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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 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
NASA NTRS2000

Novel Vibration Damping of Ceramic Matrix Composite Turbine Blades Developed for RLV Applications

The Reusable Launch Vehicle (RLV) represents the next generation of space transportation for the U.S. space program. The goal for this vehicle is to lower launch costs by an order of magnitude from $10,000/lb to $1,000/lb. Such a large cost reduction will require a highly efficient operation, which naturally will require highly efficient engines. The RS-2200 Linear Aerospike Engine is being considered as the main powerplant for the RLV. Strong, lightweight, temperature-resistant ceramic matrix composite (CMC) materials such as C/SiC are critical to the development of the RS-2200. Preliminary engine designs subject turbopump components to extremely high frequency dynamic excitation, and ceramic matrix composite materials are typically lightly damped, making them vulnerable to high-cycle fatigue. The combination of low damping and high-frequency excitation creates the need for enhanced damping. Thus, the goal of this project has been to develop well-damped C/SiC turbine components for use in the RLV. Foster-Miller and Boeing Rocketdyne have been using an innovative, low-cost process to develop light, strong, highly damped turbopump components for the RS-2200 under NASA s Small Business Innovation Research (SBIR) program. The NASA Glenn Research Center at Lewis Field is managing this work. The process combines three-dimensionally braided fiber reinforcement with a pre-ceramic polymer. The three-dimensional reinforcement significantly improves the structure over conventional two-dimensional laminates, including high through-the-thickness strength and stiffness. Phase I of the project successfully applied the Foster-Miller pre-ceramic polymer infiltration and pyrolysis (PIP) process to the manufacture of dynamic specimens representative of engine components. An important aspect of the program has been the development of the manufacturing process. Results show that the three-dimensionally braided carbon-fiber reinforcement provides good processability and good mechanical stiffness and strength in comparison to materials produced with competing processes as shown in the graphs.

Min, James B.↗
NASA NTRS2006

Numerical Evaluation of Mode 1 Stress Intensity Factor as a Function of Material Orientation For BX-265 Foam Insulation Material

Foam; a cellular material, is found all around us. Bone and cork are examples of biological cell materials. Many forms of man-made foam have found practical applications as insulating materials. NASA uses the BX-265 foam insulation material on the external tank (ET) for the Space Shuttle. This is a type of Spray-on Foam Insulation (SOFI), similar to the material used to insulate attics in residential construction. This foam material is a good insulator and is very lightweight, making it suitable for space applications. Breakup of segments of this foam insulation on the shuttle ET impacting the shuttle thermal protection tiles during liftoff is believed to have caused the space shuttle Columbia failure during re-entry. NASA engineers are very interested in understanding the processes that govern the breakup/fracture of this complex material from the shuttle ET. The foam is anisotropic in nature and the required stress and fracture mechanics analysis must include the effects of the direction dependence on material properties. Material testing at NASA MSFC has indicated that the foam can be modeled as a transversely isotropic material. As a first step toward understanding the fracture mechanics of this material, we present a general theoretical and numerical framework for computing stress intensity factors (SIFs), under mixed-mode loading conditions, taking into account the material anisotropy. We present mode I SIFs for middle tension - M(T) - test specimens, using 3D finite element stress analysis (ANSYS) and FRANC3D fracture analysis software, developed by the Cornel1 Fracture Group. Mode I SIF values are presented for a range of foam material orientations. Also, NASA has recorded the failure load for various M(T) specimens. For a linear analysis, the mode I SIF will scale with the far-field load. This allows us to numerically estimate the mode I fracture toughness for this material. The results represent a quantitative basis for evaluating the strength and fracture properties of anisotropic foam insulation material.

Knudsen, Erik↗
NASA NTRSDate not supplied

Considerations For Waste-to-Base Future Research Paths

Developing innovative technologies to reprocess low value waste into high value base products will enable a new “Waste-to-Base” (WtB) capability leading to innovative approaches to space mission design. Systems engineers and mission architects will work together under a new paradigm in logistics planning. Equipment, components, packaging, storage, and structures will be understood not only by functional requirements, but also in terms of useful lifetimes and materials of construction. The advent of a new technical discipline - reprocess engineering - will grow from the intersection between chemical, mechanical, and systems engineering, mission design, and logistics planning. A crowdsourcing approach was employed to gather low Technology Readiness Level (TRL) concepts into workable solutions for issues in trash management, CO 2 processing, foam reprocessing, and fecal processing. The results of the crowdsourcing activities are summarized along with a discussion for future technology development work.

