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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 NTRS1992

Design and testing of the Space Station Freedom Propellant Tank Assembly

Propellant storage and management functions for the Propulsion Module of the U.S. Space Station Freedom are provided by the Propellant Tank Assembly (PTA). The PTA consists of a surface-tension type propellant acquisition device contained within a welded titanium pressure vessel. The PTA design concept was selected with high reliability and low program risk as primary goals in order to meet stringent NASA structural, expulsion, fracture control and reliability requirements. The PTA design makes use of Shuttle Orbital Maneuvering System and Peacekeeper Propellant Storage Assembly design and analysis techniques. This paper summarizes the PTA design solution and discusses the underlying detailed analyses. In addition, design verification and qualification test activities are discussed.

Dudley, D. D.↗
NASA NTRS2000

Lubrication System Failure Baseline Testing on an Aerospace Quality Gear Mesh

Aerospace drive systems are required to survive a loss-of-lubrication test for qualification. In many cases emergency lubrication systems need to be designed and utilized to permit the drive system to pass this difficult requirement. The weight of emergency systems can adversely affect the mission capabilities of the aircraft. The possibility to reduce the emergency system weight through the use of mist lubrication will be described. Mist lubrication involves the delivery of a minute amount of an organic liquid as a vapor or fine mist in flowing compressed air to rubbing surfaces. At the rubbing surface, the vapor or mist reacts to form a solid lubricating film. The aim of this study was to establish a baseline for gear behavior under oil depleted conditions. A reactive vapor-mist lubrication method is described and proposed as a candidate emergency lubrication system.

Handschuh, Robert F.↗
NASA NTRS2018

Design Optimisation and Mass Saving of the Structure of the Orion-MPCV European Service Module

This paper presents an overview of the design optimisation measures that have been proposed and analysed in order to reduce the mass of the structure, including the MMOD (Micro-Meteoroid and Orbital Debris) protection system, of the ESM (European Service Module) for the “Orion” MPCV (Multi-Purpose Crew Vehicle). Under an agreement between NASA and ESA, the NASA Orion MPCV for human space exploration missions will be powered by a European Service Module, based on the design and experience of the ATV (Automated Transfer Vehicle). The development and qualification of the European Service Module is managed and implemented by ESA. The ESM prime contractor and system design responsible is Airbus Defence and Space. Thales Alenia Space Italia is responsible for the design and integration of the ESM Structure and MMOD protection system in addition to the Thermal Control System and the Consumable Storage System. The Orion Multi-Purpose Crew Vehicle is a pressurized, crewed spacecraft that transports up to four crew members from the Earth’s surface to a nearby destination or staging point. Orion then brings the crew members safely back to the Earth’s surface at the end of the mission. Orion provides all services necessary to support the crew members while on-board for short duration missions (up to 21 days) or until they are transferred to another orbiting habitat. The ESM supports the crew module from launch through separation prior to re-entry by providing: in-space propulsion capability for orbital transfer, attitude control, and high altitude ascent aborts; water and oxygen/nitrogen needed for a habitable environment; and electrical power generation. In addition, it maintains the temperature of the vehicle's systems and components and offers space for unpressurized cargo and scientific payloads. The ESM has been designed for the first 2 Lunar orbit missions, EM-1 (Exploration mission 1) is an un-crewed flight planned around mid-2020, and EM-2, the first crewed flight, is planned in 2022. At the time where the first ESM is about to be weighted, the predicted mass lies slightly above the initial requirement. For future builds, mass reduction of the Service Module has been considered necessary. This is being investigated, together with other design improvements, in order to consolidate the ESM design and increase possible future missions beyond the first two Orion MPCV missions. The mass saving study has introduced new optimised structural concepts, optimisation of the MMOD protection shields, and optimised redesign of parts for manufacturing through AM (Additive Manufacturing).

Micro-Meteroids and Orbital Debris Protection Syst↗
NASA NTRS2019

Thermal design and validation of Mars 202 gas Dust Removal Tool (gDRT)

As part of the science goals for the planned Mars 2020 mission, two instruments, PIXL and SHERLOC, intend to study the Mars surface at a close scale. These two instruments are planned to be used on smooth rock surfaces that are free of dust and other particles. Such surfaces are prepared by using a drill with an abrading drill bit; residual dust and particles are then blown away using a compressed gas system—the Gas Dust Removal Tool (gDRT). Early in the design process a risk of valve leakage below the vendor’s -20C rating was identified. To mitigate this risk a parallel path was implemented: 1) qualify the valves to operate at -135C, and 2) develop thermal control capability to elevated temperatures in case qualification efforts are unsuccessful. While qualification efforts are ongoing, it is expected that the valves will be qualified to an operating temperature of -135C. In the event that qualification is not successful, thermal control has been realized via a thermally isolated valve configuration and thermostatically controlled heaters. Thermal testing of gDRT has validated this design and enabled thermal model correlation in order to provide more accurate survival energy predictions. The resulting energy consumption for heating the valves at the Jezero landing site represents a minimal impact to the Rover energy budget.

