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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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Reaction control thrustor injector requires precisely machined orifices and slots. Tooling setup consists of rotary table, numerical control system and torque sensitive drill press. Components used to drill oxidizer orifices. Electric discharge machine drills fuel-feed orifices. Device automates production of identical parts so several are completed in less time than previously.
An electric propulsion machine includes an ion thruster having an annular discharge chamber housing an anode having a large surface area. The ion thruster includes flat annular ion optics with a small span to gap ratio. Optionally, a second electric propulsion thruster may be disposed in a cylindrical space disposed within an interior of the annulus.
A robotic system includes a dexterous robot having robotic joints, angle sensors adapted for measuring joint angles at a corresponding one of the joints, load cells for measuring a set of strain values imparted to a corresponding one of the load cells during a predetermined pose of the robot, and a host machine. The host machine is electrically connected to the load cells and angle sensors, and receives the joint angle values and strain values during the predetermined pose. The robot presses together mating pairs of load cells to form the poses. The host machine executes an algorithm to process the joint angles and strain values, and from the set of all calibration matrices that minimize error in force balance equations, selects the set of calibration matrices that is closest in a value to a pre-specified value. A method for calibrating the load cells via the algorithm is also provided.
NASA is developing the high efficiency megawatt motor (HEMM), a 1.4 MW partially superconducting machine, to ad-dress the need for highly efficient, lightweight, MW-class ma-chines to support aviation sustainability efforts. This paper presents progress on the thermal, structural, and rotordynamics aspects of HEMM’s superconducting rotor. Emissivity measurements of gold coated cobalt iron and titanium parts are presented and then used to correlate a thermal model of the rotor to existing data from a thermo-electrical test of the full-scale rotor. Lessons learned from the correlated model are presented, including a rank ordering of the contributors to the temperature of the superconducting coils. An updated structural design of the HEMM rotor is presented and compared to the prior design. Finite element analysis demonstrates that the updated design improves stress margins while reducing magnetic flux leakage and retaining thermal performance. The key conclusions of the rotordynamics design are presented.
Advanced thermal systems developed for the Space Station Freedom project are now in use on the International Space Station. These thermal systems employ evaporative ammonia as their coolant, and though they employ the same series of chemical reactions as terrestrial refrigerators, the space-bound coolers are significantly smaller. Two Small Business Innovation Research (SBIR) contracts between Creare Inc. of Hanover, NH and Johnson Space Center developed an ammonia evaporator for thermal management systems aboard Freedom. The principal investigator for Creare Inc., formed Mikros Technologies Inc. to commercialize the work. Mikros Technologies then developed an advanced form of micro-electrical discharge machining (micro-EDM) to make tiny holes in the ammonia evaporator. Mikros Technologies has had great success applying this method to the fabrication of micro-nozzle array systems for industrial ink jet printing systems. The company is currently the world leader in fabrication of stainless steel micro-nozzles for this market, and in 2001 the company was awarded two SBIR research contracts from Goddard Space Flight Center to advance micro-fabrication and high-performance thermal management technologies.
The proposed Aerosol/Cloud/Ecosystems (ACEs) mission development would advance cloud profiling radar from that used in CloudSat by adding a 35-GHz (Ka-band) channel to the 94-GHz (W-band) channel used in CloudSat. In order to illuminate a single antenna, and use CloudSat-like quasi-optical transmission lines, a spatial diplexer is needed to add the Ka-band channel. A dichroic filter separates Ka-band from W-band by employing advances in electrical discharge machining (EDM) and mode-matching analysis techniques developed and validated for designing dichroics for the Deep Space Network (DSN), to develop a preliminary design that both met the requirements of frequency separation and mechanical strength. First, a mechanical prototype was built using an approximately 102-micron-diameter EDM process, and tolerances of the hole dimensions, wall thickness, radius, and dichroic filter thickness measured. The prototype validated the manufacturing needed to design a dichroic filter for a higher-frequency usage than previously used in the DSN. The initial design was based on a Ka-band design, but thicker walls are required for mechanical rigidity than one obtains by simply scaling the Ka-band dichroic filter. The resulting trade of hole dimensions for mechanical rigidity (wall thickness) required electrical redesign of the hole dimensions. Updates to existing codes in the linear solver decreased the analysis time using mode-matching, enabling the electrical design to be realized quickly. This work is applicable to missions and instruments that seek to extend W-band cloud profiling measurements to other frequencies. By demonstrating a dichroic filter that passes W-band, but reflects a lower frequency, this opens up the development of instruments that both compare to and enhance CloudSat.
The use of a superconducting rotor in the High Efficiency Megawatt Motor (HEMM) comes with a number of challenges. The HEMM’s rotor must be designed so that the superconducting coil can tolerate the forces it will encounter during operation. These forces introduce considerable risk to the design of the HEMM. Because this risk cannot be adequately addressed through refined analysis, a set of experiments was deemed necessary to demonstrate that the HEMM’s superconducting coils can survive the stresses imparted by the centrifugal forces acting on the coil during full-speed operation of the machine. These experiments required spin testing a full-scale HEMM coil on a representative rotor structure at room temperature and sequentially higher rotation speeds and measuring the superconductivity response of the coil in liquid nitrogen (LN2) before and after each spin test. Tests were carried out to the full centripetal loading of a recent HEMM design. According to finite element analysis, this load produced stress components in the coil that exceed their design limit by a factor of 1 to 7.4. Although not yet confirmed, the current HEMM design is expected to produce even smaller stresses in the coil due to a 20 percent reduction in the coil’s mass and an increased volume of structural material. The only degradation of the coil that occurred during this testing resulted from a test rig failure and from the voltage taps, which are not part of the final coil design.
