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Additive Manufacturing of NASA HR-1 Material for Liquid Rocket Engine Component ApplicationsNASA HR-1 is a high-strength Fe-Ni superalloy designed to resist high pressure, hydrogen environment embrittlement, oxidation, and corrosion. NASA HR-1 was originally developed at NASA in the 1990’s and derived from JBK-75 to increase strength and ductility in high-pressure hydrogen environments. The NASA HR-1 chemistry was formulated to meet requirements for liquid rocket engine applications, specifically components used in a high-pressure hydrogen environment. Recent developments using additive manufacturing (AM) have made this material an attractive option for channel-cooled nozzles under the Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) program and other liquid rocket engine component applications. The RAMPT program has baselined to fully evolve and characterize NASA HR-1 material. NASA HR-1 meets materials requirements for liquid rocket engine components, including good hydrogen resistance, high conductivity, good low cycle fatigue performance, and high elongation and strength for channel-cooled nozzles in high heat flux environments. Initial development and characterization has been completed using blown powder Directed Energy Deposition (DED) and Laser Powder Bed Fusion (L-PBF) additive manufacturing techniques to develop material test samples and nozzle hardware. NASA HR-1 powder has been sourced and characterized from several powder suppliers, and a series of development and hardware samples completed fabrication using DED and L-PBF. Characterization of the material has included heat treatment development, metallography, chemistry evaluations, mechanical testing, measurement of thermophysical properties, and fabrication of relevant nozzle hardware to demonstrate feasibility. This paper presents results from the process and early materials development and provide future development work including hardware fabrication.
Document ID
20200001007
Document Type
Conference Paper
Authors
Katsarelis, Colton (NASA Marshall Space Flight Center Huntsville, AL, United States)
Chen, Po (NASA Marshall Space Flight Center Huntsville, AL, United States)
Gradl, Paul (NASA Marshall Space Flight Center Huntsville, AL, United States)
Protz, Chris (NASA Marshall Space Flight Center Huntsville, AL, United States)
Jones, Zachary (NASA Marshall Space Flight Center Huntsville, AL, United States)
Ellis, David (NASA Glenn Research Center Cleveland, OH, United States)
Evans, Laura (NASA Glenn Research Center Cleveland, OH, United States)
Date Acquired
February 20, 2020
Publication Date
December 9, 2019
Subject Category
Spacecraft Propulsion and Power
Report/Patent Number
M19-7797
Meeting Information
JANNAF Dec 2019(Tampa, FL)
Distribution Limits
Public
Copyright
Work of the US Gov. Public Use Permitted.

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