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Novel non-destructive inspection of the STAR additively manufactured resistojet

Novel non-destructive inspection of the STAR additively manufactured resistojet
Novel non-destructive inspection of the STAR additively manufactured resistojet
Introduction

Surrey Satellite Technology Limited (SSTL) has used a low power hot gas system known as a resistojet since 2002, which uses either Butane or Xenon as propellant. This system has flown on 20 spacecraft including the European GPS Galileo Testbed GIOVE-A validation satellite. This low cost and relatively low temperature resistojet significantly improves the performance of traditional cold gas propulsion systems. A collaborative development programme between the University of Southampton and Surrey Satellite Technologies Limited (SSTL) is currently proceeding to develop a Super-high Temperature Additive-manufactured Resistojet (STAR), which nearly doubles current ISP performance. The STAR is designed to increase the stagnation temperature of the propellant to approximately 3,000 K. Multiphysics models predict the total thruster efficiency to be in the range of 65-90%, resulting in an ISP for xenon propellant above 80s. The intricate design of the resistojet, as well as the high temperatures involved present significant design, manufacturing and materials challenges. The University of Southampton have identified novel solutions to these issues in a research programme that includes electrothermal simulations, additive manufacturing, performance testing and ultimately the validation of a breadboard model thruster.

Discussion

The paper presents the design, manufacturing and postproduction analysis of a novel high-temperature spacecraft resistojet heat exchanger manufactured through selective laser melting to validate the manufacturing approach. The work includes the analysis of critical features of a heat exchanger with integrated converging-diverging nozzle as a single piece element. The metrology of the component is investigated using optical analysis and profilometry to verify the integrity of components. A novel process of high-resolution micro-Computed Tomography (CT) is applied as a tool for volumetric non-destructive inspection and conformity since the complex geometry of the thruster does not allow internal examination.

The CT volume data is utilised to determine a surface mesh on which a novel performed coordinate measurement technique is applied for nominal/actual comparison and wall thickness analysis. A thin-wall concentric tubular heat exchanger design is determined to meet dimensional accuracy requirements through nominal/actual comparison analysis.

Conclusion

The work indicates the production of fine structures with feature sizes below 200 μm in 316L stainless via selective laser melting is feasible and opens up new possibilities for the future developments in multiple industries. The paper will also include the non-destructive inspection of Inconel and refractory alloys via the same method.

Bibliography

Romei, F., Grubišić, A., Gibbon, D. Performance Testing and Evaluation of High Temperature Xenon Resistojet Prototype Manufactured by Selective Laser Melting. 35th IEPC, Atlanta, Georgia, USA, 0CT. 2017
Ogunlesi, Christopher
d7a11918-d503-4df7-9bd3-1fca49f4d01b
Grubisic, Angelo
a4cab763-bbc0-4130-af65-229ae674e8c8
Romei, Federico
2c01d8c3-430b-49f8-9c8c-e30d0d135f89
Robinson, Matthew, David
27da85d7-512a-4ce6-9e55-7e2e576311d7
Aimone, Paul
df676b25-c763-4db6-bf5b-025e5178d261
Dary, Francois
8e54b21d-eb3a-48a7-b7cb-a946ab794992
Gibbon, Dave
e60476ec-e06b-418d-a71f-bf3a6ae2ecc2
Curtis-Rouse, Mike
706b3fac-493c-44dc-aff6-bdf59362c2fb
Ogunlesi, Christopher
d7a11918-d503-4df7-9bd3-1fca49f4d01b
Grubisic, Angelo
a4cab763-bbc0-4130-af65-229ae674e8c8
Romei, Federico
2c01d8c3-430b-49f8-9c8c-e30d0d135f89
Robinson, Matthew, David
27da85d7-512a-4ce6-9e55-7e2e576311d7
Aimone, Paul
df676b25-c763-4db6-bf5b-025e5178d261
Dary, Francois
8e54b21d-eb3a-48a7-b7cb-a946ab794992
Gibbon, Dave
e60476ec-e06b-418d-a71f-bf3a6ae2ecc2
Curtis-Rouse, Mike
706b3fac-493c-44dc-aff6-bdf59362c2fb

Ogunlesi, Christopher, Grubisic, Angelo, Romei, Federico, Robinson, Matthew, David, Aimone, Paul, Dary, Francois, Gibbon, Dave and Curtis-Rouse, Mike (2018) Novel non-destructive inspection of the STAR additively manufactured resistojet. Space Propulsion 2018, Seville, Spain. 14 - 18 May 2018.

Record type: Conference or Workshop Item (Paper)

Abstract

Introduction

Surrey Satellite Technology Limited (SSTL) has used a low power hot gas system known as a resistojet since 2002, which uses either Butane or Xenon as propellant. This system has flown on 20 spacecraft including the European GPS Galileo Testbed GIOVE-A validation satellite. This low cost and relatively low temperature resistojet significantly improves the performance of traditional cold gas propulsion systems. A collaborative development programme between the University of Southampton and Surrey Satellite Technologies Limited (SSTL) is currently proceeding to develop a Super-high Temperature Additive-manufactured Resistojet (STAR), which nearly doubles current ISP performance. The STAR is designed to increase the stagnation temperature of the propellant to approximately 3,000 K. Multiphysics models predict the total thruster efficiency to be in the range of 65-90%, resulting in an ISP for xenon propellant above 80s. The intricate design of the resistojet, as well as the high temperatures involved present significant design, manufacturing and materials challenges. The University of Southampton have identified novel solutions to these issues in a research programme that includes electrothermal simulations, additive manufacturing, performance testing and ultimately the validation of a breadboard model thruster.

Discussion

The paper presents the design, manufacturing and postproduction analysis of a novel high-temperature spacecraft resistojet heat exchanger manufactured through selective laser melting to validate the manufacturing approach. The work includes the analysis of critical features of a heat exchanger with integrated converging-diverging nozzle as a single piece element. The metrology of the component is investigated using optical analysis and profilometry to verify the integrity of components. A novel process of high-resolution micro-Computed Tomography (CT) is applied as a tool for volumetric non-destructive inspection and conformity since the complex geometry of the thruster does not allow internal examination.

The CT volume data is utilised to determine a surface mesh on which a novel performed coordinate measurement technique is applied for nominal/actual comparison and wall thickness analysis. A thin-wall concentric tubular heat exchanger design is determined to meet dimensional accuracy requirements through nominal/actual comparison analysis.

Conclusion

The work indicates the production of fine structures with feature sizes below 200 μm in 316L stainless via selective laser melting is feasible and opens up new possibilities for the future developments in multiple industries. The paper will also include the non-destructive inspection of Inconel and refractory alloys via the same method.

Bibliography

Romei, F., Grubišić, A., Gibbon, D. Performance Testing and Evaluation of High Temperature Xenon Resistojet Prototype Manufactured by Selective Laser Melting. 35th IEPC, Atlanta, Georgia, USA, 0CT. 2017

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More information

In preparation date: 2018
Published date: 18 May 2018
Venue - Dates: Space Propulsion 2018, Seville, Spain, 2018-05-14 - 2018-05-18

Identifiers

Local EPrints ID: 417166
URI: https://eprints.soton.ac.uk/id/eprint/417166
PURE UUID: 860c4d0b-10d4-4835-b837-fa259e0e885e
ORCID for Federico Romei: ORCID iD orcid.org/0000-0003-2283-4658

Catalogue record

Date deposited: 23 Jan 2018 17:30
Last modified: 14 Jul 2018 04:01

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