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Completed TRL 2 (started at 1, targeting 2)
NASA’s endeavors in cis-lunar, lunar, and Martian exploration all benefit from being able to use cryogenic fueled methods of propulsion. However, maintaining the cryogenic temperatures those propellants require, poses a significant challenge, and remains an obstacle for its efficient use as a mode of in-space travel.
The core objective of this initiative was to facilitate improved manufacturability, significantly enhanced performance, and substantial mass reduction across various propulsion system components. A specific focus was placed on cryocoolers, which served as essential systems for maintaining the necessary propellant temperatures throughout missions. Within these cryocoolers, cryogenic recuperators (also known as Heat Exchangers) were identified as key components dictating overall system performance. The project sought to drastically reduce the cost and simultaneously increase the thermal and hydraulic performance of these recuperators through the strategic application of Additive Manufacturing (AM) technologies.
AM enabled designers to capitalize on the fabrication of complex geometries with intricate internal structures and fine channel sizes, configurations that were difficult or entirely impossible to achieve with conventional manufacturing practices. Beyond driving down production costs, the primary technical goals centered on measurable improvements in several areas: increasing thermal heat exchange efficiency, achieving substantial reductions in mass and volume, and minimizing pressure drops across the component. Furthermore, the program explored innovative materials and unique material properties that were specifically produced and optimized through the advanced additive manufacturing processes, ultimately yielding a new generation of high-performance cryogenic heat exchangers capable of meeting the stringent demands of deep space exploration.
The goal is to demonstrate the capabilities of a novel recuperative heat exchanger design that makes use of AM or other innovative manufacturing methodology. Design should exhibit a reduced cost and schedule from traditional heat exchanger designs (shell and tube), and/or improved performance characteristics.
The desired deliverable is a recuperator design, a test article and analysis to predict performance. Additional testing or validation via a test article is highly desired.
The requirements for this concept are flexible to account for design innovation but are expected to be around the following:
Power Density: ~100 W/Kg, priority – high
Effectiveness: >0.97, priority - high
Operating temperatures: Cold side – 90K, Hot Side – 300K
Operating pressure: ~150psi
Secondary objectives would be to facilitate a working fluid (neon) at a rate >20 gm/s, and to minimize pressure drop
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