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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Additive Manufacturing and Working Fluid Characterization of Ceramic Heat Pipes

In this work, additively manufactured aluminum nitride (AlN) ceramic heat pipes are developed to improve spacecraft heat rejection capabilities beyond the current state-of-the-art metal systems. Printed AlN parts are characterized via SEM, EDS, X-ray diffraction, optical profilometry, thermal conductivity, and emissivity testing. AlN 3D-printed parts are also tested for compatibility with aluminum bromide, aluminum chloride, and iodine, among other proposed working fluids at 500-600 K in vacuum.

Thermal management↗
NASA NTRS2018

Three-Dimensional Printing GRCop-42

GRCop-42 (Cu-4 at.% Cr-2 at.% Nb) is a copper (Cu)-chromium (Cr)-niobium (Nb) alloy that NASA developed for use in rocket propulsion components that required high thermal conductivity, excellent creep resistance, low-cycle fatigue life, and strength at elevated temperatures, such as combustion chamber liners and fuel injector face plates. Using powder bed fusion (PBF) 3D printing, NASA Marshall Space Flight Center (MSFC) and NASA Glenn Research Center (GRC) successfully printed near-fully-dense GRCop-42 components that may equal to or exceed their traditionally manufactured predecessors. This Technical Memorandum serves to summarize the process that was developed to achieve 3D printable near-fully-dense and functional GRCop-42.

Cooper, K. G.↗
NASA NTRS2017

Application of Temperature-Controlled Thermal Atomization for Printing Electronics in Space

Additive Manufacturing (AM) is a technology that builds three dimensional objects by adding material layer-upon-layer throughout the fabrication process. The Electrical, Electronic and Electromechanical (EEE) parts packaging group at Marshall Space Flight Center (MSFC) is investigating how various AM and 3D printing processes can be adapted to the microgravity environment of space to enable on demand manufacturing of electronics. The current state-of-the art processes for accomplishing the task of printing electronics through non-contact, direct-write means rely heavily on the process of atomization of liquid inks into fine aerosols to be delivered ultimately to a machine's print head and through its nozzle. As a result of cumulative International Space Station (ISS) research into the behaviors of fluids in zero-gravity, our experience leads us to conclude that the direct adaptation of conventional atomization processes will likely fall short and alternative approaches will need to be explored. In this report, we investigate the development of an alternative approach to atomizing electronic materials by way of thermal atomization, to be used in place of conventional aerosol generation and delivery processes for printing electronics in space.

Wu, Chih-Hao↗
NASA NTRS2018

Lightweight, Durable, and Multifunctional Electrical Insulation Material Systems for High Voltage Applications

Newly developed multilayer structures of well-known polymer insulation materials significantly improved dielectric breakdown voltage, VB, or dielectric strength, K, if well-bonded, when compared to those of single material insulations or the commercial SOA systems, such as Teflon-Kapton-Teflon (TKT), at the same overall thickness. To date, the greatest improvement of the new structures from a few candidate materials, including various types of Kapton PIs and PFA or PET as bond layer (BL), was about 61% higher than that of the Kapton PI alone films, 40.1 vs. 24.9 kV, which was translated to 86.3% decrease in insulation thickness, thus significant volume and weight reduction of the final system. However, it was of interest to note that most improvements of the multilayer structures occurred at thicker overall thicknesses, above ~ 0.15 mm. Extensive analyses also showed that K of the multilayer structures increased with (i) decreasing individual layer thickness regardless of material type, (ii) increasing total accumulated thickness of PI or overall PI/BL ratio, and (iii) increasing number of interface or total number of layers, but only above the aforementioned overall thickness limit. Increases in VB of the multilayer structures were directly correlated with damage evolution and failure mode. With further material-design-process optimizations of the multilayer structures, it was expected to achieve other multifunctionalities, such as high partial discharge (PD) resistance, improved durability, EMI shielding, and high thermal dissipation in addition to high dielectric strength. These new structures can be used in various high voltage and high temperature applications, such as future hybrid or all electric aircraft wiring and power transmission as well as many other non-aerospace high power cables, electronic parts and components, printed circuit board, and so forth. The multilayer insulation system can be easily processed and manufactured with various conductor types via calendaring, compression-molding, stamping, laminating, vacuum-bagging and autoclaving, or 3D printing, even for complex 3-D components. Based on their unique structural configurations and potential capabilities, the new insulation system was identified as micro-multilayer multifunctional electrical insulation (MMEI). Patent application of the MMEI concept and current design configurations was filed for a 1-year provisional application (OAI-58834, Serial No.: 62/659,234), pending conversion to a U.S. utility application. This paper presents details of the MMEI structures, their dielectric performance analyses, potential mechanisms, and commercial scaleup feasibility assessment.

