NASA Technical Reports Server (NTRS) 20170000895: Advanced Manufacturing Technology

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by  NASA Technical Reports Server (NTRS)

Space Technology Mission Directorate
Game Changing Development Program
National Aeronautics and
Space Administration
2017 1st Quarter Review
Advanced Manufacturing Technology
Presented By: John Fikes
January 2017
TECHNOLOGY DRIVES EXPLORATION
2017 GCD 1stQuarter Review
AMT Project Manager Annual
Assessment
Technology Performance Comments
T C S P
Technical is yellow due to the EBF3 process to add an inconel
structural jacket to the GRCop-84 liner is producing cracks along
forward and aft ends at the inconel/GRCop-84 interface. Currently
Low Cost implementing trial on Unit 2.1 as part of the approved recovery
Upper Stage plan.
Class Cost is yellow due to the new recovery plan requiring more
Propulsion resources at LaRC. Project is carrying as a “threat” for now.
Actual increase will not be realized until later in FY17.
Schedule is yellow due to minimum schedule reserves in current
plan approved by change request.
Additive Technical is yellow due to on-going challenges to meet the U.S.
Construction Army Corp of Engineers (USACE) requirements with their current
with Mobile material (3/8th inch aggregate). Schedule is yellow due to
Emplacement minimum schedule reserves for meeting ACES 3 hardware
(ACME) deliverables.
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2017 GCD 1stQuarter Review
Resources: Non-Labor Obligations and
Cost
FY 2017 Non-Labor Financial Status
$1,000 $3,500
$900
$3,000
$800
$700 $2,500
$600
$2,000
$500
$400 $1,500
$300
$1,000
$200
$500
$100
$0
$0
OCT NOV DEC JAN FEB MAR APR MAY JUN JUL AUG SEP
Actuals - Obs Actuals - Cost Phasing Plan - Obs Phasing Plan - Cost Guideline Forecast - Obs Forecast - Cost
Cum ($K) Carry-In PY11-16 Funds OCT NOV DEC JAN FEB MAR APR MAY JUN JUL AUG SEP Carry Out
Guideline 65.0 2,559.0 2,559.0 2,559.0 2,559.0 2,559.0 2,559.0 2,559.0 2,559.0 2,559.0 2,559.0 2,559.0 2,559.0
Phasing Plan (RLP) 276.5 553.0 829.5 1,265.4 1,701.2 2,137.1 2,417.1 2,697.0 2,977.0 3,046.7 3,116.3 3,186.0 (621.6)
s
b Actuals 65.0 59.6 11.8 52.3 106.7
O
Forecast 11.8 52.3 106.7 5 42.6 978.4 1,414.3 1,694.2 1,974.2 2 ,254.2 2,323.8 2,393.5 2,463.2 101.3
Phasing Plan (RLP) 61.0 122.0 183.0 538.7 894.4 1,250.1 1,626.9 2,003.6 2,380.4 2,661.0 2,941.7 3,222.3 555.0
st
o Actuals 901.3 364.1 0.0 7.2 23.9
C
Forecast - 7.2 23.9 3 79.6 735.3 1,091.0 1,467.8 1,844.5 2 ,221.3 2,501.9 2,782.6 3,063.2 (8.7)
Note: Carry-In is the unobligated/uncosted portion of PY11-16 funding end of FY16
YTD Status Explanation required for YTD Variance in excess of 5% from Phasing Plan (shaded red)
bs Phasing $ 830 Currently operating under CR thru April 2017. Contractual commitments/obligations are on-going and are expected
7 O Actuals $ 107 to start catching up during the 2ndquarter of FY2017. Project activities on-going and there have been no impact to
'1 Variance $ ( 723) project milestones.