Novak, Keith↗
NASA NTRS1996

Advanced Failure Determination Measurement Techniques Used in Thermal Fatigue Life Testing of Electronic Packaging

Thermal fatigue life testing of various electronic packaging technologies is being performed by the Reliability Technology Group at the Jet Propulsion Laboratory. These testing efforts are in progress to improve uderstanding of the reliability issues associated with low volume packaging technologies for space applications and to develop qualification and acceptance approaches for these technologies. The work described here outlines the electrical failure detection techniques used during testing by documenting the circuits and components used to make these measurements, the sensitivity of the measurements, and the applicability of each specific measurement.

fatigue surface mount measurement testing thermal ↗
DOE OSTI2021

Photonic Doppler Velocimetry for Valve Analysis and Surveillance

This study is an experimental evaluation to measure and surveil the velocity of stainless steel (Carpenter 455) pistons within a forged 21-6-9 stainless steel valve body. The velocity of the piston “stroke” will be identified using Photonic Doppler Velocimetry (PDV). The piston velocity will be the measured variable of interest. The outcome of this testing series provides further understanding to whether the extracted piston velocity can provide enough information to determine valve integrity. PDV has been identified as a diagnostic of interest as it can detect surface motion at high speeds with reliable accuracy. Through preliminary studies conducted with velocity interferometer system for any reflector (VISAR), the velocity of the piston is expected to stroke with a speed of 135 m/s. The PDV technique is much more reliable and repeatable than the VISAR technique because of its high-speed precision and accuracy, so it will not only validate the preliminary data, but also provide a testing technique that is capable of being used in future valve qualification efforts. The initial testing was completed using valves that were assembled per qualified procedures in a pristine condition. These initial tests were conducted to provide baseline data. This baseline data was then compared to data collected from valves where man-made defects were introduced. These defects are discussed in later sections. Lastly, actuators used to operate the valves were loaded with varied amounts of high explosives to identify if velocity is a function of the amount of explosive in an actuator. These parameters were adjusted to conclusively determine and identify if PDV can be used as a method to assess valve integrity. It was concluded through the testing discussed in this paper that in fact, PDV is capable of measuring the differences in piston velocities based on varied parameters. As far as understanding the PDV accuracy of the measured differences, this is ongoing and will have to be assessed in continued testing series.

42 ENGINEERING↗
NASA NTRS2005

Lightweight Nonmetallic Thermal Protection Materials Technology

To fulfill President George W. Bush's "Vision for Space Exploration" (2004) - successful human and robotic missions to and from other solar system bodies in order to explore their atmospheres and surfaces - the National Aeronautics and Space Administration (NASA) must reduce the trip time, cost, and vehicle weight so that the payload and scientific experiments' capabilities can be maximized. The new project described in this paper will generate thermal protection system (TPS) product that will enable greater fidelity in mission/vehicle design trade studies, support risk reduction for material selections, assist in the optimization of vehicle weights, and provide materials and processes templates for use in the development of human-rated TPS qualification and certification plans.

Valentine, Peter G.↗
NASA NTRS2004

Laser Range and Bearing Finder for Autonomous Missions

NASA has recently re-confirmed their interest in autonomous systems as an enabling technology for future missions. In order for autonomous missions to be possible, highly-capable relative sensor systems are needed to determine an object's distance, direction, and orientation. This is true whether the mission is autonomous in-space assembly, rendezvous and docking, or rover surface navigation. Advanced Optical Systems, Inc. has developed a wide-angle laser range and bearing finder (RBF) for autonomous space missions. The laser RBF has a number of features that make it well-suited for autonomous missions. It has an operating range of 10 m to 5 km, with a 5 deg field of view. Its wide field of view removes the need for scanning systems such as gimbals, eliminating moving parts and making the sensor simpler and space qualification easier. Its range accuracy is 1% or better. It is designed to operate either as a stand-alone sensor or in tandem with a sensor that returns range, bearing, and orientation at close ranges, such as NASA's Advanced Video Guidance Sensor. We have assembled the initial prototype and are currently testing it. We will discuss the laser RBF's design and specifications. Keywords: laser range and bearing finder, autonomous rendezvous and docking, space sensors, on-orbit sensors, advanced video guidance sensor