Electric aircrafts↗
NASA NTRS2018

Lightweight, Durable, and Multifunctional Electrical Insulation Material Systems for High Voltage Applications

Newly developed multilayer structures of well-known polymer insulation materials significantly improved dielectric breakdown voltage, VB, or dielectric strength, K, if well-bonded, when compared to those of single material insulations or the commercial SOA systems, such as Teflon-Kapton-Teflon (TKT), at the same overall thickness. To date, the greatest improvement of the new structures from a few candidate materials, including various types of Kapton PIs and PFA or PET as bond layer (BL), was about 61% higher than that of the Kapton PI alone films, 40.1 vs. 24.9 kV, which was translated to 86.3% decrease in insulation thickness, thus significant volume and weight reduction of the final system. However, it was of interest to note that most improvements of the multilayer structures occurred at thicker overall thicknesses, above ~ 0.15 mm. Extensive analyses also showed that K of the multilayer structures increased with (i) decreasing individual layer thickness regardless of material type, (ii) increasing total accumulated thickness of PI or overall PI/BL ratio, and (iii) increasing number of interface or total number of layers, but only above the aforementioned overall thickness limit. Increases in VB of the multilayer structures were directly correlated with damage evolution and failure mode. With further material-design-process optimizations of the multilayer structures, it was expected to achieve other multifunctionalities, such as high partial discharge (PD) resistance, improved durability, EMI shielding, and high thermal dissipation in addition to high dielectric strength. These new structures can be used in various high voltage and high temperature applications, such as future hybrid or all electric aircraft wiring and power transmission as well as many other non-aerospace high power cables, electronic parts and components, printed circuit board, and so forth. The multilayer insulation system can be easily processed and manufactured with various conductor types via calendaring, compression-molding, stamping, laminating, vacuum-bagging and autoclaving, or 3D printing, even for complex 3-D components. Based on their unique structural configurations and potential capabilities, the new insulation system was identified as micro-multilayer multifunctional electrical insulation (MMEI). Patent application of the MMEI concept and current design configurations was filed for a 1-year provisional application (OAI-58834, Serial No.: 62/659,234), pending conversion to a U.S. utility application. This paper presents details of the MMEI structures, their dielectric performance analyses, potential mechanisms, and commercial scaleup feasibility assessment.

Multifunctional↗
NASA NTRS2014

NASA GSFC Strategic Nanotechnology Interests: Symposium on High‐Rate Nanoscale Printing for Devices and Structures

The seminars invitees include representatives from industry, nonprofit research facility and universities. The presentation provides an overview of the NASAGSFC locations, technical capabilities and applied nanotechnology interests. Initially presented are advances by the broader technological communities on current miniaturized multiscale advanced manufacturing and 3D printing products on the micro and macro scale. Briefly assessed is the potential of moving toward the nanoscale for possible space flight applications and challenges. Lastly, highlighted are GSFCs current successes in nano-technology developments and targeted future applications.

