Arcjet Segment Development

This SBIR-sponsored research and development will create a simple, cost-effective, and reliable fabrication process to construct arc heater constrictor segments. Currently, a single company, utilizing a proprietary, sophisticated process, which still results in a significant failure rate, fabricates nearly all such segments. This proposal offers several design concepts to be considered in Phase I, some of which have already been tested in operating arc heaters. Prototype segments demonstrating these alternatives will be designed, constructed, and evaluated to determine the optimal design and construction procedure, which may be dependent on required performance objectives. The improved design resulting from this R&D effort will not only reduce costs, likely by eliminating the costly furnace brazing with a much simpler and more straightforward e-beam welding process, but it will also allow segments to be manufactured by a much wider selection of vendors, permitting competition and mitigating procurement conflicts due to having a sole source. Sierra Lobo's arc heater system expertise gained in the NASA Ames Research Center Arc Jet Complex, high-performance thermal and mechanical test system design experience, flight-hardware machining capabilities, and relationships with important arc jet developers make it uniquely qualified to undertake this project.