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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Metal Additive Manufacturing Process Selection and Development Lifecycle for Propulsion Components

Metal additive manufacturing (AM) is a generic term that captures a variety of fabrication processes. Each of these manufacturing process has unique advantages and challenges for use in aerospace propulsion applications. The most commonly used AM processes include Powder Bed Fusion (PBF), Directed Energy Deposition (DED), and solid-state processes as in Cold Spray, Ultrasonic Additive Manufacturing, and Additive Friction Stir Deposition. While detailed research has been conducted among many of the AM processes to mature processing parameters and material properties, navigating which processes are best to select is difficult as it is based on specific component requirements. The focus of this presentation is to provide an overview of considerations for each of metal AM process selection for aerospace components based on various key attributes. These key attributes include geometric considerations, metallurgical characteristics, cost basis, post-processing and maturity of the processes. The data for these trade selections are based on studies that NASA as performed internally and with academic and industry partners. These studies include multiple AM build experiments to evaluate (1) geometric variations and constraints within the processes, (2) alloy characterization and mechanical testing, (3) pathfinder component development and hot-fire evaluations, and (4) certification approaches. This presentation summarizes these results and is meant to introduce specific examples which show what to consider when designing a metal AM component for aerospace propulsion applications.

Paul Gradl↗
NASA NTRS1977

Experimental melting relations of 63545, 76015, and 76055

The experiments discussed were conducted for the purpose of placing additional constraints on the origin of lunar highlands noritic compositions. The sample 63545 represents a fine-grained, crystalline melt rock consisting of pink spinel, plagioclase, divine, interstitial glass, minor oxides, and metal. According to Chao (1973), 76055 is an olivine-bearing micronorite hornfels with abundant xenocrysts and xenoliths. The sample 76015 is a vesicular, poikilitic impact melt with a homogeneous matrix. The obtained experimental melting relations of 63545, 76055, and 76015, are examined, taking into account experimental petrology and trace element chemistry of mare basalts. It is concluded that the studied compositions do not represent magmas derived by partial melting of either cosmic or differentiated source regions at any pressure in the moon. Presently available information would seem to favor an origin by impact-fusion of several highlands components.

Delano, J. W.↗
NASA NTRS2014

Topical Issue on Optical Particle Characterization and Remote Sensing of the Atmosphere: Part I

Increasing our understanding of the Earth-atmosphere system has been a scientific and political priority for the last few decades. This system not only touches on environmental science, but it has applicability to our broader understanding of planetary atmospheres in general. While this issue focuses primarily on electromagnetics, other fundamental fields of science, including fluid and thermodynamics play major roles. In recent years, significant research efforts have led to advances in the fields of radiative transfer and electromagnetic scattering from irregularly shaped particles. Recently, several workshops and small conferences have taken place to promote the fusion of these efforts. Late in 2013, for instance, two such meetings took place. The Optical Characterization of Atmospheric Aerosols (OCAA) meeting took place in Smolenice, Slovakia to promote a better understanding of microphysical properties of aerosol particles, and the characterization of such atmospheric particles using optical techniques. A complementary conference was organized in Nagoya, Japan, the 3rd International Symposium on Atmospheric Light Scattering and Remote Sensing (ISALSaRS), whose goal is to fuse the advances achieved in particle characterization with remote-sensing techniques. While the focus of these meetings is slightly different, they represent the same aspects of this rapidly growing field. This Topical Issue is the first of two parts. Within this issue we analyze different aspects of the problem of atmospheric characterization and present a broad overview of the topical area. Research includes theory and experiment, ranging from fundamental microphysical properties of individual aerosol particles to broad characterizations of atmospheric properties. Since this is an active field, we also have encouraged the submission of ideas for new methodologies that may represent the future of the field.

aerosols↗
NASA NTRS2002

Functional Characterization of G12, a Gene Required for Mitotic Progression during Gastrulation in Zebrafish