Logistics reduction↗
NASA NTRS2010

Grain Boundary Engineering the Mechanical Properties of Allvac 718Plus(Trademark) Superalloy

Grain Boundary Engineering can enhance the population of structurally-ordered "low S" Coincidence Site Lattice (CSL) grain boundaries in the microstructure. In some alloys, these "special" grain boundaries have been reported to improve overall resistance to corrosion, oxidation, and creep resistance. Such improvements could be quite beneficial for superalloys, especially in conditions which encourage damage and cracking at grain boundaries. Therefore, the effects of GBE processing on high-temperature mechanical properties of the cast and wrought superalloy Allvac 718Plus (Allvac ATI) were screened. Bar sections were subjected to varied GBE processing, and then consistently heat treated, machined, and tested at 650 C. Creep, tensile stress relaxation, and dwell fatigue crack growth tests were performed. The influences of GBE processing on microstructure, mechanical properties, and associated failure modes are discussed.

Gabb, Timothy P.↗
NASA NTRS2000

Mechanically Induced g-Jitter from Space Station Rotary Joints

The mission of the International Space Station is to provide a working laboratory in orbit for research in engineering, life sciences, and microgravity. Among the microgravity disciplines that are preparing to utilize this international resource are materials processing, combustion, fluid dynamics, biotechnology, and fundamental physics. The Station promises to enable significant advances in each of these areas by making available a research facility in which gravitational and other accelerations, and their corresponding buoyancy and diffusion effects on various physical processes, are orders of magnitude lower than they are on Earth. In order to fulfill this promise, it is not enough for the Space Station to simply replicate a typical terrestrial scientific laboratory in orbit. Although an orbiting laboratory is free of most of the effects of gravitational acceleration by virtue of its free fall condition, it also produces structural vibration or jitter that can interfere with the processes under study. To ensure the quality of the acceleration environment and enable a successful mission, the Space Station Program has limited potential disturbances in two ways: first, by isolating the most sensitive payloads from the vehicle structure, and second, by quieting major disturbances at their sources. The first area, payload isolation, is implemented inside the pressurized modules at the rack level. Sub-rack level isolators have also been developed. This paper addresses the second area, disturbance source limits, for one of the major sources of mechanical noise on the Space Station: the Solar Alpha Rotary Joints. Due to the potential for large disturbances to the microgravity environment, an initial analytical prediction of rotary joint vibration output was made. Key components were identified and tested to validate the analytical predictions. Based on the component test results, the final vibration output of the joints was verified by a test on each fully assembled flight unit. This paper describes the Space Station microgravity requirements, the rotary joint hardware, and the disturbance producing aspects of joint operation. The test setup, instrumentation, test conditions, and results for the component level and system level measurements are described. An overall forcing function that describes the maximum torque imparted to the Station is created based on the test results, and these disturbances are shown to meet the applicable Space Station microgravity requirements.

Boucher, Robert L.↗
NASA NTRS2014

SpaceCube v2.0 Space Flight Hybrid Reconfigurable Data Processing System

This paper details the design architecture, design methodology, and the advantages of the SpaceCube v2.0 high performance data processing system for space applications. The purpose in building the SpaceCube v2.0 system is to create a superior high performance, reconfigurable, hybrid data processing system that can be used in a multitude of applications including those that require a radiation hardened and reliable solution. The SpaceCube v2.0 system leverages seven years of board design, avionics systems design, and space flight application experiences. This paper shows how SpaceCube v2.0 solves the increasing computing demands of space data processing applications that cannot be attained with a standalone processor approach.The main objective during the design stage is to find a good system balance between power, size, reliability, cost, and data processing capability. These design variables directly impact each other, and it is important to understand how to achieve a suitable balance. This paper will detail how these critical design factors were managed including the construction of an Engineering Model for an experiment on the International Space Station to test out design concepts. We will describe the designs for the processor card, power card, backplane, and a mission unique interface card. The mechanical design for the box will also be detailed since it is critical in meeting the stringent thermal and structural requirements imposed by the processing system. In addition, the mechanical design uses advanced thermal conduction techniques to solve the internal thermal challenges.The SpaceCube v2.0 processing system is based on an extended version of the 3U cPCI standard form factor where each card is 190mm x 100mm in size The typical power draw of the processor card is 8 to 10W and scales with application complexity. The SpaceCube v2.0 data processing card features two Xilinx Virtex-5 QV Field Programmable Gate Arrays (FPGA), eight memory modules, a monitor FPGA with analog monitoring, Ethernet, configurable interconnect to the Xilinx FPGAs including gigabit transceivers, and the necessary voltage regulation. The processor board uses a back-to-back design methodology for common parts that maximizes the board real estate available. This paper will show how to meet the IPC 6012B Class 3A standard with a 22-layer board that has two column grid array devices with 1.0mm pitch. All layout trades such as stack-up options, via selection, and FPGA signal breakout will be discussed with feature size results. The overall board design process will be discussed including parts selection, circuit design, proper signal termination, layout placement and route planning, signal integrity design and verification, and power integrity results. The radiation mitigation techniques will also be detailed including configuration scrubbing options, Xilinx circuit mitigation and FPGA functional monitoring, and memory protection.Finally, this paper will describe how this system is being used to solve the extreme challenges of a robotic satellite servicing mission where typical space-rated processors are not sufficient enough to meet the intensive data processing requirements. The SpaceCube v2.0 is the main payload control computer and is required to control critical subsystems such as autonomous rendezvous and docking using a suite of vision sensors and object avoidance when controlling two robotic arms.

