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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 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Correlations Between Porosity, Spatter, and Process Metrics for Powder Bed Fusion Laser Beam Metallic Additive Manufacturing

Components fabricated using the powder bed fusion laser beam metallic (PBF-LB/M)additive manufacturing process are the result of a multitude of weld passes conducted sequentially. Qualifying components for aerospace applications requires a thorough understanding of the process-structure-properties relationships. Porosity defects are known to have a strong adverse effect on the mechanical properties of a component. In particular, porosity defects created by lack of fusion have high aspect ratio morphologies leading to stress concentrations that become crack initiation sites. In the present work, the occurrence of spatter induced lack of fusion porosity was studied using synchronized in-situ process monitoring, additive manufacturing model-based process metrics, and high-resolution X-ray computed tomography. The results show that lack of fusion porosity is statistically correlated with unremoved welding spatter ejecta of the PBF-LB/M process and process metrics related to the hatching strategy.

Qualification↗
NASA NTRS2005

Advanced Ceramic Matrix Composites (CMCs) for High Temperature Applications

Advanced ceramic matrix composites (CMCs) are enabling materials for a number of demanding applications in aerospace, energy, and nuclear industries. In the aerospace systems, these materials are being considered for applications in hot sections of jet engines such as the combustor liner, vanes, nozzle components, nose cones, leading edges of reentry vehicles, and space propulsion components. Applications in the energy and environmental industries include radiant heater tubes, heat exchangers, heat recuperators, gas and diesel particulate filters, and components for land based turbines for power generation. These materials are also being considered for use in the first wall and blanket components of fusion reactors. In the last few years, a number of CMC components have been developed and successfully tested for various aerospace and ground based applications. However, a number of challenges still remain slowing the wide scale implementation of these materials. They include robust fabrication and manufacturing, assembly and integration, coatings, property modeling and life prediction, design codes and databases, repair and refurbishment, and cost. Fabrication of net and complex shape components with high density and tailorable matrix properties is quite expensive, and even then various desirable properties are not achievable. In this presentation, a number of examples of successful CMC component development and testing will be provided. In addition, critical need for robust manufacturing, joining and assembly technologies in successful implementation of these systems will be discussed.

Singh, M.↗
NASA NTRS1991

An architectural approach to create self organizing control systems for practical autonomous robots

For practical industrial applications, the development of trainable robots is an important and immediate objective. Therefore, the developing of flexible intelligence directly applicable to training is emphasized. It is generally agreed upon by the AI community that the fusion of expert systems, neural networks, and conventionally programmed modules (e.g., a trajectory generator) is promising in the quest for autonomous robotic intelligence. Autonomous robot development is hindered by integration and architectural problems. Some obstacles towards the construction of more general robot control systems are as follows: (1) Growth problem; (2) Software generation; (3) Interaction with environment; (4) Reliability; and (5) Resource limitation. Neural networks can be successfully applied to some of these problems. However, current implementations of neural networks are hampered by the resource limitation problem and must be trained extensively to produce computationally accurate output. A generalization of conventional neural nets is proposed, and an architecture is offered in an attempt to address the above problems.

Greiner, Helen↗
NASA NTRSDate not supplied

Lattice Confinement Fusion & Fast Fission for Space

Lattice Confinement Fusion (LCF) 1 • Fusion of hydrogen isotopes into helium isotopes • No tokamak magnets or laser power supplies • Nuclear fuel is confined and triggered within lattice • Nuclear reactions enhanced by electron screening • Extended Electrodynamics (EED) role • NASA published results in Physical Review C 2,3 • Locally hot but globally cold • Commercialized in 2025 to produce medical radioisotopes 4 Lattice Confinement Fusion Fast-Fission Hybrid Reactor • Fusion neutrons fission uranium, spent fuel rods or thorium • No enriched uranium, cleaner fission! • Demonstrated with US Navy and GEC • Supported by NASA STMD (NIAC) and NSF Application • LEO, Deep Space Power and High I sp Propulsion • (Terrestrial)

lattice confinement fusion↗
NASA NTRS1992

An experimental system for determining the influence of microgravity on B lymphocyte activation and cell fusion