Granade, Stephen R.↗
NASA NTRS1981

Test results of Spacelab 2 infrared telescope focal plane

The small helium cooled infrared telescope for Spacelab 2 is designed for sensitive mapping of extended, low-surface-brightness celestial sources as well as highly sensitive investigations of the shuttle contamination environment (FPA) for this mission is described as well as the design for a thermally isolated, self-heated J-FET transimpedance amplifier. This amplifier is Johnson noise limited for feedback resistances from less than 10 to the 8th power Omega to greater than 2 x 10 to the 10th power Omega at T = 4.2K. Work on the focal plane array is complete. Performance testing for qualification of the flight hardware is discussed, and results are presented. All infrared data channels are measured to be background limited by the expected level of zodiacal emission.

Young, E. T.↗
NASA NTRS2016

The International Space Station (ISS) Solar Alpha Rotary Joint (SARJ): Materials & Processes (M&P) Lessons Learned for a Large, Rotating Spacecraft Mechanism

The International Space Station (ISS) utilizes two large rotating mechanisms, the solar alpha rotary joints (SARJs), as part of the solar arrays' alignment system for more efficient power generation. Each SARJ is a 10.3m circumference, nitrided 15-5PH steel race ring of triangular cross-section, with 12 sets of trundle bearing assemblies transferring load across the rolling joint. The SARJ mechanism rotates continuously and slowly - once every orbit, or every 90 minutes. In 2007, the starboard SARJ suffered a lubrication failure, resulting in severe damage (spalling) to one of the race ring surfaces. Extensive effort was conducted to prevent the port SARJ from suffering the same failure, and fortunately that effort was ultimately successful in also recovering the functionality of the starboard SARJ. The M&P engineering function was key in determining the cause of failure and the means for mechanism recovery. From a M&P lessons-learned perspective, observations are made concerning the original SARJ design parameters (boundary conditions), the perceived need for nitriding the race ring, the test conditions employed during qualification, the environmental controls used for the hardware preflight, and the lubrication robustness necessary for complex kinematic mechanisms expecting high-reliability and long-life.

Golden, Johnny L.↗
NASA NTRS2000

Development of Electrostatically Clean Solar Array Panels

Certain missions require Electrostatically Clean Solar Array (ECSA) panels to establish a favorable environment for the operation of sensitive scientific instruments. The objective of this program was to demonstrate the feasibility of an ECSA panel that minimizes panel surface potential below 100mV in LEO and GEO charged particle environments, prevents exposure of solar cell voltage and panel insulating surfaces to the ambient environment, and provides an equipotential, grounded structure surrounding the entire panel. An ECSA panel design was developed that uses a Front Side Aperture-Shield (FSA) that covers all inter-cell areas with a single graphite composite laminate, composite edge clips for connecting the FSA to the panel substrate, and built-in tabs that interconnect the FSA to conductive coated coverglasses using a conductive adhesive. Analysis indicated the ability of the design to meet the ECSA requirements. Qualification coupons and a 0.5m x 0.5m prototype panel were fabricated and tested for photovoltaic performance and electrical grounding before and after exposure to acoustic and thermal cycling environments. The results show the feasibility of achieving electrostatic cleanliness with a small penalty in mass, photovoltaic performance and cost, with a design is structurally robust and compatible with a wide range of current solar panel technologies.

Stern, Theodore G.↗
NASA NTRSDate not supplied

Space-qualified Chalcogenide Materials through ISS MISSE Exposure —From Property to Application