st Phasing $ 183
o Currently operating under CR thru April 2017. Project utilizing uncostedFY2016 carryover for management support
C
7 Actuals $ 24 activities. Project activities on-going and no impact to project at this time.
1
' Variance $ ( 159)
2017 GCD 1stQuarter Review 10
Resources: Total Project Workforce
FTEs/WYEs
2017 GCD 1stQuarter Review 11
AMT Milestones and Forward Plans
Green = Controlled Milestone
Bold Black = Key Milestone
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2017 GCD 1stQuarter Review
Risk Summary
Approac
LC 1
5
ID Trend h/ Risk Title
L Affinity
I
AC15 W/Sc Facility Operating Space
4
K
E AC19 M/T Safety Keep Out Zones CLOSED
L
AC15 Integration, Testing Space (Weather
3 AC20 M/Sc
I AC22 Impacts) CLOSED
H
AC21 M/T Hose Management CLOSED
O
2 AC24 AC23
Logistics for Fabrication, Assembly,
O
AC22 Sc/C
Integration
D
LC8
AC23 T Nozzle Development and Test
1
AC24 T Accumulator Development and Test
1 2 3 4 5
CONSEQUENCES LC1* M/T,C,Sc EBF3 weld technology
Criticality L x C Trend Approach
LC8* M/T GRCop-84 and Inconel625 Interface flaws
Decreasing (Improving) M - Mitigate
High
Increasing (Worsening) W - Watch
only high and medium risks are
Med Unchanged A -Accept
shown on summary chart
New Since Last Period R - Research
Low
Affinity: T-Technical C-Cost Sc-Schedule
Sa-Safety
* LCUSP risks currently under revision
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2017 GCD 1stQuarter Review
Advanced Manufacturing Technology
Low Cost Upper Stage-
Class Propulsion
2017 GCD 1stQuarter Review
Advanced Manufacturing Technology
LCUSP Overview
The LCUSP will demonstrate the ability to produce a low cost upper stage-class propulsion component system using additive
manufacturing technologies. LCUSP will do this by (1) developing a copper alloy additive manufacturing design process, (2)
developing a new Nickel Jacket additive manufacture/application process (3) additive manufacture of a 35K-class regenerative
chamber/nozzle, (4) testing chamber and then chamber/nozzle system in a hot fire resistance test.
Integration with other projects/programs and partnerships Technology Infusion Plan:
Liquid Propulsion System (LPS) Test Bed (being developed at MSFC with additive PC, Propulsion, HEOMD, Potential use in
manufactured components such as injectors, LOxand H Turbopumpsplans to utilize
2 manufacturing process of flight engines
the LCUSP Combustion Chamber or utilize the capability established under this project
to fabricate a chamber. Test and Fabrication Data infused into Lander Technology 2017. Military & Industry, SpaceX, Aerojet-
Office methane thruster work. Follow-on regen Methane Engine Thrust Assembly for
Rocketdyne, Orbital-ATK, ULA, Blue Origin,
4K lbf(META4) chamber design utilized SLM GRCop-84 process developed by LCUSP
ASRC Federal, numerous copper machine
and incorporates LCUSP chamber mid-line weld design to enable required
length. LCUSP printed faceplate provided strength, conductivity, and oxidation shops, suppliers, and electronics
resistance needed for staged combustion testing in a much shorter time than it would
manufactories.
have taken to procure stock and machine a traditionally fabricated GRCopfaceplate,
allowing MSFC to provide the first US data to USAF SMC. Industry partners are
investigating possible partnerships with LCUSP for possible opportunities for fabrication
of SLM combustion chambers to reduce cost of engine development.