APPLIED NANOTECHNOLOGY↗
NASA NTRSDate not supplied

Fast Assessment of Metal Performance through Dislocation Physics and Machine Learning

The microstructure of metals is key to their mechanical properties. The types, density, composition and morphology of crystal defects all have pronounced impact on the properties. Changes to the microstructure occurring during processing and use can be very striking. The emerging technology additive manufacturing (AM) has the potential to improve performance by allowing optimized designs, but the process and environments can lead to unusual microscale features whose properties must be understood and characterized to enable higher technological readiness levels and application. Experimentally, an extensive evaluation of mechanical properties of 3D printed metals is a challenge, and anomalous effects related to the AM process add complexity. We present a new machine learning (ML) model predicting mechanical response based on dislocation mediated plasticity simulations. A large set of 3D discrete dislocation dynamics simulations with wide ranges of loading conditions is transformed to preprocessed data ready for training with the ML model. The trained model can predict the mechanical response of Mo30W for a given microstructure evolution, providing key information essential for optimization of AM processing.

Jaehyun Cho↗
NASA NTRSDate not supplied

Fast Assessment of Metal Performance through Dislocation Physics and Machine Learning

The microstructure of metals is key to their mechanical properties. The types, density, composition and morphology of crystal defects all have pronounced impact on the properties. Changes to the microstructure occurring during processing and use can be very striking. The emerging technology additive manufacturing (AM) has the potential to improve performance by allowing optimized designs, but the process and environments can lead to unusual microscale features whose properties must be understood and characterized to enable higher technological readiness levels and application. Experimentally, an extensive evaluation of mechanical properties of 3D printed metals is a challenge, and anomalous effects related to the AM process add complexity. We present a new machine learning (ML) model predicting mechanical response based on dislocation mediated plasticity simulations. A large set of 3D discrete dislocation dynamics simulations with wide ranges of loading conditions is transformed to preprocessed data ready for training with the ML model. The trained model can predict the mechanical response of Mo30W for a given microstructure evolution, providing key information essential for optimization of AM processing.

Jaehyun Cho↗
NASA NTRSDate not supplied

Metabolic Vessel for Impedance Spectroscopy and Electrochemistry (MVISE): The Ground Mapping Unit for the Lunar Explorer Instrument for Space Biology Applications (LEIA)​

The BioSensor payload on the upcoming LEIA platform aboard a CLPS lander will carry yeast to the moon to study response to radiation and lunar gravity. The LEIA BioSensor is designed to monitor metabolic activity using absorbance in conjunction with alamarBlue for measuring colorimetric changes as proxy measurement for redox potential. The science data returned from small spacecraft mission modules like LEIA is limited as it relies solely on optical measurements, necessitating a corresponding ground mapping unit that is equipped with multiple electrochemical sensors for accurate mapping of the optical data and operates fully automatically. This technology development work discusses the extensive design and optimization efforts put into the ground mapping unit, MVISE. MVISE is a custom designed, 3D-printed vessel with an agitation system, with six different electrochemical sensor probes, and ports for sample collection and a pressure release valve. The sensors provide real-time data, with dry absorbance measurements aligning with LEIA flight hardware and wet measurements demonstrating invasive sensor design enabling a comparison between the two setups. The 3D printer resin was tested for mechanical robustness, biocompatibility, and resistance to autoclave sterilization. The inner walls were coated with food-grade epoxy, ensuring a smooth finish to prevent microbial lodging and dye staining. The MVISE has successfully passed a week-long leak test and is now undergoing active biology tests. The MVISE prototype will be prepared for radiation tests, with three identical units being tested for varying radiation levels and culture compositions at the NASA Space Radiation Laboratory in November 2024. The integrated sensor approach proposed in this work will enable the accurate mapping of the BioSentinel/LEIA optical flight data to six sensor parameters on the ground unit for better science data return and will enable the first effort to evaluate classical biochemical sensor measurements by comparing and contrasting their responses.

