{"project":{"acronym":"","projectId":17966,"title":"Low-Cost Manufacturing Technique for Advanced Regenerative Cooling for In-Space Cryogenic Engines","primaryTaxonomyNodes":[{"taxonomyNodeId":10543,"taxonomyRootId":8816,"parentNodeId":10542,"level":3,"code":"TX01.2.1","title":"Integrated Systems and Ancillary Technologies","definition":"This area covers pertinent technology areas that are strongly coupled to, but are not part of, electric in-space propulsion, such that focused development within these related areas will allow significant improvements in performance for some in-space propulsion technology areas.","exampleTechnologies":"Engine health monitoring, materials and manufacturing, heat rejection systems for in-space propulsion","hasChildren":false,"hasInteriorContent":true}],"startTrl":3,"currentTrl":6,"endTrl":6,"benefits":"
The Affordable Upper Stage Enginer (AUSE) is our primary NASA application. The upper stage engine, which will replace the RL10, will benefit from our SLM-manufactured MCC in three ways. First, SLM is known to reduce the cost of component manufacture by 50-70%, which will help satisfy affordability requirements. Second, the pressure drop penalty incurred by using our advanced cooling approach is reduced by about an order of magnitude over current state of the art, which will reduce turbompump requirements, which will also contribute to lower cost. Third, our approach provides a dramatic increase in heat flux to the regenerative propellant, which will enable an increase in expander cycle engine performance, by increasing its potential for doing work across the turbine. The Space Launch System (SLS) Program is another opportunity, particularly since the core stage will use the RS-25 engine, a staged combustion cycle that will likewise benefit from reductions in cooling jacket pressure drop. The Altair ascent and descent engines would also both benefit from our technology.
We are already actively pursuing a non-NASA opportunity with the Missile Defense Agency (MDA), which is forced to fly very expensive foreign missile systems as targets for interept missions. Today, these targets cost about $40M per mission. We have identified a low cost target that we can upgrade with a version of our SLM-manufactured advanced combustion chamber that will improve the range of that target, such that it can be used instead of the expensive foreign systems. If we are successful with the design, development and testing, MDA could fly our targets and save a massive $39M per intercept test.
The goal of the proposed effort is to use selective laser melting (SLM, an additive manufacturing technique) to manufacture a hot fire-capable, water-cooled spool piece that features an advanced regenerative cooling technique that combines high heat flux performance with low pressure drop. SLM enables us to \"print\" the spool piece in days, despite the complexity of the regenerative liner's inherent flow passage complexity. This reduction in manufacturing lead time, combined with the fact that SLM manufacturing costs are driven in large part by the amount of raw powder used during fabrication, results in a substantial cost reduction for future regeneratively-cooled rocket engines. Additionally, the proposed advanced regenerative cooling approach features a heat-pickup efficiency that is at least two orders of magnitude higher than traditional milled channel liners and/or brazed tube bundle chambers. As a result of our Phase I activity and confidence in our commercialization path, we will be making a capital investment to stand up an SLM manufacturing capability in house. We plan to augment that investment with an internally-funded trade study that we will use to derive main combustion chamber performance requirements for a future expander cycle engine. Those requirements will feed into Phase II design requirements and, ultimately, to supporting our commercialization opportunity presented by the Affordable Upper Stage Engine Program.