The influence of microgravity on lymphocyte activation is central to the understanding of immunological function in space. Moreover, the adaptation of ground-based technologies to microgravity conditions presents opportunities for biotechnological applications including high efficiency production of antibody forming hybridomas. Because the emerging technology of microgravity hybridoma generation is dependent upon activation and cultivation of B lymphocytes during flight, mitogen-driven B lymphocyte stimulation and culture were adapted that allow for the in vitro generation of large numbers of antibody forming cells suitable for cell fusion over a period of 1-2 weeks. It is believed that this activation and cultivation system can be flown on near-term space flights to test fundamental hypotheses about mammalian cell activation, cell fusion, metabolism, secretion, growth, and bioseparation.

Sammons, D. W.↗
NASA NTRS1996

Investigation of Machine Design for Friction Stir Welding

The process of joining two pieces of metal together has not significantly changed over the last few decades. The basic idea used is to bring the pieces together and apply enough heat to melt the metal at the interface. The molten metal mixes and after cooling forms a strong joint. This process is called the fusion process. The most significant difference between the many fusion processes is how the heat is generated and applied. The Welding Institute (TWI), in Great Britain, has recently patented an innovative application of mechanical friction. TWI designed a tool and process called Friction Stir Welding (FSW) that uses friction to heat the metal to within a few hundred degrees Fahrenheit of melting, just to the point of being plastic-like. The tool then stirs the plasticized metal together forming a joint that has been shown to be as good or better than an equivalent fusion joint. The FSW process is well suited for the joining of the aluminum alloys used in the aerospace industry. The relatively low melting point of aluminum eliminates the requirements for exotic materials for pin tool design. The FSW process has been successfully used to join alloys such as 7075 which were before considered "unweldable", and aluminum-lithium 2195 which exhibits many problems when fusion welded. The objective this summer was to investigate the design of a FSW system that could take this process from the laboratory to the manufacturing floor. In particular, it was the goal of my NASA colleague to develop a concept for applying the FSW process to the manufacturing of aluminum cryogenic oxygen and hydrogen tanks, of the sort used to make the Shuttle External Tank.

Romine, Peter L.↗
NASA NTRS2001

Enhancement of Tropical Land Cover Mapping with Wavelet-Based Fusion and Unsupervised Clustering of SAR and Landsat Image Data

The characterization and the mapping of land cover/land use of forest areas, such as the Central African rainforest, is a very complex task. This complexity is mainly due to the extent of such areas and, as a consequence, to the lack of full and continuous cloud-free coverage of those large regions by one single remote sensing instrument, In order to provide improved vegetation maps of Central Africa and to develop forest monitoring techniques for applications at the local and regional scales, we propose to utilize multi-sensor remote sensing observations coupled with in-situ data. Fusion and clustering of multi-sensor data are the first steps towards the development of such a forest monitoring system. In this paper, we will describe some preliminary experiments involving the fusion of SAR and Landsat image data of the Lope Reserve in Gabon. Similarly to previous fusion studies, our fusion method is wavelet-based. The fusion provides a new image data set which contains more detailed texture features and preserves the large homogeneous regions that are observed by the Thematic Mapper sensor. The fusion step is followed by unsupervised clustering and provides a vegetation map of the area.

LeMoigne, Jacqueline↗
NASA NTRS1972

Development of dispersion-strengthened Ni-Cr-ThO2 alloys for the space shuttle thermal protection system.

An improved manufacturing process has been developed for TD-NiCr that provides sheet of improved quality, better gage control, and reproducible properties. A standard manufacturing process has been developed for the alternate alloy, DS-NiCr, produced by pack-chromizing Ni-2ThO2 sheet. Extension of forming and joining technology for TD-NiCr is in process. Formability criteria are being established for basic sheet forming processes related to the manufacture of Shuttle TPS panels. They include brake forming, corrugation forming, joggling, dimpling, and beading. Joining processes applicable to TPS panels are being optimized with emphasis on establishment of joint efficiencies. Resistance spot welding (fusion and solid state), resistance seam welding, solid-state diffusion welding, and brazing are included in the joining programs. Development of improved manufacturing technology for TD-NiCr fasteners is also being accomplished. Mechanical and physical properties of TD-NiCr are being characterized to provide design-allowable data.