Chinmayee Govinda Raj↗
NASA NTRS2026

Extrusion-based Additive Manufacturing of Regolith-Filled Shape Memory Vitrimer Composite for Lunar Construction

The National Aeronautics and Space Administration (NASA) is visiting the moon again. This time, the objective is to explore establishing a permanent lunar base. To achieve both longterm human habitation on the moon and future deep space travel, it is crucial to make the most of the in-situ resources and build autonomous systems on the moon to support the construction of a lunar habitat. NASA’s In-situ Resource Utilization (ISRU) program aims to minimize the need to ship heavy prefabricated structures, reducing cost and enhancing sustainability. Here, we developed an economical extrusion method for printing lunar regolith-based composites using shape memory vitrimer as a binder. A rheological study is conducted to determine the extrudability of the composite with different regolith weight percentages. Several characterizations were conducted on the composites. The as-printed composites exhibited compressive and flexural strengths of 73.32 MPa and 156.59 MPa, respectively, and good impact tolerance. The composite maintained 57.92% of its mechanical properties even after the second crack healing cycle. The composites also exhibit shape fixity ratio of 90.02% and shape recovery ratio of 83.46%. The simple synthesis method, sustainability, and good thermomechanical properties make the 3D printed composite an ideal material for lunar construction applications.

Kingsley Yeboah Gyabaah↗
NASA NTRSDate not supplied

Topology Optimization of Low-Speed Aeroelastic Wind Tunnel Models

The goal of this work is to utilize topology optimization methods to obtain low-speed flexible wind tunnel models with simple jig outer mold lines, but highly-tuned aeroelastic flutter behavior. The wing is conceptually constructed with commonly-available 3D printed materials, of which the optimizer may select one of two at every location in the wing; a stiffer material meant to bear the loads, and a softer rubber-like material for space filling, and to form the outer mold line, where needed. Results are shown for three topological parameterizations: 2D topologies with a fixed nondesignable plate through the camber line, 2D parameterizations without the plate, and 3D parameterizations where the topology can vary though the depth of the wing, at a given planform location.

Aeroelasticity↗
NASA NTRSDate not supplied

An Open-Source Numerical Model for Mitigating Refractory Alloy Hot Cracking Susceptibility

Refractory alloys are susceptible to solidification cracking during welding and 3D printing. Composition control is an effective method of controlling solidification cracking. This work evaluates the effect of compositional variation in refractory metal systems on a computed solidification cracking susceptibility. A numerical model has been developed using Python code and open-source CALPHAD software to calculate Kou’s crack susceptibility index. The model is validated against past weldability studies performed on several refractory alloy systems. The approach is extended towards the development of new alloys with improved 3D printability and weldability and is shown to have utility in defining compositional limits for existing alloys and feedstocks. Furthermore, the model will aid in determining process controls for powder reuse and recycling.

pycalphad↗
NASA NTRS2015

Effects of Polyhydroxybutyrate Production on Cell Division

Synthetic biological engineering can be utilized to aide the advancement of improved long-term space flight. The potential to use synthetic biology as a platform to biomanufacture desired equipment on demand using the three dimensional (3D) printer on the International Space Station (ISS) gives long-term NASA missions the flexibility to produce materials as needed on site. Polyhydroxybutyrates (PHBs) are biodegradable, have properties similar to plastics, and can be produced in Escherichia coli using genetic engineering. Using PHBs during space flight could assist mission success by providing a valuable source of biomaterials that can have many potential applications, particularly through 3D printing. It is well documented that during PHB production E. coli cells can become significantly elongated. The elongation of cells reduces the ability of the cells to divide and thus to produce PHB. I aim to better understand cell division during PHB production, through the design, building, and testing of synthetic biological circuits, and identify how to potentially increase yields of PHB with FtsZ overexpression, the gene responsible for cell division. Ultimately, an increase in the yield will allow more products to be created using the 3D printer on the ISS and beyond, thus aiding astronauts in their missions.