","startYear":2014,"startMonth":4,"endYear":2018,"endMonth":1,"statusDescription":"Completed","principalInvestigators":[{"contactId":3164670,"canUserEdit":false,"firstName":"Dr. Joe","lastName":"Sims","fullName":"Dr. Joe Sims","fullNameInverted":"Sims, Dr. Joe","primaryEmail":"Joseph.Sims@asrcfederal.com","publicEmail":true,"nacontact":false},{"contactId":225176,"canUserEdit":false,"firstName":"Joe","lastName":"Sims","fullName":"Joe Sims","fullNameInverted":"Sims, Joe","primaryEmail":"joseph.sims@asi-hsv.com","publicEmail":true,"nacontact":false}],"programDirectors":[{"contactId":206378,"canUserEdit":false,"firstName":"Jason","lastName":"Kessler","fullName":"Jason L Kessler","fullNameInverted":"Kessler, Jason L","middleInitial":"L","primaryEmail":"jason.l.kessler@nasa.gov","publicEmail":true,"nacontact":false}],"programExecutives":[{"contactId":215154,"canUserEdit":false,"firstName":"Jennifer","lastName":"Gustetic","fullName":"Jennifer L Gustetic","fullNameInverted":"Gustetic, Jennifer L","middleInitial":"L","primaryEmail":"jennifer.l.gustetic@nasa.gov","publicEmail":true,"nacontact":false}],"programManagers":[{"contactId":62051,"canUserEdit":false,"firstName":"Carlos","lastName":"Torrez","fullName":"Carlos Torrez","fullNameInverted":"Torrez, Carlos","primaryEmail":"carlos.torrez@nasa.gov","publicEmail":true,"nacontact":false}],"projectManagers":[{"contactId":461333,"canUserEdit":false,"firstName":"Theresa","lastName":"Stanley","fullName":"Theresa M Stanley","fullNameInverted":"Stanley, Theresa M","middleInitial":"M","primaryEmail":"theresa.m.stanley@nasa.gov","publicEmail":true,"nacontact":false},{"contactId":3164087,"canUserEdit":false,"firstName":"William","lastName":"Marshall","fullName":"William Marshall","fullNameInverted":"Marshall, William","primaryEmail":"William.M.Marshall@nasa.gov","publicEmail":true,"nacontact":false}],"website":"","libraryItems":[{"file":{"fileExtension":"pdf","fileId":294330,"fileName":"SBIR_2012_2_BC_H2.02-8607","fileSize":54338,"objectId":290851,"objectType":{"lkuCodeId":889,"code":"LIBRARY_ITEMS","description":"Library Items","lkuCodeTypeId":182,"lkuCodeType":{"codeType":"OBJECT_TYPE","description":"Object Type"}},"objectTypeId":889,"fileSizeString":"53.1 KB"},"files":[{"fileExtension":"pdf","fileId":294330,"fileName":"SBIR_2012_2_BC_H2.02-8607","fileSize":54338,"objectId":290851,"objectType":{"lkuCodeId":889,"code":"LIBRARY_ITEMS","description":"Library Items","lkuCodeTypeId":182,"lkuCodeType":{"codeType":"OBJECT_TYPE","description":"Object Type"}},"objectTypeId":889,"fileSizeString":"53.1 KB"}],"id":290851,"title":"Briefing Chart","description":"Low-Cost Manufacturing Technique for Advanced Regenerative Cooling for In-Space Cryogenic Engines, Phase II Briefing Chart","libraryItemTypeId":1222,"projectId":17966,"primary":false,"publishedDateString":"","contentType":{"lkuCodeId":1222,"code":"DOCUMENT","description":"Document","lkuCodeTypeId":341,"lkuCodeType":{"codeType":"LIBRARY_ITEM_TYPE","description":"Library Item Type"}}},{"caption":"Low-Cost Manufacturing Technique for Advanced Regenerative Cooling for In-Space Cryogenic Engines, Phase II","file":{"fileExtension":"jpg","fileId":296431,"fileName":"SBIR_2012_2_BC_H2.02-8607","fileSize":38076,"objectId":292961,"objectType":{"lkuCodeId":889,"code":"LIBRARY_ITEMS","description":"Library Items","lkuCodeTypeId":182,"lkuCodeType":{"codeType":"OBJECT_TYPE","description":"Object Type"}},"objectTypeId":889,"fileSizeString":"37.2 KB"},"files":[{"fileExtension":"jpg","fileId":296431,"fileName":"SBIR_2012_2_BC_H2.02-8607","fileSize":38076,"objectId":292961,"objectType":{"lkuCodeId":889,"code":"LIBRARY_ITEMS","description":"Library Items","lkuCodeTypeId":182,"lkuCodeType":{"codeType":"OBJECT_TYPE","description":"Object Type"}},"objectTypeId":889,"fileSizeString":"37.2 KB"}],"id":292961,"title":"Briefing Chart Image","description":"Low-Cost Manufacturing Technique for Advanced Regenerative Cooling for In-Space Cryogenic Engines, Phase II","libraryItemTypeId":1095,"projectId":17966,"primary":true,"publishedDateString":"","contentType":{"lkuCodeId":1095,"code":"IMAGE","description":"Image","lkuCodeTypeId":341,"lkuCodeType":{"codeType":"LIBRARY_ITEM_TYPE","description":"Library Item Type"}}}],"transitions":[{"transitionId":64456,"projectId":17966,"partner":"Other","transitionDate":"2014-04-01","path":"Advanced From","relatedProjectId":16149,"relatedProject":{"acronym":"","projectId":16149,"title":"Low-Cost Manufacturing Technique for Advanced Regenerative Cooling for In-Space Cryogenic Engines","startTrl":2,"currentTrl":4,"endTrl":4,"benefits":"The Mars ascent vehicle (MAV) main engine is one potential opportunity, since the pressure drop penalty incurred by using this cooling