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At least 1,531 records · Page 85
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Imaging Electrons in Two Dimensional Materials (Final report)

Two-dimensional (2D) materials have extraordinary characteristics that offer promising new approaches for science and technology. Electrons in graphene can move ballistically through a sheet, even though it is only a single atom thick. And transition metal dichalcogenide materials can be cleaved into 2D flakes of all types – metals, semiconductors, insulators, magnetic materials, and superconductors. To benefit from these discoveries, the science needs to be understood to transform 2D materials into useful new devices and systems. The evolution in time of atomic scale graphene structures has been studied in time with a transmission electron microscope (TEM), and ballistic transport of electrons in graphene was been imaged using a cooled scanning probe microscope (SPM), as well as electron motion in MoS 2 . Graphene is only one atom thick but is extremely strong, creating the opportunity to fabricate atomic scale structures in the lateral direction. Using an atomic resolution TEM, a suspended sheet of graphene can be shaped by a Si impurity atom on its surface that acts like a chisel to open up apertures, one atom at a time. The electrons in the TEM provide both the chiseling energy and the ability to image the results. Electrons and holes in graphene form a new type of electronic system with conical conduction and valence bands that meet at the Dirac point, with no energy gap. For moderate densities, the carriers form a Fermi liquid with ballistic transport over micron-scale distances. Using a cooled SPM the cyclotron orbit of electrons in graphene has been imaged. In the magnetic focusing regime, electrons leaving a point contact circle around and leave from a second point contact when the cyclotron diameter is equal to the contact spacing. The paths of electrons are focused - they enter at different angles but converge again at the exiting contact. When the SPM tip knocks an electron out of its orbit, an imaging signal is created. The ballistic motion of carriers in graphene opens the way for ballistic devices that manipulate beams of electrons and holes. Our collaborator Gil-Ho Lee, in Philip Kim's group, created a collimating contact by placing zig-zag absorbers on either side of entering electrons. Our cooled SPM was used to image the electron beam and determine its 9-degree halfwidth. By changing the gate voltage, a collimated beam of holes was also created, opening the way for colliding beam experiments. Coherent beams of carriers are desirable for quantum information processing. Via Andreev reflection, superconducting contacts can covert Cooper pairs in a superconductor to an ingoing and outgoing electrons and holes. Using our cooled SPM, Andreev reflection was imaged from a superconducting contact on a graphene device. Magnetic focusing was used to create an incoming beam of electrons and an outgoing beam of holes, detected by a third point contact. The images show a clear transition from normal reflection above the superconducting transition temperature to Andreev reflection as the device is cooled. Transition metal dichalcogenides offer a wide array of materials that can be exfoliated into ultrathin 2D sheets. A cooled SPM can be used to detect quantum dots as well as to image electron flow. The tip charge capacitively couples to electrons on the dot, acting as a gate to tune the dot conductance. Coulomb blockade peaks appear as a bullseye pattern in an SPM image as the tip is raster scanned above the dot. This approach was used to detect quantum dots in a MoS 2 channel as the carrier density was reduced and electrons pooled in low energy points. Through our DOE supported research, cooled SPM imaging has proven to be a very useful tool to uncover the motion of electrons and holes in the new quantum materials graphene and MoS 2 .

36 MATERIALS SCIENCE↗
NASA NTRS1990

Silicate liquid immiscibility in isothermal crystallization experiments

The role of silicate liquid immiscibility (SLI) in the petrogenesis of lunar granites was investigated in experiments in which four glasses were synthesized from reagent-grade oxides and carbonates with the compositions of two of the sets of coexisting liquids reported by Hess et al. (1975): a KREEP basalt derivative and a mare basalt derivative. Isothermal crystallization experiments showed that SLI is a stable phenomenon in residual lunar liquids saturated with plagioclase, and is likely to produce large compositional separations. The results indicate that controlled-cooling-rate experiments of Rutherford et al. (1974), and Hess et al. (1975, 1978) were substantially correct analogs of the natural process of liquid immiscibility.