Blankenship, C. P.↗
NASA NTRS1989

Design of a normal incidence multilayer imaging X-ray microscope

Normal incidence multilayer Cassegrain X-ray telescopes were flown on the Stanford/MSFC Rocket X-ray Spectroheliograph. These instruments produced high spatial resolution images of the sun and conclusively demonstrated that doubly reflecting multilayer X-ray optical systems are feasible. The images indicated that aplanatic imaging soft X-ray/EUV microscopes should be achievable using multilayer optics technology. A doubly reflecting normal incidence multilayer imaging X-ray microscope based on the Schwarzschild configuration has been designed. The design of the microscope and the results of the optical system ray trace analysis are discussed. High resolution aplanatic imaging X-ray microscopes using normal incidence multilayer X-ray mirrors should have many important applications in advanced X-ray astronomical instrumentation, X-ray lithography, biological, biomedical, metallurgical, and laser fusion research.

Shealy, David L.↗
NASA NTRS2017

Real-Time Radar-Based Tracking and State Estimation of Multiple Non-Conformant Aircraft

In this study, a novel solution for automated tracking of multiple unknown aircraft is proposed. Many current methods use transponders to self-report state information and augment track identification. While conformant aircraft typically report transponder information to alert surrounding aircraft of its state, vehicles may exist in the airspace that are non-compliant and need to be accurately tracked using alternative methods. In this study, a multi-agent tracking solution is presented that solely utilizes primary surveillance radar data to estimate aircraft state information. Main research challenges include state estimation, track management, data association, and establishing persistent track validity. In an effort to realize these challenges, techniques such as Maximum a Posteriori estimation, Kalman filtering, degree of membership data association, and Nearest Neighbor Spanning Tree clustering are implemented for this application.

RADAR tracking↗
NASA NTRS1998

Friction Stir Welding of Large Scale Cryogenic Tanks for Aerospace Applications

The Marshall Space Flight Center (MSFC) has established a facility for the joining of large-scale aluminum cryogenic propellant tanks using the friction stir welding process. Longitudinal welds, approximately five meters in length, have been made by retrofitting an existing vertical fusion weld system, designed to fabricate tank barrel sections ranging from two to ten meters in diameter. The structural design requirements of the tooling, clamping and travel system will be described in this presentation along with process controls and real-time data acquisition developed for this application. The approach to retrofitting other large welding tools at MSFC with the friction stir welding process will also be discussed.

Russell, Carolyn↗
NASA NTRSDate not supplied

Parameter, Post-Processing Sensitivities, and Qualification Approach of Laser Powder Bed Fusion Hydrogen Resistant Alloy NASA HR-1

Metal additive manufacturing (AM) processes are being used to enable economical manufacturing of legacy alloys as well as advancing new alloys. Laser powder bed fusion (L-PBF) is a metal AM process that has high maturity and being used to produce a variety of parts for space applications including complex propulsion components. The National Aeronautics and Space Administration (NASA) has identified the need to develop and advance new materials in unique space applications such as high-pressure hydrogen environments. NASA HR-1 is a high strength Fe-Ni based superalloy designed to resist high pressure hydrogen environment embrittlement (HEE), oxidation, and corrosion that has been successfully adapted to laser powder directed energy deposition (LP-DED). Insights gained from the NASA HR-1 development for LP-DED have guided the development process for L-PBF. However, adapting NASA HR-1 to L-PBF posed new challenges due to the distinct differences between the additive manufacturing processes. During parameter development, sensitivities were observed in post-processing that necessitated additional optimization of heat treatments. Additionally, the variations in thickness and how it influenced the microstructural response during heat treatment was characterized. Understanding these sensitivities is important to qualification of the material in a L-PBF machine. This ensures that the microstructures and properties of the material maintain consistency in production. This presentation will cover parameter development along with post-processing challenges and solutions will be discussed in addition to key material properties as it pertains to application performance and qualification per NASA-STD-6030. Improvements made by developing a derivative alloy, NASA HR-2, will be highlighted through preliminary small scale parameter development, material characterization, and initial property testing.

