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  • 1
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    Development and Hot-fire Testing of Additively Manufactured Copper Combustion Chambers for Liquid Rocket Engine Applications (2017)
    In:  CASI
    Details
    Publication Date: 2019-07-13
    Description: 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 has completed a series of development programs and hot-fire tests to demonstrate SLM GRCop-84 and other AM techniques. NASA's efforts include a 4K lbf thrust liquid oxygen/methane (LOX/CH4) combustion chamber and subscale thrust chambers for 1.2K lbf LOX/hydrogen (H2) applications that have been designed and fabricated with SLM GRCop-84. The same technologies for these lower thrust applications are being applied to 25-35K lbf 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.
    Keywords: Spacecraft Propulsion and Power
    Type: AIAA Paper 2017-4670 , M17-6113 , AIAA/SAE/ASEE Joint Propulsion Conference; Jul 10, 2017 - Jul 12, 2017; Atlanta, GA; United States
    Format: application/pdf
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    NASA TECHNICAL REPORTS
  • 2
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    Development and Hot-fire Testing of Additively Manufactured Copper Combustion Chambers for Liquid Rocket Engine Applications (2017)
    In:  CASI
    Details
    Publication Date: 2019-07-13
    Description: No abstract available
    Keywords: Spacecraft Propulsion and Power
    Type: M17-6132 , AIAA Propulsion and Energy Forum 2017; Jul 10, 2017 - Jul 12, 2017; Atlanta, GA; United States
    Format: application/pdf
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    NASA TECHNICAL REPORTS
  • 3
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    Subscale Carbon-Carbon Nozzle Extension Development and Hot Fire Testing in Support of Upper Stage Liquid Rocket Engines (2016)
    In:  CASI
    Details
    Publication Date: 2019-08-13
    Description: Upper stage and in-space liquid rocket engines are optimized for performance through the use of high area ratio nozzles to fully expand combustion gases to low exit pressures increasing exhaust velocities. Due to the large size of such nozzles and the related engine performance requirements, carbon-carbon (C/C) composite nozzle extensions are being considered for use in order to reduce weight impacts. NASA and industry partner Carbon-Carbon Advanced Technologies (C-CAT) are working towards advancing the technology readiness level of large-scale, domestically-fabricated, C/C nozzle extensions. These C/C extensions have the ability to reduce the overall costs of extensions relative to heritage metallic and composite extensions and to decrease weight by 50%. Material process and coating developments have advanced over the last several years, but hot fire testing to fully evaluate C/C nozzle extensions in relevant environments has been very limited. NASA and C-CAT have designed, fabricated and hot fire tested multiple subscale nozzle extension test articles of various C/C material systems, with the goal of assessing and advancing the manufacturability of these domestically producible materials as well as characterizing their performance when subjected to the typical environments found in a variety of liquid rocket and scramjet engines. Testing at the MSFC Test Stand 115 evaluated heritage and state-of-the-art C/C materials and coatings, demonstrating the capabilities of the high temperature materials and their fabrication methods. This paper discusses the design and fabrication of the 1.2k-lbf sized carbon-carbon nozzle extensions, provides an overview of the test campaign, presents results of the hot fire testing, and discusses potential follow-on development work.
    Keywords: Spacecraft Propulsion and Power
    Type: M16-5431 , Modeling and Simulation (MSS) Joint Subcommittee Meeting; Dec 05, 2016 - Dec 08, 2016; Phoenix, AZ; United States|JANNAF Programmatic and Industrial Base (PIB) Joint Subcommittee Meeting; Dec 05, 2016 - Dec 08, 2016; Phoenix, AZ; United States|Liquid Propulsion (LPS) Joint Subcommittee Meeting; Dec 05, 2016 - Dec 08, 2016; Phoenix, AZ; United States|Spacecraft Propulsion Joint Subcommittee Meeting; Dec 05, 2016 - Dec 08, 2016; Phoenix, AZ; United States
    Format: application/pdf
    Location Call Number Expected Availability
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    NASA TECHNICAL REPORTS
  • 4
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    Unknown
    Design, Development and Hotfire Testing of Monolithic Copper and Bimetallic Additively Manufactured Combustion Chambers (2016)
    In:  CASI
    Details
    Publication Date: 2019-08-13
    Description: 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) otherwise commonly referred to as additive manufacturing. The NASA Low Cost Upper Stage Propulsion (LCUSP) program was designed to develop processes and material characterization for the GRCop-84 copper-alloy commensurate with powder bed additive manufacturing, 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. As a direct spin off of this program, NASA is working with industry partners to further develop the printing process for the GRCop-84 material in addition to the C-18150 (CuCrZr) material. To advance the process further and allow for optimization with multiple materials, NASA is also investigating the feasibility of bimetallic additively manufactured chambers. A 1.2k sized thrust-chamber was designed and developed to compare the printing process of the GRCop-84 and C-18150 SLM materials. A series of similar MCC liners also completed development with an Inconel 625 jacket bonded to the GRcop-84 liner evaluating direct metal deposition (DMD) laser and arc-based techniques. This paper describes the design, development, manufacturing and testing of these combustion chambers and associated lessons learned throughout the design and development process.
    Keywords: Spacecraft Propulsion and Power
    Type: M16-5438 , Liquid Propulsion; Dec 05, 2016 - Dec 08, 2016; Phoenix, AZ; United States|Modeling and Simulation (MSS); Dec 05, 2016 - Dec 08, 2016; Phoenix, AZ; United States|Spacecraft Propulsion; Dec 05, 2016 - Dec 08, 2016; Phoenix, AZ; United States|JANNAF Programmatic and Industrial Base (PIB); Dec 05, 2016 - Dec 08, 2016; Phoenix, AZ; United States
    Format: application/pdf
    Location Call Number Expected Availability
    BibTip Others were also interested in ...
    NASA TECHNICAL REPORTS
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