Longhi, J.↗
NASA NTRS1979

Armalcolite/ilmenite - Mineral chemistry, paragenesis, and origin of textures

In order to understand the origin of differing ilmenite/armalcolite textural relationships, bulk rock composition, oxygen fugacity and cooling rate have been experimentally investigated. Results show that armalcolite and ilmenite compositions are dependent upon the liquid composition and temperature at the time of crystallization. Furthermore, the different armalcolite/ilmenite textures rely to a greater extent on f sub O2 than on cooling rate or bulk rock composition, and the Ti(3+) content of armalcolite can be used as an indicator of the approximate f sub O2 prevailing at the time of crystallization.

Stanin, F. T.↗
DOE OSTI2024

Fluid Mixing during Phase Separation in Crystallizing White Dwarfs

Abstract Accurate models of cooling white dwarfs must treat the energy released as their cores crystallize. This phase transition slows the cooling by releasing latent heat and also gravitational energy, which results from phase separation: liquid C is released from the solid C/O core, driving an outward carbon flux. The Gaia color–magnitude diagram provides striking confirmation of this theory by revealing a mass-dependent overdensity of white dwarfs, indicating slowed cooling at the expected location. However, the observed overdensity is enhanced relative to the models. Additionally, it is associated with increased magnetism, suggesting a link between crystallization and magnetic field generation. Recent works aimed at explaining an enhanced cooling delay and magnetic field generation employ a uniform mixing prescription that assumes large-scale turbulent motions; we show here that these calculations are not self-consistent. We also show that thermohaline mixing is most likely efficient enough to provide the required chemical redistribution during C/O phase separation, and that the resulting velocities and mixing lengths are much smaller than previous estimates. These reduced fluid motions cannot generate measurable magnetic fields, suggesting any link with crystallization needs to invoke a separate mechanism. Finally, this mixing alters the chemical profiles, which in turn affects the frequencies of the pulsation modes.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2025

Thermal Performance of a Conduction-Cooled CCT Dipole ReBCO Magnet: Several Cycles of Cool-Down and Thermal Gradient Measurements

Here, this paper presents experimental results from conduction-cooled thermal testing of a ReBCO canted cosine theta (CCT) magnet (C2), originally designed and fabricated at LBNL using CORC cables. While the performance of the coil under liquid helium and nitrogen environments has been previously established, this study explores its behavior under conduction cooling using a large test cryostat at The Ohio State University. The magnet, measuring 613 mm in length and weighing ∼75 kg, consists of four helical layers wound with ReBCO-based CORC wire and was thermally anchored to a copper cold ring supported by a G-10 strongback. Cooling was provided by two Sumitomo RDK-415D cryocoolers, offering a combined 3 W at 4.2 K and 150 W at 77 K. Multiple thermal cycles were performed, with cooldown durations of up to 45 hours. Final base temperatures of approximately 10.8 K (at the coil edge) and 12.0 K (at the coil center) were achieved, with an axial temperature difference of approximately 1.2 K. The warm-up period extended over approximately 24.6 hours. Voltage measurements from all four layers were recorded during cooldown and warmup. The system demonstrated stable cooldown performance, repeatable gradients, and good thermal anchoring. These results support the feasibility of conduction cooling in large-scale HTS magnets, aligning with broader goals for “green” cryogen-free accelerator technologies and paving the way for more sustainable, scalable, and energy-efficient high-field magnet systems in next-generation particle accelerators.