Xilinx FPGA↗
NASA NTRS1972

Diffusion bonding and its application to manufacturing

In its simplest form diffusion bonding is accomplished by placing clean metal surfaces together under a sufficient load and heating. The natural interatomic attractive force between atoms transforms the interface into a natural grain boundary. Therefore, in principle, the properties of the bond area are identical to those of the parent metal. Other advantages of diffusion bonding over conventional methods of bonding include freedom from residual stresses, excessive deformation, foreign metals, or changed crystal structures. Stainless steels, nickel-base superalloys, and aluminum alloys have all been successfully joined. Complex hardware, including integrated flueric devices, jet engine servovalves, and porous woven structures have been fabricated. The processing involved is discussed, along with such theoretical considerations as the role of metal surfaces, the formation of metal contact junctions, and the mechanisms of material transport in diffusion bonding.

Spurgeon, W. M.↗
NASA NTRS1980

Materials processing in Space/Spacelab. FES/VCGS payload critical design review

A 25 mW He-Ne laser holographic recorder for recording the solution growth of triglycine sulfate crystals under low-zero gravity conditions is described. A systems engineering and design analysis, and mechanical and electrical design analyses of the equipmentation are presented. The equipment, fabricated for the Sl-3 flight on the space shuttle, was designed to take 300 holograms (two orthogonal views) on 50-235 film of each growth experiment. Specifications and capabilities for support module mechanical assemblies are lso presented.

Source record↗
NASA NTRS1982

Acoustic methodology review

It is important for industry and NASA to assess the status of acoustic design technology for predicting and controlling helicopter external noise in order for a meaningful research program to be formulated which will address this problem. The prediction methodologies available to the designer and the acoustic engineer are three-fold. First is what has been described as a first principle analysis. This analysis approach attempts to remove any empiricism from the analysis process and deals with a theoretical mechanism approach to predicting the noise. The second approach attempts to combine first principle methodology (when available) with empirical data to formulate source predictors which can be combined to predict vehicle levels. The third is an empirical analysis, which attempts to generalize measured trends into a vehicle noise prediction method. This paper will briefly address each.

Schlegel, R. G.↗
NASA NTRS1985

Crystal growth for high-efficiency silicon solar cells workshop: Summary

The state of the art in the growth of silicon crystals for high-efficiency solar cells are reviewed, sheet requirements are defined, and furture areas of research are identified. Silicon sheet material characteristics that limit cell efficiencies and yields were described as well as the criteria for the ideal sheet-growth method. The device engineers wish list to the material engineer included: silicon sheet with long minority carrier lifetime that is uniform throughout the sheet, and which doesn't change during processing; and sheet material that stays flat throughout device processing, has uniform good mechanical strength, and is low cost. Impurities in silicon solar cells depreciate cell performance by reducing diffusion length and degrading junctions. The impurity behavior, degradation mechanisms, and variations in degradation threshold with diffusion length for silicon solar cells were described.