Synthetic Biology↗
NASA NTRSDate not supplied

Virtual Fit Assessment: Validation using Historical Spacesuit Fit Data

Virtual fit tests using 3D body scans have provided a cost-effective means to predictively assess spacesuit fit for the current and future astronaut population. However, fit is a complex issue influenced by physical interferences, subjective preference, and many other factors. Fit can substantially differ between the type of hardware, environmental conditions, and tasks being performed. Namely, fit changes across different contexts, such as 3D printed mockup evaluations, pressurized one-g suited test events, neutral buoyancy and other training events, and flight extravehicular activities (EVA). These challenges make it difficult to validate virtual fit frameworks to physical suit sizing. This study proposes a new method of validation using the wealth of historically archived suit fit data. Physically Assessed Fit (PAF) data was assessed from astronauts and test volunteers who wore the legacy Extravehicular Mobility Unit (EMU). The data was collected during the past decades at NASA and considered to be most reliable and dependable. Each participant was 3D scanned for body shape and spacesuit-critical dimensions were measured per NASA guidelines. The participants’ size preference for hard upper torso (HUT) assembly was retrieved from their pressurized suit fit check records. Fit assessments were also updated after one-g EVA training, neutral buoyancy training, and EVA flights. Virtually Assessed Fit (VAF) was done by overlaying the CAD model of a HUT with the 3D body scans of the PAF participants. Each body scan was iteratively adjusted for the position inside the HUT to minimize the suit-to-body contact interference while satisfying a set of prescribed requirements. Then the residual contact area, depth, and volume were quantified as VAF metrics. This process was repeated for the different HUT sizes, including medium, large, and extra-large. Statistical modeling is currently in progress and will be presented at the conference. A statistical classifier will be developed to predict a fit probability for different HUT sizes as a function of the corresponding person’s VAF metrics. The HUT size with the highest fit probability will constitute the most likely size selection for the person, and the prediction will be compared against the corresponding PAF data. The participant data will be randomly pre-grouped into either a model development or validation subset. While the model development subset will be used to build the probability model, the validation subset will be used to assess the model accuracy. Also, the locations and magnitudes of suit-body-contacts will be estimated from VAF. This information can identify the critical suit geometry and body shape features that influence suit fit. The variations found in PAF size selections by subjects with similar VAF metrics will allow for investigations into subjective preferences, for example, tight versus loose fit. Overall, this study is expected to provide a structured validation of a virtual suit fit framework, which has not been possible in the past. The outcome can also provide useful insights and potential limitations for interpreting virtual fit tests for future spacesuit designs and population accommodation.

Han Kim↗
NASA NTRSDate not supplied

Laboratory Radar Measurements in Support of the NASA Orbital Debris Program Office’s Size Estimation Model

The NASA Orbital Debris Program Office (ODPO) relies on ground-based radar measurements from both the Haystack Ultrawideband Satellite Imaging Radar (HUSIR) and the Goldstone Solar System Radar (Goldstone) to characterize mm to cm debris population in low Earth orbit (LEO). Radar measurements help characterize the size of orbital debris objects, particularly fragmentation debris. However, debris size is not directly measured by radar but inferred from the measured radar cross section (RCS) which depends on several parameters in addition to physical size including electrical conductivity and polarization. To interpret the observed RCS of orbital debris objects detected by radar measurements as physical sizes, NASA uses an empirical size estimation model (SEM) based on laboratory RCS measurements of breakup fragments generated during hypervelocity impact tests as well as some pieces of non-impact-generated “artificial” debris-like objects expected to be representative of the debris population. Since the development of the ODPO SEM, many new materials have been introduced to spacecraft construction. Consequently, ODPO plans to update the radar SEM based on planned laboratory RCS measurements of debris fragments from DebriSat, a ground-based hypervelocity impact experiment conducted in 2014 that consisted of a high-fidelity spacecraft model characteristic of a modern LEO spacecraft. Prior to measuring DebriSat fragments, a set of calibration targets with well-defined geometries and material compositions were measured at The Ohio State University’s ElectroScience Laboratory (OSU-ESL) compact radar range. These calibration measurements help to validate, and understand any limitations of, laboratory measurements of RCS. Calibration targets include idealizations of typical shape categories seen in DebriSat fragments such as nuggets, flat plates, and cylinders. As with DebriSat, calibration target materials were chosen to represent typical modern-day spacecraft components and include stainless steel, aluminum, printed circuit board (PCB) substrate, and carbon fiber-reinforced polymer (CFRP). These materials also represent a wide range of electrical conductivities, which strongly influences measured RCS and inferred target size. The RCS calibration measurements were collected over a frequency sweep from 2 to 18 GHz and stepping through different azimuth angles from 0 to 360 degrees at an elevation of 0 degrees. A second set of calibration measurements is in work consisting of more complex shapes such as bent rods and plates as well as different mounting options including epoxy and a 3D printed holder. These further measurements along with our initial calibration set will inform selection of representative DebriSat fragments for laboratory RCS measurements that will contribute to the planned update to the ODPO radar SEM. An appropriate subset of both the radar calibration and DebriSat samples will also be measured in the ODPO Optical Measurements Center to cross-calibrate size estimates over these different wavelength regimes.