Canted cosine theta magnets↗
DOE OSTI2022

FFTF Acceptance and Startup Testing for GAIN

The Fast Flux Test Facility (FFTF) is the most recent liquid metal reactor (LMR) to be designed, constructed, and operated by the U.S. Department of Energy (DOE). The 400-MWt sodium-cooled, fast-neutron flux reactor plant was designed for irradiation testing of nuclear reactor fuels and materials for liquid metal fast breeder reactors. Following the demise of the breeder reactor program in the United States, FFTF continued to play a key role in providing a test bed for demonstrating performance of advanced fuel designs and demonstrating operation, maintenance, and safety of advanced liquid metal reactors. FFTF operations ceased in April 1992 after a determination by DOE that no combination of proposed missions was financially feasible over a ten-year period. The reactor is currently deactivated and in a long-term surveillance and maintenance (S&M) mode. This report provides information on the extensive and rigorous process that was used to conduct turnover from construction followed by acceptance and startup testing of the FFTF. This paper is in support of the Gateway for Accelerated Innovation in Nuclear (GAIN), which provides the nuclear energy community with access to the technical, regulatory, and financial support necessary to move new or advanced nuclear reactor designs toward commercialization while ensuring the continued safe, reliable, and economic operation of the existing nuclear fleet. The information obtained from the design, startup, and operation of the FFTF provides valuable insight for follow-on reactor projects, such as the Versatile Test Reactor (VTR), in the areas of plant system and component design, component fabrication, fuel design and performance, prototype testing, site construction, reactor startup and operations, and reactor deactivation and decommissioning (D&D). The focus of this report is on the process used to startup the FFTF and to ensure that operations could be conducted efficiently and safely. A reference section is provided of documents detailing the successful turnover and testing process implemented for startup of the reactor and its supporting systems. The documents listed can be retrieved upon request and are believed useful for future reactor startup endeavors.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
NASA NTRS2011

Failure Investigation of an Intra-Manifold Explosion in a Horizontally-Mounted 870 lbf Reaction Control Thruster

In June 2010, an 870 lbf Space Shuttle Orbiter Reaction Control System Primary Thruster experienced an unintended shutdown during a test being performed at the NASA White Sands Test Facility. Subsequent removal and inspection of the thruster revealed permanent deformation and misalignment of the thruster valve mounting plate. Destructive evaluation determined that after three nominal firing sequences, the thruster had experienced an energetic event within the fuel (monomethylhydrazine) manifold at the start of the fourth firing sequence. The current understanding of the phenomenon of intra-manifold explosions in hypergolic bipropellant thrusters is documented in literature where it is colloquially referred to as a ZOT. The typical ZOT scenario involves operation of a thruster in a gravitational field with environmental pressures above the triple point pressure of the propellants. Post-firing, when the thruster valves are commanded closed, there remains a residual quantity of propellant in both the fuel and oxidizer (nitrogen tetroxide) injector manifolds known as the "dribble volume". In an ambient ground test configuration, these propellant volumes will drain from the injector manifolds but are impeded by the local atmospheric pressure. The evacuation of propellants from the thruster injector manifolds relies on the fluids vapor pressure to expel the liquid. The higher vapor pressure oxidizer will evacuate from the manifold before the lower vapor pressure fuel. The localized cooling resulting from the oxidizer boiling during manifold draining can result in fuel vapor migration and condensation in the oxidizer passage. The liquid fuel will then react with the oxidizer that enters the manifold during the next firing and may produce a localized high pressure reaction or explosion within the confines of the oxidizer injector manifold. The typical ZOT scenario was considered during this failure investigation, but was ultimately ruled out as a cause of the explosion. Converse to the typical ZOT failure mechanism, the failure of this particular thruster was determined to be the result of liquid oxidizer being present within the fuel manifold.

Durning, Joseph G., III↗
DOE OSTI2022

Analysis of Conduction Cooling Strategies for Wire Arc Additive Manufacturing

Metal additive manufacturing (AM) processing consists of numerous parameters which take time to optimize for various geometries. One aspect of the metal AM process that continues to be explored is the control of thermal energy accumulation during component manufacturing due to the melting and solidification of the feedstock. Excessive energy accumulation causes thermal failure of the component while minimal energy accumulation causes lack of fusion with the build plate or previous layer. The ability to simulate the thermal response of an AM component can increase research efficiency by reducing the time to optimize thermal energy accumulation. This paper presents an effective implementation of finite element analysis to determine the thermal response of a wire arc additive manufactured component with various build plate sizes and cooling methods including, integral build plate cooling, oversized build plates with passive cooling, and non-integral build plate cooling. The use of integral build plate cooling channels was shown to decrease the interpass temperature at the conclusion of the build process by 55% and build plate temperature by 96% compared to the conventionally deposited sample with 20 second dwell time. The use of a tall build plate with passive cooling was shown to reduce the interpass temperature by 32% as compared to the conventionally deposited sample with 20 second dwell time. Each cooling strategy evaluated decreased the interpass temperature within a range of 20–55% which enables higher deposition rates and decreased dwell times during depositions. The cooling strategies are designed to be implemented in a hybrid or retrofit AM platform to mitigate concerns of the thermal input from the additive process having detrimental effects on the precision of the machining process. This paper shows that accurate simulations of all strategies can be used to accurately predict the thermal response of the various strategies discussed. These cooling strategies will allow for increased deposition rates with comparable interpass temperature and decreased dwell time, increasing deposition efficiency. This model and these simulations are verified by experimental results. It is concluded that passive strategies, such as the over-sized tall build plate, can be used when liquid coolant in the AM environment could negatively affect the deposition process. Active cooling strategies, such as the integral build plate cooling could be used if low thermal conductivity materials are deposited or higher material deposition rates are desired. This paper discusses the use of active and passive cooling used during AM and shows how a simulation model can be used to make design choices for cooling strategies. The model also enables verification of select critical process parameters such as dwell times for a desired interpass temperature.