Dumas, K. A.↗
NASA NTRS1994

A versatile nondestructive evaluation imaging workstation

Ultrasonic C-scan and eddy current imaging systems are of the pointwise type evaluation systems that rely on a mechanical scanner to physically maneuver a probe relative to the specimen point by point in order to acquire data and generate images. Since the ultrasonic C-scan and eddy current imaging systems are based on the same mechanical scanning mechanisms, the two systems can be combined using the same PC platform with a common mechanical manipulation subsystem and integrated data acquisition software. Based on this concept, we have developed an IBM PC-based combined ultrasonic C-scan and eddy current imaging system. The system is modularized and provides capacity for future hardware and software expansions. Advantages associated with the combined system are: (1) eliminated duplication of the computer and mechanical hardware, (2) unified data acquisition, processing and storage software, (3) reduced setup time for repetitious ultrasonic and eddy current scans, and (4) improved system efficiency. The concept can be adapted to many engineering systems by integrating related PC-based instruments into one multipurpose workstation such as dispensing, machining, packaging, sorting, and other industrial applications.

Chern, E. James↗
NASA NTRS1997

Methods for the Organogenesis of Skeletal Muscle in Tissue Culture

Skeletal muscle structure is regulated by many factors, including nutrition, hormones, electrical activity, and tension. The muscle cells are subjected to both passive and active mechanical forces at all stages of development and these forces play important but poorly understood roles in regulating muscle organogenesis and growth. For example, during embryogenesis, the rapidly growing skeleton places large passive mechanical forces on the attached muscle tissue. These forces not only help to organize the proliferating mononucleated myoblasts into the oriented, multinucleated myofibers of a functional muscle but also tightly couple the growth rate of muscle to that of bone. Postnatally, the actively contracting, innervated muscle fibers are subjected to different patterns of active and passive tensions which regulate longitudinal and cross sectional myofiber growth. These mechanically-induced organogenic processes have been difficult to study under normal tissue culture conditions, resulting in the development of numerous methods and specialized equipment to simulate the in vivo mechanical environment.These techniques have led to the "engineering" of bioartificial muscles (organoids) which display many of the characteristics of in vivo muscle including parallel arrays of postmitotic fibers organized into fascicle-like structures with tendon-like ends. They are contractile, express adult isoforms of contractile proteins, perform directed work, and can be maintained in culture for long periods. The in vivo-like characteristics and durability of these muscle organoids make them useful for long term in vitro studies on mechanotransduction mechanisms and on muscle atrophy induced by decreased tension. In this report, we described a simple method for generating muscle organoids from either primary embrionic avain or neonatal rodent myoblasts.

Vandenburgh, Herman↗
NASA NTRS2003

Low Cost Heat Treatment Process for Production of Dual Microstructure Superalloy Disks

There are numerous incidents where operating conditions imposed on a component mandate different and distinct mechanical property requirements from location to location within the component. Examples include a crankshaft in an internal combustion engine, gears for an automotive transmission, and disks for a gas turbine engine. Gas turbine disks are often made from nickel-base superalloys, because these disks need to withstand the temperature and stresses involved in the gas turbine cycle. In the bore of the disk where the operating temperature is somewhat lower, the limiting material properties are often tensile and fatigue strength. In the rim of the disk, where the operating temperatures are higher than those of the bore, because of the proximity to the combustion gases, resistance to creep and crack growth are often the limiting properties.

