner experiments are conducted for a range of increasing O 2 concentrations from 17% to 100% in the oxidizer stream. Non-intrusive two-color pyrometry is used to determine flame temperature, soot volume fraction, and flame to fuel surface RHF. Measurements and modeling confirm soot volume fraction attains a local maximum for an O 2 concentration of 45%. Low-strain diffusion flame modeling shows the reason for the local maximum is the relative location of the soot formation/nucleation fronts relative to oxidation which decreases with increasing O 2 concentration. Overall good agreement between modeling and measurements of radiative heat flux to the fuel is observed for the fuel and range of O 2 concentrations considered. Furthermore, these results demonstrate the viability of using flamelet modeling approaches for describing hybrid rocket motors.

2D slab burner↗
DOE OSTI2022

Numerical Analysis of Combustion Dynamics in a Full-Scale Rotating Detonation Rocket Engine using Large Eddy Simulations

Large eddy simulations (LES) using detailed chemistry and leveraging adaptive mesh refinement (AMR) are performed to gain insights into the combustion dynamics within a full-scale methane-oxygen non-premixed rotating detonation rocket engine (RDRE) employing impinging discrete injection schemes. In particular, a comparative analysis of two operating conditions corresponding to the same global equivalence ratio but different mass flow rates is carried out to investigate the resultant impact on detonation wave characteristics and RDRE global performance. Multiple co-rotating detonation waves with spatially-distributed wave structure and preferential alignment with the inner wall of the annulus (due to asymmetry in fuel distribution) are encountered under both conditions. Both cases exhibit pre-detonation deflagrative burning in the fill region, while one of the cases shows higher susceptibility to backflow into the feed plenums due to lower plenum pressures. Furthermore, heat release analysis shows that the thrust obtained from the RDRE is closely linked to the distribution of total heat release between detonative and deflagrative combustion. On the other hand, combustion efficiency is associated with the fraction of heat release occurring in fuel-rich versus fuel-lean regions within the RDRE.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2018

Solid Rocket Propellant Fires Characterization, Final Scientific/Technical Report for 8 May 2014 through 4 October 2017

The Solid Rocket Propellant Fires Characterization Program continued the Johns Hopkins University Applied Physics Laboratory's (JHU/APL's) characterization of solid propellant fires under relevant accident conditions [at 1 atmosphere (atm) ambient pressure, in humid weather], with significant findings that have revolutionized the understanding of these fires and the response and behavior of plutonium dioxide (plutonia) surrogates in the fires. These findings have been disseminated in Department of Energy (DOE) internal working meetings and at technical interchange meetings (TIMs) with DOE, the Interagency Nuclear Safety Review Panel (INSRP), and NASA in support of the Presidential nuclear safety launch approval process for the Mars 2020 mission, as well as via several conference and journal papers.

10 SYNTHETIC FUELS↗
DOE OSTI2019

Damping Decrements in the Combustion Chambers of Liquid-Propellant Rocket Engines

The damping decrements of pressure fluctuations in the combustion chambers of liquid-propellant rocket engines may be estimated on the basis of hard excitation of acoustic vibrations of a specific mode. A device for hard excitation of high-frequency pressure fluctuations has been developed. This device prevents damage to the components of the combustion chamber by flying metal fragments. Recommendations are made regarding the calculation of the acoustic characteristics for complex channels.

42 ENGINEERING↗