Heinrich, Lauren↗
DOE OSTI2023

Heat recovery from an electrochemical hydrogen separation system

An EHS system includes a EHS cell having an anode, a cathode, and a cooling plate disposed proximate at least one of the anode or the cathode, the cooling plate configured to receive water and configured to output steam or a mixture of water and steam. The system further includes a liquid-vapor separator (LVS) configured to receive the steam or the mixture of water and steam from the cooling plate and to separate water and steam. The LVS is configured to output water to the cooling plate.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS2009

Investigating Liquid CO2 as a Coolant for a MTSA Heat Exchanger Design

Metabolic heat regenerated Temperature Swing Adsorption (MTSA) technology is being developed for thermal and carbon dioxide (CO 2) control for a future Portable Life Support System (PLSS), as well as water recycling. CO 2 removal and rejection is accomplished by driving a sorbent through a temperature swing of approximately 210 K to 280 K . The sorbent is cooled to these sub-freezing temperatures by a Sublimating Heat Exchanger (SHX) with liquid coolant expanded to sublimation temperatures. Water is the baseline coolant available on the moon, and if used, provides a competitive solution to the current baseline PLSS schematic. Liquid CO2 (LCO2) is another non-cryogenic coolant readily available from Martian resources which can be produced and stored using relatively low power and minimal infrastructure. LCO 2 expands from high pressure liquid (~5800 kPa) to Mars ambient (0.8 kPa) to produce a gas / solid mixture at temperatures as low as 156 K. Analysis and experimental work are presented to investigate factors that drive the design of a heat exchanger to effectively use this sink. Emphasis is given to enabling efficient use of the CO 2 cooling potential and mitigation of heat exchanger clogging due to solid formation. Minimizing mass and size as well as coolant delivery are also considered. The analysis and experimental work is specifically performed in an MTSA-like application to enable higher fidelity modeling for future optimization of a SHX design. In doing so, the work also demonstrates principles and concepts so that the design can be further optimized later in integrated applications (including Lunar application where water might be a choice of coolant).

Paul, Heather L.↗
DOE OSTI2026

A comparative assessment of the economic viability of nuclear-integrated direct air capture systems

Direct air capture (DAC) systems require heat and electricity to operate, which can be supplied by nuclear power plants (NPPs). In this study, the performance and cost of various conceptual nuclear-DAC systems are assessed, and their performance is compared with several non-nuclear options. Three nuclear-DAC systems are considered: (1) a liquid solvent direct air capture (L-DAC) system with heat supplied from natural gas (NG) and electricity supplied by an NPP, (2) an electrified L-DAC system, fully powered by electricity from an NPP, and (3) a solid sorbent direct air capture (S-DAC) system utilizing both heat and electricity generated by an NPP. Two nuclear technologies are considered: a pressurized water reactor and a high-temperature gas-cooled reactor. Under the medium conservatism scenario, the levelized cost of direct air capture (LCOD) for these systems range from $\$$310/tCO 2 to $\$$525/tCO 2 with the L-DAC system having an NG heat supply at the lower end of the range, and the electrified L-DAC system and the S-DAC system at the higher end of the range. Coupling with nuclear energy led to a 21 % reduction in LCOD for the L-DAC system with NG heat supply and a 29 % reduction for the S-DAC system when compared to fully NG-powered options. When powering the DAC system with grid electricity, the LCOD is highly dependent on the assumed electricity price and carbon intensity. The nuclear option is the cheaper choice when the price of low-carbon grid electricity exceeds $\$$95/MWh and $\$$45/MWh for the L-DAC and S-DAC systems, respectively.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS1972