Gayda, John↗
NASA NTRS2019

Powering OSCAR

Recycling waste has been an issue on Earth for decades. The OSCAR project seeks to find ways to make sure that it does not become an issue in space. The main focus of OSCAR is the combustion of waste and reclamation of gaseous products in microgravity. The first phase of testing relies on a ground rig that operates both under normal (Earth) gravity and in drop tower tests that briefly simulate a microgravity environment. In the second phase, a test will be performed during a suborbital flight were the experiment will be carried out in microgravity. Throughout the spring term, interns have played an integral part in continuing the progress made by the project. They performed work in upgrading the electrical and mechanical systems that make up OSCAR. They made multiple improvements to the test rig's operating software to improve readability and usability. They prepared and edited documents that were vital to the engineering process. And, they were responsible for performing lab tests and refining the lab operations document and procedure. The interns were a big help in maintaining the rigorous test schedule. OSCAR, which stands for Orbital Syngas Commodity Augmentation Reactor, is to find a way to turn astronaut waste into chemical energy. The two parts of this are important: finding a way to dispose of waste generated in space, and seeing if there is a way to recycle that waste into chemical energy. The importance of the disposal aspect is that there is currently no way to dispose of, or recycle, waste that is created in space other than jettisoning it (which is what the ISS does via empty supply capsules). As manned missions go deeper into space, that method will no longer be viable, as a craft would essentially be littering the space and planets that they visit. Energy reclamation is also important because of the high monetary and spatial costs of sending supplies on space missions. Every little bit extra that can be reused out of what is sent can save room and funds for other supplies. The facet of this problem that the OSCAR project is focusing on is how to combust waste in zero gravity. Combustion in the presence of gravity is one of those things that is taken for granted. When something burns on Earth, the flames rise above the fuel as oxygen flows from underneath. In microgravity, the flames surround the object completely, which restricts the amount of oxygen that can reach the fuel, and retards the combustion. OSCAR uses a vortex reaction chamber to counter this phenomenon. The OSCAR test rig will eventually be tested on a suborbital flight to see if it is an effective solution to the issue in real-world conditions. Currently, there is a prototype test rig that is fully functional. This rig has been previously tested in a 2 second drop test at Glenn Research Center’s (GRC) Zero Gravity Facility (ZGF). (The free-fall conditions of the drop mimic microgravity, if only for a brief period of time). This session’s focus was on upgrading the test rig and software, updating the paperwork, performing additional lab tests, and readying the rig for the five second drop test, again at GRC. II. Upgrades The state of the testing rig at the start of the session was in between its configurations for the two second drop tower and the five second drop tower. The rig needed upgrades to address various insufficiencies that either were discovered during the two second campaign or were a direct result of the differences between the two drop tower setups. The main differences that had to be handled were the increase in shock loads from 30g to 65g, a difference in drop indicating signal (on the falling edge of a pulse instead of a change from high to low), and the ambient pressure of the test apparatus (the two second tower dropped the rig in atmosphere, while the five second tower drops in vacuum).

Cauvel, Thomas↗
NASA NTRS2015

Noise Characteristics of a Four-Jet Impingement Device Inside a Broadband Engine Noise Simulator

The noise generation mechanisms for four directly impinging supersonic jets are investigated employing implicit large eddy simulations with a higher-order accurate weighted essentially non-oscillatory shock-capturing scheme. Impinging jet devices are often used as an experimental apparatus to emulate a broadband noise source. Although such devices have been used in many experiments, a detailed investigation of the noise generation mechanisms has not been conducted before. Thus, the underlying physical mechanisms that are responsible for the generation of sound waves are not well understood. The flow field is highly complex and contains a wide range of temporal and spatial scales relevant for noise generation. Proper orthogonal decomposition of the flow field is utilized to characterize the unsteady nature of the flow field involving unsteady shock oscillations, large coherent turbulent flow structures, and the sporadic appearance of vortex tubes in the center of the impingement region. The causality method based on Lighthill's acoustic analogy is applied to link fluctuations of flow quantities inside the source region to the acoustic pressure in the far field. It will be demonstrated that the entropy fluctuation term in the Lighthill's stress tensor plays a vital role in the noise generation process. Consequently, the understanding of the noise generation mechanisms is employed to develop a reduced-order linear acoustic model of the four-jet impingement device. Finally, three linear acoustic FJID models are used as broadband noise sources inside an engine nacelle and the acoustic scattering results are validated against far-field acoustic experimental data.

Broadband↗
NASA NTRS1990

Impact of a process improvement program in a production software environment: Are we any better?

For the past 15 years, Computer Sciences Corporation (CSC) has participated in a process improvement program as a member of the Software Engineering Laboratory (SEL), which is sponsored by GSFC. The benefits CSC has derived from involvement in this program are analyzed. In the environment studied, it shows that improvements were indeed achieved, as evidenced by a decrease in error rates and costs over a period in which both the size and the complexity of the developed systems increased substantially. The principles and mechanics of the process improvement program, the lessons CSC has learned, and how CSC has capitalized on these lessons are also discussed.

Heller, Gerard H.↗
NASA NTRS1972

Solar energy, its conversion and utilization

The work being carried out at the University of Florida Solar Energy and Energy Conversion Laboratory in converting solar energy, our only income, into other needed and useful forms of energy is described. A treatment such as this demonstrates, in proper perspective, how solar energy can benefit mankind with its many problems of shortages and pollution. Descriptions were given of the conversion processes, equipment, and performance. The testing of materials, solar water heating, space heating, cooking and baking, solar distillation, refrigeration and air-conditioning, work with the solar furnace, conversion to mechanical power, hot air engines, solar-heated sewage digestion, conversion to electricity, and other devices will be discussed.

Farber, E. A.↗