NASA HR-1↗
NASA NTRS2002

First Results of the Gasdynamic Mirror Fusion Propulsion Experiment

An experimental Gasdynamic Mirror or GDM device has been constructed at the NASA Marshall Space Flight Center to provide an initial assessment of the applicability of this technology for propulsion systems. This paper presents the first experimental results obtained from the machine and an analysis of the types of plasma instabilities likely to be encountered. It is intended that this device operate at higher plasma densities and with much larger L/D ratios than previous mirror machines. The high L/D ratio minimizes to a large extent certain magnetic curvature effects which lead to plasma instabilities causing a loss of plasma confinement. The high plasma density results in the plasma behaving much more like a conventional fluid with a mean free path shorter than the length of the device. This characteristic helps reduce problems associated with "loss cone" microinstabilities. The device has been constructed to allow a considerable degree of flexibility in its configuration thus permitting the experiment to grow over time without necessitating a great deal of additional fabrication.

Emrich, William J., Jr.↗
NASA NTRS1988

Kuhn-Tucker optimization based reliability analysis for probabilistic finite elements

The fusion of probability finite element method (PFEM) and reliability analysis for fracture mechanics is considered. Reliability analysis with specific application to fracture mechanics is presented, and computational procedures are discussed. Explicit expressions for the optimization procedure with regard to fracture mechanics are given. The results show the PFEM is a very powerful tool in determining the second-moment statistics. The method can determine the probability of failure or fracture subject to randomness in load, material properties and crack length, orientation, and location.

Liu, W. K.↗
NASA NTRS1998

Friction Stir Weld Tooling Development for Application on the 2195 Al-Cu-Li Space Transportation System External Tank

Friction Stir Welding (FSW) is a new and innovative solid-state joining process which can be applied to difficult-to- weld aluminum alloys. However, the large forces involved with the process have posed a production tooling challenge. Lockheed Martin Michoud Space Systems has overcome many of these challenges on the Super Lightweight External Tank (ET) program. Utilizing Aluminum-Copper-Lithium alloy 2195 in the form of plate and extrusions, investigations of FSW process parameters have been completed. Major loading mechanisms are discussed in conjunction with deflection measurements. Since the ET program is a cryogenic application, a brief comparison of cryogenic material properties with room temperature material properties is offered for both FSW and fusion welds. Finally, a new approach to controlling the FSW process from a load perspective is introduced. Emphasis will be put on tooling development, as well as the impact of tooling design and philosophy on Friction Stir Weld success probability.

Loftus, Zachary↗
NASA NTRS1998

ELIPS: Toward a Sensor Fusion Processor on a Chip

The paper presents the concept and initial tests from the hardware implementation of a low-power, high-speed reconfigurable sensor fusion processor. The Extended Logic Intelligent Processing System (ELIPS) processor is developed to seamlessly combine rule-based systems, fuzzy logic, and neural networks to achieve parallel fusion of sensor in compact low power VLSI. The first demonstration of the ELIPS concept targets interceptor functionality; other applications, mainly in robotics and autonomous systems are considered for the future. The main assumption behind ELIPS is that fuzzy, rule-based and neural forms of computation can serve as the main primitives of an "intelligent" processor. Thus, in the same way classic processors are designed to optimize the hardware implementation of a set of fundamental operations, ELIPS is developed as an efficient implementation of computational intelligence primitives, and relies on a set of fuzzy set, fuzzy inference and neural modules, built in programmable analog hardware. The hardware programmability allows the processor to reconfigure into different machines, taking the most efficient hardware implementation during each phase of information processing. Following software demonstrations on several interceptor data, three important ELIPS building blocks (a fuzzy set preprocessor, a rule-based fuzzy system and a neural network) have been fabricated in analog VLSI hardware and demonstrated microsecond-processing times.

Daud, Taher↗
NASA NTRS1989

Data Acquisition Systems

Technology developed during a joint research program with Langley and Kinetic Systems Corporation led to Kinetic Systems' production of a high speed Computer Automated Measurement and Control (CAMAC) data acquisition system. The study, which involved the use of CAMAC equipment applied to flight simulation, significantly improved the company's technical capability and produced new applications. With Digital Equipment Corporation, Kinetic Systems is marketing the system to government and private companies for flight simulation, fusion research, turbine testing, steelmaking, etc.

Source record↗