Electron paramagnetic resonance study of alinement induced by magnetic fields in two smectic-A liquid crystals not exhibiting nematic phases

Using vanadyl acetylacetonate (VAAC) as a paramagnetic probe, the molecular ordering in two smectic-A liquid crystals that do not display nematic phases were studied. Reproducible alinement was attained by slow cooling throughout the isotropic smectic-A transition in dc magnetic fields of 1.1 and 2.15 teslas. The degree of order attained is small for a smectic-A liquid crystal. Measurements were made of the variation of the average hyperfine splitting of the alined samples as a function of orientation relative to the dc magnetic field of the spectrometer. This functional dependence is in agreement with the theoretical prediction except where the viscosity of the liquid crystal becomes large enough to slow the tumbling of the VAAC, as indicated by asymmetry in the end lines of the spectrum.

Fryburg, G. C.↗
DOE OSTI2020

Active analog tuning of the phase of light in the visible regime by bismuth-based metamaterials

The active and analog tuning of the phase of light by metamaterials is needed to boost the switching performance of photonic devices. However, demonstrations of this type of tuning in the pivotal visible spectral region are still scarce. Herein, we report the active analog tuning of the phase of visible light reflected by a bismuth (Bi)-based metamaterial, enabled by a reversible solid-liquid transition. This metamaterial, fabricated by following a lithography-free approach, consists of twodimensional assemblies of polydisperse plasmonic Bi nanostructures embedded in a refractory and transparent aluminum oxide matrix. The analog tuning of the phase is achieved by the controlled heating of the metamaterial to melt a fraction of the nanostructures. A maximum tuning of 320° (1.8 π) is observed upon the complete melting of the nanostructures at 230°C. This tuning is reversible by cooling to 25°C. In addition, it presents a wide hysteretic character due to liquid Bi undercooling. This enables the phase achieved by this analog approach to remain stable over a broad temperature range upon cooling and until resolidification occurs around 100°C. Therefore, Bi-based metamaterials are endowed with analog optical memory capabilities, which are appealing for a wide range of applications, including optical data storage with enhanced information density or bistable photonic switching with a tunable “on” state.

36 MATERIALS SCIENCE↗
NASA NTRS2004

High Power Density Motors

With the growing concerns of global warming, the need for pollution-free vehicles is ever increasing. Pollution-free flight is one of NASA's goals for the 21" Century. , One method of approaching that goal is hydrogen-fueled aircraft that use fuel cells or turbo- generators to develop electric power that can drive electric motors that turn the aircraft's propulsive fans or propellers. Hydrogen fuel would likely be carried as a liquid, stored in tanks at its boiling point of 20.5 K (-422.5 F). Conventional electric motors, however, are far too heavy (for a given horsepower) to use on aircraft. Fortunately the liquid hydrogen fuel can provide essentially free refrigeration that can be used to cool the windings of motors before the hydrogen is used for fuel. Either High Temperature Superconductors (HTS) or high purity metals such as copper or aluminum may be used in the motor windings. Superconductors have essentially zero electrical resistance to steady current. The electrical resistance of high purity aluminum or copper near liquid hydrogen temperature can be l/lOO* or less of the room temperature resistance. These conductors could provide higher motor efficiency than normal room-temperature motors achieve. But much more importantly, these conductors can carry ten to a hundred times more current than copper conductors do in normal motors operating at room temperature. This is a consequence of the low electrical resistance and of good heat transfer coefficients in boiling LH2. Thus the conductors can produce higher magnetic field strengths and consequently higher motor torque and power. Designs, analysis and actual cryogenic motor tests show that such cryogenic motors could produce three or more times as much power per unit weight as turbine engines can, whereas conventional motors produce only 1/5 as much power per weight as turbine engines. This summer work has been done with Litz wire to maximize the current density. The current is limited by the amount of heat it generates. By increasing the heat transfer out of the wire, the wires can carry a larger current and therefore produce more force. This was done by increasing the surface area of the wire to allow more coolant to flow over it. Litz wire was used because it can carry high frequency current. It also can be deformed into configurations that would increase the surface area. The best configuration was determined by heat transfer and force plots that were generated using Maxwell 2D. Future work will be done by testing and measuring the thrust force produced by the wires in a magnetic field.