In March 2021, twenty-four samples of various phase change materials (PCMs - Ge2Sb2Te5, Ge2Sb2Se4Te1, and Sb2Se3) along with metasurface optical components comprised of these PCMs, were delivered to the International Space Station (ISS) as part of the Materials International Space Station Experiment (MISSE-14) test campaign [1]. Although PCMs have previously been noted for their resilience to various forms of radiation [2], they had not been tested in a realistic space environment until this exposure campaign with joint NASA and MIT collaboration. During the six-month total open exposure time in low earth orbit (LEO), high-resolution cameras scanned and captured photographs of the samples to detect changes as a function of time along with on-orbit measured temperature, UV radiation, total atomic oxygen fluence, and total ionizing radiation doses. The samples were returned to NASA Langley Research Center in March 2022 for post-flight characterization. This duplicated the preflight characterization (i.e., material composition and crystallinity that limits switching speed, index contrast, loss, etc.) conducted before launch. The space sector has witnessed tremendous growth within the past decade—not only from government agencies but also entrants from the private sector. Future growth in the capabilities of Earth observation, deep space, and planetary surface missions using miniaturized spacecraft platforms can only be sustained by innovations in the design of remote sensors and other sub-systems. Active metasurface optics with enhanced tunability and reconfigurability continues to redefine the boundaries of optical science [3]. The introduction of PCM technology and associated optical devices will help to accelerate the adoption of new architectures for reduced size, weight, power, and cost (SWaP-C) platforms in space.Here we introduce results obtained from the MISSE-14 mission related to space qualification of PCM-based optic devices and constituent materials. We then discuss our recent work developing active integrated photonic devices and metasurface optics based on PCMs for space applications. This includes tunable and reconfigurable optical metasurface devices to support NASA space communication and LIDAR applications. PCMs are quickly becoming interesting photonics materials but questions related to mission suitability remain, particularly in regard to key properties like figures-of-merit (FOM, Δn/Δk), glass forming temperatures, and phase transition speeds. This talk will describe efforts to afford researchers the ability to have access to cost-effective data on exposure-induced changes to PCM fundamental physical and optical properties to assess their utility for space applications. The MISSE-14 sample exposure campaign allows a complete understanding of the limitations of the PCMs for various space-based electronic and optoelectronic applications.

Chalcogenide Phase change material↗
DOE OSTI2022

Detecting missing struts in metallic micro-lattices using high speed melt pool thermal monitoring

Metal lattices are an important class of cellular materials that offer great advantages by providing high-strength and lightweight structures as compared to bulk materials. Progress in additive manufacturing techniques has led to increased complexity in design and shape of produced objects and is greatly beneficial for the development of metallic lattice structures. However additive manufacturing of lattices suffers from unpredictable defect creation that can compromise its mechanical integrity. Although post-build inspection techniques can provide quality assurance of the process, accurate assessment can be technically challenging, time consuming and costly. In this work, we investigate the use of high-speed measurements of thermal emission from the melt pool to identify defective individual struts formed with a missing bottom half in an otherwise fully built lattice structure produced with laser powder bed fusion. Surprisingly, results indicate lower photodiode signal, suggesting colder melt pool surface temperature, when printing struts with missing bottom half as compared to nominal struts. Additional thermographic imaging and multi-physics simulations reveal that the low photodiode signal is accompanied by presence of hot spatters carrying heat away from detection and continuous avalanche of powder on the melt pool. Based on these observations, a method was developed to identify defective individual struts with missing bottom half in full built lattices. This prediction approach provides valuable insights about part quality which are important for process qualification and illustrates the utility of melt pool thermal emission monitoring for identifying specific defects introduced by laser powder bed fusion.

36 MATERIALS SCIENCE↗
DOE OSTI2023

BISON validation to in situ cladding burst test and high-burnup LOCA experiments

The process for developing and qualifying nuclear fuels for commercial nuclear application requires fundamental material development, characterization, and design; out-of-pile testing on unirradiated materials; integral fuel rod irradiations, testing, and postirradiation examinations; and transient analyses. The historical approach depends on the generation of large empirical datasets and series of integral fuel rod irradiations, and this approach ultimately takes ~20 years—or sometimes longer—to acquire data through extensive sequential testing. Thus, the qualification and eventual deployment of new fuel systems constitute a long process. However, recent technological advancements have provided researchers the opportunity to perform out-of-cell, in situ measurements to assess material performance for the duration of the experiment. One such example of this capability is the use of digital image coordination and thermal imaging to assess Zircaloy cladding performance under a simulated loss-of-coolant accident (LOCA) transient condition. In situ measurements generally provide high-fidelity strain, strain rates, and temperature surface maps. This is critical for the US nuclear industry, which is actively developing a technical basis to support extending the peak rod average burnup from 62 to ~75 GWd/tU and the deployment of accident-tolerant fuel. However, the US Nuclear Regulatory Commission (NRC) outlined in its research information letter several technical issues that the industry must address before extending burnup. One topic of specific interest is understanding the cladding balloon and rupture geometry during the LOCA heat-up phase. By leveraging these advanced in situ capabilities, this work used in situ data generated from a simulated LOCA to better understand high-temperature creep and its effect on Zircaloy balloon and rupture performance. Here, this work used the BISON fuel performance code to assess the high-temperature creep model predictions with in situ data.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1980