Electrical discharge machining /EDM/ damaged layer can be effectively removed from Rene 41, Inconel 625, Inconel 718, and Monel K-500 by abrasive-grit blasting or electropolishing /at room temperature/ at a current density of 5A/inches squared in a water solution of phosphoric and sulfuric acids.
Infrared converter, photoluminescence in CdS thin films, tunneling barriers, ionization gage and electrical-discharge machining studies
The effects of notches in thin beryllium sheets were studied as functions of material variables and notch severity. Double edge notched samples having stress concentration factors of 1.0 to 15.4 were prepared by milling to size, etching, and electrical discharge machining the notches. Strength was not reduced greatly by sharp notches, and duller notches were more deleterious than sharp notches. The trend was for reduced strength for dull notches, increased strength for sharper notches, and reduced strength for very sharp notches. Differences in material purity or source of the sheet had little affect on notch sensitivity. The most important factors appear to be oxide content and directionality of the sheet microstructure; high oxide content and highly directional microstructure tend to give more notch sensitivity than low oxide content, and more bidirectional microstructure. Postulated causes of the change in notched/unnotched strength are given.
Mirror refurbishment processing is described, and the results of processing 251 mirror assemblies are reported. The mirror replica bonding, optical tests, electrical discharge machining, and vacuum coating are discussed.
Results are presented for an experimental study intended to provide sustained load crack growth (SLCG) data for Ti-6Al-4V titanium alloy tanks containing MIL-P-26536 hydrazine and refined hydrazine. Fracture mechanics data on crack growth threshold for heat-treated forgings, aged and unaged welds, and aged and unaged heat-affected zones (HAZ) are presented. All tests were made on uniaxially loaded fracture mechanics specimens involving part-through cracks, and an electrical discharge machined notch was used to start the crack. Fracture mechanics design curves of crack growth threshold stress intensity versus temperature are obtained for the temperature range 40-71 C. Major conclusions are that extreme susceptibility to SLCG in hydrazine is a universal property of unaged weld metal in Ti-6Al-4V titanium alloy of normal interstitial content, and that aging both weld metal and HAZ at 510 C for 4 hr after welding completely removes all susceptibility to SLCG induced by hydrazine, with less susceptibility to SLCG in refined hydrazine.
A simple, fully automatic assembler associated with the on-orbit assembly of tetrahedral truss platforms erected of graphite epoxy tapered columns is described. The assembler, which can operate either as a free flyer or attached to the Orbiter, is capable of constructing a platform from a full load of truss columns and node joints in 36 hours. The geometry of this electrically-driven machine is based on a compound parallelogram system which permits backward as well as lateral translations. Concepts have been developed for half-column assembly as well as for column and node joint insertion into the platform.
Concept uses commercial titanium honeycomb core brazed to cap material and panel skin. In fabrication of stringers, large sheets of cap material are brazed to pieces of honeycomb core of desired height. After brazing, individual stringers are cut by electrical-discharge machining, and stringers are subsequently brazed to skin. Sandwich beam stringer is light-weight, structurally-efficient, low-cost stiffener for metal-matrix composite structural panels.
Electroerosive process inexpensive alternative to broaching. Hollow brass electrodes, soldered at one end to stainless-steel holding ring, held in grooves in mandrel. These electrodes used to machine grooves electrically in stainless-steel tube three-eights inch (9.5 millimeters) in diameter. Tool used on tubes already in place in equipment.
Concept for acoustic coupler allows sound efficiently conveyed from bearings to external sensor. Noise from bearings in bearing test machine monitored for signs of incipient failure. Straight through acoustic-coupler assembly inserted through existing ports in housing of bearing-testing machine. Threaded electrical connector at top rotated to adjust force applied to sensing element and contact bearing.
The closure behavior of cracks of different length and at different cyclic strain levels (ranging from predominantly elastic to grossly plastic strains) was studied to observe the effect of residual crack-tip plasticity on crack closure. Cracks were initiated either naturally or artificially (from electric discharge machining pits) in uniaxial test specimens of strengthened alloy steel AISI 4340 with a grain size of 0.016 mm. It was found that, at high strains, cracks closed only when the lowest stress level in the cycle was approached. The stress or the strain opening level depended upon the exact point along the crack length where the observations were made. As the plastic deformation increased, the relative crack opening level was found to decrease and approach the value of stress ratio R. The experimental results were compared with those of three analytical models of crack closure and opening, demonstrating the limitations of the currently available elastic-plastic crack growth analysis.
Adherent, abrasion-resistant coat deposited with existing equipment. Carbon formed and deposited as coating on copper substrate by pyrolysis of hydrocarbon oil in electrical-arc discharges. Technique for producing carbon deposits on copper accomplished with electrical-discharge-machining equipment used for cutting metals. Applications for new coating technique include the following: solar-energy-collecting devices, coating of metals other than copper with carbon, and carburization of metal surfaces.