Kascak, Daniel J.↗
NASA NTRS1987

Measuring Contact Thermal Conductances at Low Temperatures

Instrument measures thermal conductance of pressed contacts in liquid helium. Makes measurements automatically as function of force on pairs of brass samples having various surface finishes. Developed as part of effort to determine heat-transfer characteristics of bolted joints on cryogenically cooled focal planes in infrared equipment. Cylindrical chamber hangs from cover plate in bath of liquid helium. Inside chamber rocker arm applies controlled force to samples. Upper sample made slightly wider than lower one so two samples remain in complete contact even under slight lateral misalignment.

Salerno, Louis J.↗
NASA NTRS2016

Modeling Droplet Heat and Mass Transfer during Spray Bar Pressure Control of the Multipurpose Hydrogen Test Bed (MHTB) Tank in Normal Gravity

A CFD model for simulating pressure control in cryogenic storage tanks through the injection of a subcooled liquid into the ullage is presented and applied to the 1g MHTB spray bar cooling experiments. An Eulerian-Lagrangian approach is utilized to track the spray droplets and capture the interaction between the discrete droplets and the continuous ullage phase. The spray model is coupled with the VOF model by performing particle tracking in the ullage, removing particles from the ullage when they reach the interface, and then adding their contributions to the liquid. A new model for calculating the droplet-ullage heat and mass transfer is developed. In this model, a droplet is allowed to warm up to the saturation temperature corresponding to the ullage vapor pressure, after which it evaporates while remaining at the saturation temperature. The droplet model is validated against the results of the MHTB spray-bar cooling experiments with 50% and 90% tank fill ratios. The predictions of the present T-sat based model are compared with those of a previously developed kinetic-based droplet mass transfer model. The predictions of the two models regarding the evolving tank pressure and temperature distributions, as well as the droplets' trajectories and temperatures, are examined and compared in detail. Finally, the ullage pressure and local vapor and liquid temperature evolutions are validated against the corresponding data provided by the MHTB spray bar mixing experiment.

mass transfer↗
NASA NTRS1993

Transient liquid-crystal technique used to produce high-resolution convective heat-transfer-coefficient maps

In this transient technique the preheated isothermal model wall simulates the classic one-dimensional, semi-infinite wall heat transfer conduction problem. By knowing the temperature of the air flowing through the model, the initial temperature of the model wall, and the surface cooling rate measured at any location with time (using the fast-response liquid-crystal patterns recorded on video tape), the heat transfer coefficient can be calculated for the color isothermal pattern produced. Although the test was run transiently, the heat transfer coefficients are for the steady-state case. The upstream thermal boundary condition was considered to be isothermal. This transient liquid-crystal heat-transfer technique was used in a transient air tunnel in which a square-inlet, 3-to-1 exit transition duct was placed. The duct was preheated prior to allowing room temperature air to be suddenly drawn through it. The resulting isothermal contours on the duct surfaces were revealed using a surface coating of thermochromic liquid crystals that display distinctive colors at particular temperatures. A video record was made of the temperature and time data for all points on the duct surfaces during each test. The duct surfaces were uniformly heated using two heating systems: the first was an automatic temperature-controlled heater blanket completely surrounding the test duct like an oven, and the second was an internal hot-air loop through the inside of the test duct. The hot-air loop path was confined inside the test duct by insulated heat dams located at the inlet and exit ends of the test duct. A recirculating fan moved hot air into the duct inlet, through the duct, out of the duct exit, through the oven, and back to the duct inlet. The temperature nonuniformity of the test duct model wall was held very small. Test results are reported for two inlet Reynolds numbers of 200,000 and 1,150,000 (based on the square-inlet hydraulic diameter) and two free-stream turbulence intensities of about 1 percent, which is typical of wind tunnels, and up to 20 percent (using a grid), which is typical of real engine conditions.

Hippensteele, Steven A.↗
NASA NTRSDate not supplied

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

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

LP-DED↗