approach is minimal. A low-cost, high-performance chamber made from relatively ordinary materials could easily replace the radiation-cooled, refractory/precious metal spacecraft engines. The next generation engine (NGE) will likely be an advanced expander cycle upper stage engine, and represents a NASA and Air Force opportunity for this technology. An expander cycle engine would benefit greatly from the reduced pressure drop, either by an increase in chamber pressure and thrust or in MCC and turbomachinery life. The Space Launch System (SLS) Program is another opportunity, particularly since the expendable boosters will be competed. PWR, our commercialization partner, is working to define booster concepts, and their engines, that would also benefit from a low-cost, high-performance regenerative cooling scheme. Since we have partnered with them on this technology, it presents an unusually good commercialization opportunity.The NASA SBIR and STTR programs fund the research, development, and demonstration of innovative technologies that fulfill NASA needs as described in the annual Solicitations and have significant potential for successful commercialization. If you are a small business concern (SBC) with 500 or fewer employees or a non-profit RI such as a university or a research laboratory with ties to an SBC, then NASA encourages you to learn more about the SBIR and STTR programs as a potential source of seed funding for the development of your innovations.
The SBIR and STTR programs have 3 phases:
The SBIR and STTR Phase I contracts last for 6 months with a maximum funding of $125,000, and Phase II contracts last for 24 months with a maximum funding of $750,000 - $1.5 million.
Opportunity for Continued Technology Development Post-Phase II:
The NASA SBIR/STTR Program currently has in place two initiatives for supporting its small business partners past the basic Phase I and Phase II elements of the program that emphasize opportunities for commercialization. Specifically, the NASA SBIR/STTR Program has the Phase II Enhancement (Phase II-E) and Phase II eXpanded (Phase II-X) contract options.
Please review the links below to obtain more information on the SBIR/STTR programs.
Provides an overview of the SBIR and STTR programs as implemented by NASA
Provides access to the annual SBIR/STTR Solicitations containing detailed information on the program eligibility requirements, proposal instructions and research topics and subtopics
Schedule and links for the SBIR/STTR solicitations and selection announcements
Federal and non-Federal sources of assistance for small business
Search our complete archive of awarded project abstracts to learn about what NASA has funded
Still have questions? Visit the program FAQs
","programId":73,"responsibleMd":{"acronym":"STMD","canUserEdit":false,"city":"","external":false,"linkCount":0,"organizationId":4875,"organizationName":"Space Technology Mission Directorate","organizationType":"NASA_Mission_Directorate","naorganization":false,"organizationTypePretty":"NASA Mission Directorate"},"responsibleMdId":4875,"stockImageFileId":36648,"title":"Small Business Innovation Research/Small Business Tech Transfer"},"lastUpdated":"2024-1-10","releaseStatusString":"Released","viewCount":327,"endDateString":"Nov 2013","startDateString":"May 2013"},"infoText":"Advanced from another project within the program","infoTextExtra":"Another project within the program (Low-Cost Manufacturing Technique for Advanced Regenerative Cooling for In-Space Cryogenic Engines)","dateText":"April 2014"}],"primaryImage":{"file":{"fileExtension":"jpg","fileId":296431,"fileSizeString":"0 Byte"},"id":292961,"description":"Low-Cost Manufacturing Technique for Advanced Regenerative Cooling for In-Space Cryogenic Engines, Phase II","projectId":17966,"publishedDateString":""},"responsibleMd":{"acronym":"STMD","canUserEdit":false,"city":"","external":false,"linkCount":0,"organizationId":4875,"organizationName":"Space Technology Mission Directorate","organizationType":"NASA_Mission_Directorate","naorganization":false,"organizationTypePretty":"NASA Mission Directorate"},"program":{"acronym":"SBIR/STTR","active":true,"description":"The NASA SBIR and STTR programs fund the research, development, and demonstration of innovative technologies that fulfill NASA needs as described in the annual Solicitations and have significant potential for successful commercialization. If you are a small business concern (SBC) with 500 or fewer employees or a non-profit RI such as a university or a research laboratory with ties to an SBC, then NASA encourages you to learn more about the SBIR and STTR programs as a potential source of seed funding for the development of your innovations.