Radar↗
NASA NTRSDate not supplied

A Historical Overview of the NASA Orbital Debris Program Office’s Laboratory Optical Measurements

The NASA Orbital Debris Program Office (ODPO) has used laboratory measurements to help bring ground-based measurements together with models to ascertain Earth-orbiting target parameters of interest to support various orbital debris models. In 2005, the Optical Measurement Center (OMC) was established to simulate space-based illumination conditions using equipment and techniques that recreate telescopic observations, particularly source-target-sensor orientations. The intent was to recreate light curves using known aspect angles of known targets and phase angles (angle is defined by the vertex between illumination source-object-detector) to complement telescopic observations that could be used to update the current optical size estimation model (OSEM) – a model that converts object brightness into size for orbital debris models. To support the above goals, the laboratory has undergone several equipment upgrades to increase capabilities over almost 20 years of operation. The primary instrumentation acquires reflectance measurements and includes a solar-like light source, CCD camera with astrometric filters, and robotic arm. A rotary arm was added approximately five years after full operation to allow acquisition through a full 360° range of phase angles. Another part of the OMC instrumentation is a field spectrometer, predominately used for field operations to acquire pre- and post-flight spacecraft material spectral measurements. Additionally, reflectance spectroscopy of various materials is also of interest resulting from hypervelocity impact tests, pristine spacecraft materials, or samples of materials that are used in spacecraft design. These measurements are stored in NASA’s Spectral Material Database, a resource that is still being populated today. The study of spectral measurements also enabled the development of spectral unmixing routines to support the identification of spacecraft materials from spectral data gathered by ground based telescopes. Preliminary OMC investigations focused on feasibility studies to acquire 360° rotation light curves of simple shapes at a single-phase angle and extended to measurements of representative fragments from ground-based explosion tests. To correlate the light curves with ground-based optical measurements, a focused study on high area to mass materials was conducted in support of a newly identified population (at the time) in geosynchronous orbit (GEO) consisting of multi-layered insulation. To further characterize orbital debris, a larger selection of materials was analyzed using laboratory photometric measurements that included representative targets from pristine spacecraft materials and ground-based impact tests. Around 2012, an initiative was requested to understand the feasibility of active debris removal (ADR) of larger targets using grappling methods for spent rocket bodies. Using a priori information on selected targets, scaled-down versions of rocket bodies were generated thanks to improvements in 3D printing technology and machining. These targets were studied in the OMC to understand rotation characteristics. These were compared with telescopic data to determine if the tumble and rotation angles would allow ADR. In 2013, the OMC focused on combining spectral measurements with photometric data to characterize GEO orbital debris. Several years later, NASA acquired a Titan III Transtage test article from “The Boneyard” with a high-resemblance to on-orbit Titan III Transtage rocket bodies, allowing physical access to a representative rocket body that suffered fragmentations in GEO. This prompted the creation of 3D models using lidar technology and spectral measurements of the materials. Focused research also transitioned to specific materials (i.e., solar cells) when telescopic surveys requested characterization of specific GEO targets. In the different research products presented, the focus has been to understand the various parameters that influence optical size estimation, including albedo, phase functions, and brightness variations. Work in this area continues with newer sources of data, including DebriSat, a high-fidelity 56-kg spacecraft replica representative of a modern low Earth orbit (LEO) satellite subjected to a laboratory hypervelocity impact test to understand fragmentation events and to support updates to satellite breakup models and size estimation models. Utilizing the vast population of fragments from DebriSat and prior laboratory impact experiments, the ODPO has focused on acquiring bidirectional reflectance distribution function (BRDF) data to characterize targets in the laboratory, thus removing aspect angle dependencies. Additionally, the DebriSat project has provided improved processes for measuring size via image acquisition, such that a true fragment size can be directly compared to the derived size using the OSEM. The team continues to assess BRDFs and use spectral measurement data to investigate the parameters used in the OSEM, specifically magnitudes, albedo, and phase functions.