Key Personnel: Key Facts:
Project Manager: John Fikes GCD Theme: LMAM, Lightweight Materials and
Project Element Manager: Eric Eberly Advanced Manufacturing
Lead Center: MSFC Execution Status: Year 3 of 3
Supporting Centers: LaRC & GRC Technology Start Date: April 2014
NASA NPR: 7120.8 Technology End Date: September 2017
Guided or Competed: Guided Technology TRL Start: 3
Type of Technology: Push Technology TRL End: 6
Technology Current TRL: 4/5
Technology Lifecycle Phase: Implementation
(Phase C/D)
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2017 GCD 1stQuarter Review
LCUSP Component and System
TRL Quarterly Assessment
Use in applicable environment
SLM
Material testing & analysis
Fabrication process development
Use in applicable environment
EBF3
Material testing & analysis
Fabrication process development
Lox/Methane Chamber &
Chamber Hot Nozzle Hot
Fire Test Fire Test
6
Chamber
Additive
Hot Fire Test
Manufacture
of Chamber
5
EBF3 Bonded
LR Procewssit hD eGvReClooppment Samples Testing JaCcokmetp &le Mtea EnBifFo3l d SLM & EBF3 PDK
T EBF3 on SLM on GRCopLiner Process n
EBF3 on 18150 Cu GRCop-84 Refinements (TBD) ois
Alloy u
4 fn
I n
o
Initial GRCop Machining, is
s
Metallography, & iM
Process Development Mechanical Testing
with 18150 Cu Alloy
3
FY15 FY16 FY17
Cu Alloy material Characterization Controlled Milestones
Cu Alloy manufacturing process development
Ni Alloy deposition to Cu Alloys Key Milestone Goal
Actual Value
Additive Manufacturing of upper stage components
Predicted Value
2017 GCD 1stQuarter Review
Advanced Manufacturing Technology
LCUSP Performance
• Technology Advancements
 Selective Laser Melting (SLM) fabrication with GRCop-84 powder for rocket components (combustion chamber).
 Electron Beam Free Form Fabrication (EBF3) application of In625 on SLM GRCop-84 (structural jacket for combustion chamber).
• Technology advances mean
 Additive Manufacturing techniques to reduce cost and shorten schedule as well as produce intricate rocket propulsion
components that may have been expensive or impossible to build with conventional techniques.
• This is push technology
 Missions that require new propulsion systems can take advantage of this technology.
Key Performance Parameters
Performance
State of the Art Threshold Value Project Goal Estimated Current Value
Parameter
Processcontrol SLM demonstrated with Demonstrate parameterset that Developan optimized parameter set to GRCopSLM process yielding >99% dense
of using Copper Inconel 718,Inconel 625, allows fabrication of monolithic maximize build speed, control surface parts with properties comparable to
via SLM and Al 357, and CoCrby structures to be used for finish, and maximize mechanical traditionallymanufactured GRCop84
MSFC, but not with copper mechanical properties and surface properties of SLM copper samples.
finish testing External vendor has extended process to
commercial application.
Copper alloy Not established for copper SLM’dGRCop-84 thermal 90% of baseline extruded GRCop-84 GRCopSLM process yielding >99% dense
material conductivity at 90% of baseline material properties parts with properties comparable to
characterization extruded GRCopand remaining traditionallymanufactured GRCop84
using SLM material properties at or greater samples.
than those of OFHC Copper
Deposition of Demonstrated for pure Deposition of nickel alloy to copper Depositionof nickel alloy onto copper Depositionprocess developed. Joint
nickelalloy to nickel to pure copper, but alloy that remains intact at the alloy with a ductile transition zone and samples microscopy inspection and pull
SLM Copper not for nickel alloys to bond through a thermalcycle and mechanical properties equivalent to cast tests with no initial cracking show sufficient
copperalloys with minimum defects annealed condition bond strength for designapplication.
Further properties samples and process
improvements to remove cracking being
developed and tested.
Manufacture of SLM upper stage engine Demonstratebuild of subscale Demonstrate build of full-scale monolithic Full scale H2 chamber go forward path
AM upper stage components demonstrated components or subassemblies with GRCopcomponent parts with materials developed. Successfulmethane tests of
engine with Inconel 718, Inconel properties and geometry sufficient properties and geometric tolerance SLM printed chamber occurred 08/10/2016.
components 625 by MSFC, but not with to be utilized in initial subscale meeting key design features that allow
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2017 GCD 1stQuaCrtoeprp Rere (vGieRwCop) chambers testing successful tests with flightlike conditions