The SBIR and STTR programs have 3 phases:
The SBIR and STTR Phase I contracts last for 6 months with a maximum funding of $125,000, and Phase II contracts last for 24 months with a maximum funding of $750,000 - $1.5 million.
Opportunity for Continued Technology Development Post-Phase II:
The NASA SBIR/STTR Program currently has in place two initiatives for supporting its small business partners past the basic Phase I and Phase II elements of the program that emphasize opportunities for commercialization. Specifically, the NASA SBIR/STTR Program has the Phase II Enhancement (Phase II-E) and Phase II eXpanded (Phase II-X) contract options.
Please review the links below to obtain more information on the SBIR/STTR programs.
Provides an overview of the SBIR and STTR programs as implemented by NASA
Provides access to the annual SBIR/STTR Solicitations containing detailed information on the program eligibility requirements, proposal instructions and research topics and subtopics
Schedule and links for the SBIR/STTR solicitations and selection announcements
Federal and non-Federal sources of assistance for small business
Search our complete archive of awarded project abstracts to learn about what NASA has funded
Still have questions? Visit the program FAQs
","programId":73,"responsibleMd":{"acronym":"STMD","canUserEdit":false,"city":"","external":false,"linkCount":0,"organizationId":4875,"organizationName":"Space Technology Mission Directorate","organizationType":"NASA_Mission_Directorate","naorganization":false,"organizationTypePretty":"NASA Mission Directorate"},"responsibleMdId":4875,"stockImageFileId":36648,"title":"Small Business Innovation Research/Small Business Tech Transfer"},"leadOrganization":{"acronym":"ASI","canUserEdit":false,"city":"Huntsville","congressionalDistrict":"Alabama 05","country":{"abbreviation":"US","countryId":236,"name":"United States"},"countryId":236,"external":true,"linkCount":0,"organizationId":4418,"organizationName":"Analytical Services, Inc.","organizationType":"Industry","stateTerritory":{"abbreviation":"AL","country":{"abbreviation":"US","countryId":236,"name":"United States"},"countryId":236,"name":"Alabama","stateTerritoryId":18},"stateTerritoryId":18,"msiData":{},"setAsideData":["Minority-Owned Business","Small Disadvantaged Business (SDB)"],"ein":"471979101 ","uei":"K5Y3MDHD2MB5","naorganization":false,"organizationTypePretty":"Industry"},"supportingOrganizations":[{"acronym":"GRC","canUserEdit":false,"city":"Cleveland","country":{"abbreviation":"US","countryId":236,"name":"United States"},"countryId":236,"external":false,"linkCount":0,"organizationId":4860,"organizationName":"Glenn Research Center","organizationType":"NASA_Center","stateTerritory":{"abbreviation":"OH","country":{"abbreviation":"US","countryId":236,"name":"United States"},"countryId":236,"name":"Ohio","stateTerritoryId":23},"stateTerritoryId":23,"naorganization":false,"organizationTypePretty":"NASA Center"}],"statesWithWork":[{"abbreviation":"AL","country":{"abbreviation":"US","countryId":236,"name":"United States"},"countryId":236,"name":"Alabama","stateTerritoryId":18},{"abbreviation":"OH","country":{"abbreviation":"US","countryId":236,"name":"United States"},"countryId":236,"name":"Ohio","stateTerritoryId":23}],"lastUpdated":"2024-1-10","releaseStatusString":"Released","viewCount":639,"endDateString":"Jan 2018","startDateString":"Apr 2014"}}