Heather Cowardin↗
NASA NTRSDate not supplied

STARscan: Spatial Targeting and Alignment Rig for Scanning

The Spatial Targeting and Alignment Rig for Scanning (STARScan) is a 3D photogrammetry system developed at NASA Ames Research Center to address bottlenecks in pre/post-test scanning of arcjet test articles. It reduces scan time from 15 minutes with handheld laser scanners to under 2 minutes, while maintaining high accuracy (±0.2-0.5 mm). STARScan integrates an array of cameras, a 3D-printed rack, turntable, and LED light panels, all controlled via a user-friendly graphical user interface (GUI). The system offers tools for scan visualization, mesh analysis, and data export, automating tasks such as alignment of pre/post-test scans, material recession measurements, surface roughness assessment, and curvature analysis. By integrating scanning, imaging, and post-processing into one application, STARScan significantly improves efficiency in scanning and analyzing arcjet test samples.

Ablation↗
NASA NTRS2017

Ionic Polyimides: New High Performance Polymers for Additive Manufacturing

There is currently a very limited set of engineering polymers that have been demonstrated as viable for use in 3-D printing. Additive manufacturing of custom components will require a much larger array of polymers, especially those with physical, thermal, chemical, and mechanical properties that can be tailor-made. The development of ‘Ionic Polyimides’ offers a solution to this shortage by combining the well understood and widely accepted properties of conventional polyimides, with a new approach to polymer synthesis. Polyimides and polymeric ionic liquids (poly(ILs)) are at the forefront of advanced polymer materials, each with their own set of advantages and disadvantages. While it is clear that more types of polymer materials are needed for fused deposition modeling (FDM) additive manufacturing, there is a need to explore these classes of materials. The synthesis process developed by the Bara Research Group at the University of Alabama allows full control over polymer structure, nanostructure, thermal, electrical, and physical properties making them a prime candidate for use in the additive manufacturing process. Furthermore, the new process allows us to tailor-make a high strength polymer that can be used to fabricate filament feedstock instead of pellets for 3D printing. The primary objective of this proposal is to determine the relationship between molecular structure, physical properties, and performance of ionic polyimides. Further, we seek to determine their utility as materials suitable for additive manufacturing of components used in aerospace vehicles, with an emphasis on characterizing and simulating their thermal behaviors and properties. This proposal addresses the need for fundamental research on a customizable polymer filament feedstock for 3-D printing with tailor-made properties potentially making it superior to the commercial blends offered in industry today. The deliverables for this project are the creation of a database that will detail the relationships between the molecular structure and physical properties for the ionic polyimide of interest (e.g. Tg/Tm (Glass Transition Temperature divided by Melting Point)) relative to different ionic polyimide structures). This new database will provide a “road map” to the development of the first generation of materials and ultimately proof-of-concept.

Jackson, Enrique↗