Interaction of high voltage surfaces with the space plasma

High voltage solar arrays provide spacecraft power while optimizing mass and power efficiency. Operating such arrays in the space plasma environment can result in anomalously large currents being collected through insulation defects. Two thicknesses of the insulating material were tested, with no effect found due to insulator thickness. In these tests the polyimide thickness was always much less than the pinhole diameter. The pinhole area was varied over an area range of more than 30:1. It was found that the current collected was independent of the pinhole area for hole diameters from 0.35 to 2.0 mm. Two types of adhesives were tried in two different configurations. The adhesives were chosen for their extreme difference in vacuum qualifications. Neither adhesive types nor configuration made a significant difference in current collection. The temperature of the insulating material was also varied. It was found that current collection decreased with increasing temperature. Tests were conducted to see if pinhole current collection decreased with time, as was indicated by the effects of several short tests. Current was collected for over four hours while the conductor potential was held constant at 1000 volts. A smooth decrease with time was not observed, but rather a roughly constant current collection with brief surges to high values. Tests were also conducted with the simulated solar cell biased negative. The current was found to be proportional to pinhole area.

Kaufman, H. R.↗
NASA NTRS1989

Field joint protection system rain qualification test report

This report documents the procedures, performance, and results obtained from the Field Joint Protection System (FJPS) rain test. This test was performed to validate that the flight configuration FJPS prevents the accumulation of moisture in the redesigned solid rocket motor (RSRM) field joints when subjected to simulated prelaunch natural rain environments. The FJPS test article was exposed to rain simulation for approximately 50 minutes. During the test, water entered through the open upper end of the systems tunnel and was funneled down between the tunnel and case. A sealant void at the moisture seal butt splice allowed this water to flow underneath the FJPS. The most likely cause of voids was improper bondline preparation, particularly on the moisture seal surface. In total, water penetrated underneath approximately 60 percent of the FJPS circumference. Because the test article was substantially different from flight configuration (no systems tunnel closeout), results of this test will not affect current flight motors. Due to the omission of systems tunnel covers and systems tunnel floor plate closeout, the test assembly was not representative of flight hardware and resulted in a gross overtest. It is therefore recommended that the test be declared void. It is also recommended that the test be repeated with a complete closeout of the systems tunnel, sealed systems tunnel ends, and improved adhesive bondline preparation.

Cook, M.↗
NASA NTRS1999

Development of a 12-Thrust Chamber Kerosene /Oxygen Primary Rocket Sub-System for an Early (1964) Air-Augmented Rocket Ground-Test System

Airbreathing/Rocket combined-cycle, and specifically rocket-based combined- cycle (RBCC), propulsion systems, typically employ an internal engine flow-path installed primary rocket subsystem. To achieve acceptably short mixing lengths in effecting the "air augmentation" process, a large rocket-exhaust/air interfacial mixing surface is needed. This leads, in some engine design concepts, to a "cluster" of small rocket units, suitably arrayed in the flowpath. To support an early (1964) subscale ground-test of a specific RBCC concept, such a 12-rocket cluster was developed by NASA's Marshall Space Flight Center (MSFC). The small primary rockets used in the cluster assembly were modified versions of an existing small kerosene/oxygen water-cooled rocket engine unit routinely tested at MSFC. Following individual thrust-chamber tests and overall subsystem qualification testing, the cluster assembly was installed at the U. S. Air Force's Arnold Engineering Development Center (AEDC) for RBCC systems testing. (The results of the special air-augmented rocket testing are not covered here.) While this project was eventually successfully completed, a number of hardware integration problems were met, leading to catastrophic thrust chamber failures. The principal "lessons learned" in conducting this early primary rocket subsystem experimental effort are documented here as a basic knowledge-base contribution for the benefit of today's RBCC research and development community.

Pryor, D.↗
NASA NTRS1989

Development of an infrared imaging system for the surface tension driven convection experiment

An infrared imaging system is used to quantify the imposed surface temperature distribution along a liquid/gas free surface in support of the Surface Tension Driven Convection Experiment, a planned Space Transportation System flight experiment. For ground-based work a commercially available instrument was used to determine the feasibility of using the type of imaging system for this experiment. The ground-based work was used as a baseline for compiling specifications for a flight qualified imager to be designed, fabricated, tested and qualified for flight. The requirements and specifications for the flight model are given along with the reasons for departures from the ground-based equipment. The flight qualification requirements discussed are a representative sample of the necessary procedures which must be followed to flight qualify diagnostic equipment for use aboard the STS. The potential problems and concerns associated with operating an imaging system in orbit are also discussed.

Pline, Alexander D.↗