In a differential RNA display screen we have isolated a zebrafish gene, G12, for which homologs can only be found in DNA databases for vertebrates, but not invertebrates. This suggests that this is a gene required specifically in vertebrates. G12 expression is upregulated at mid-blastula transition (MBT). Morpholino inactivation of this gene by injection into 1-cell embryos results in mitotic defects and apoptosis shortly after MBT. Nuclei in morpholino treated embryos also display segregation defects. We have characterized the localization of this gene as a GFP fusion in live and fixed embryos. Overexpression of G12-GFP is non-toxic. Animals retain GFP expression for at least 7 days with no developmental defects, Interestingly in these animals G12-GFP is never detectable in blood cells though blood is present. In the deep cells of early embryos, G 12GFP is localized to nuclei and cytoskeletal elements in interphase and to the centrosome and spindle apparatus during mitosis. In the EVL, G12-GFP shows additional localization to the cell periphery, especially in mitosis. In the yolk syncytium, G12-GFP again localizes to nuclei and strongly to cytoplasmic microtubules of migrating nuclei at the YSL margin. Morpholinc, injection specifically into the YSL after cellularization blocks epiboly and nuclei of the YSL show mitotic defects while deep cells show no mitotic defects and continue to divide. Rescue experiments in which morpholino and G12-GFP RNA are co-injected indicate partial rescue by the G12-GFP. The rescue is cell autonomous; that is, regions of the embryo with higher G12-GFP expression show fewer mitotic defects. Spot 14, the human bomolog of G12, has been shown to be amplified in aggressive breast tumors. This finding, along with our functional and morphological data suggest that G12 and spot 14 are vertebrate-specific and may function either as mitotic checkpoints or as structural components of the spindle apparatus.

Reinsch, Sigrid↗
NASA NTRS1962

Aerodynamic Analysis of Tektites and Their Parent Bodies

Experiment and analysis indicate that the button-type australites were derived from glassy spheres which entered or re-entered the atmosphere as cold solid bodies; in case of average-size specimens, the entry direction was nearly horizontal and the entry speed between 6.5 and 11.2 km/sec. Terrestrial origin of such spheres is impossible because of extremely high deceleration rates at low altitudes. The limited extension of the strewn fields rules out extraterrestrial origin of clusters of such spheres because of stability considerations for clusters in space. However, tektites may have been released as liquid droplets from glassy parent bodies ablating in the atmosphere of the earth. The australites then have skipped together with the parent body in order to re-enter as cold spheres. Terrestrial origin of a parent body would require an extremely violent natural event. Ablation analysis shows that fusion of opaque siliceous stone into glass by aerodynamic heating is impossible.

Adams, E. W.↗
NASA NTRSDate not supplied

Icing Physics Studies Using the 3D SIDRM Test Article: Aerodynamic and Supercooled Liquid Icing Analysis

In-flight icing is an important safety issue and is a factor that affects aircraft design and performance. Newer regulations are driving a need for improvements in airframe and engine icing simulation capability. Experimental data is required for development of icing physics models and simulation validation. To that end, this paper presents the analysis of the supercooled liquid icing data subset from tests conducted in 2022 at the NASA Icing Research Tunnel that studied both supercooled water and ice-crystal icing. The test article that was utilized replicated 3D geometrical features of an inter-compressor duct and strut region of a turbofan engine. The surfaces of the Simulated Inter-compressor Duct Research Model (SIDRM) can be heated to simulate the warm surfaces of the turbofan inter-compressor duct. The test article is instrumented with pressure taps, heaters, heat flux gauges, and thermocouples, while a 3D laser scanner, cameras, and a scale to measure ice mass were utilized to characterize the icing behavior. The aim of these tests was to generate ice accretions on the SIDRM test article under well-characterized supercooled liquid icing and ice crystal icing conditions. This paper discusses measurements related to aerodynamic testing and supercooled liquid icing tests that were conducted. Aerodynamic measurements were analyzed and compared to computational simulations and were found to be in good agreement for the range of airspeeds (50 to 230 knots) and angles of attack (0 to 4°) tested. Various parametric sweeps were conducted during the supercooled liquid icing portion of the test entry (cloud median volumetric diameter ranged from 15 to 90 µm, total air temperature from -3 to -17 °C, angle of attack from 0 to 4°, and accretion time from 5 to 20 min). These sweeps were performed to measure that parameter’s impact on ice accretion size, location (icing extent), characteristics (such as glaze/rime ice and shedding behavior), and test article surface temperature. Analysis of the test data showed that clouds composed of larger drops, colder air temperatures, smaller angles of attack, and longer spray times were the primary parameters that resulted in accretions with greater ice mass. Test article angle of attack and cloud droplet size influenced the location of ice accretion as these two parameters directly impact collection efficiency. With respect to icing characteristics, total air temperature dictated icing type, and smaller cloud drop size along with warmer air temperatures resulted in greater amounts of ice shedding. Surface temperature increased during ice accretion from the release of latent (fusion) heat, where total air temperature and cloud drop size impacted the amount of surface temperature change. The icing measurements collected during the SIDRM tests will be used to develop and validate 3D computational engine icing tools, such as GlennICE, that predictively assesses the onset and growth of ice. One of the goals of the sponsoring NASA project is to develop simulation models and tools that can assist in the design and certification of engines for flight in icing conditions in a cost effective way.

supercooled liquid icing↗
NASA NTRSDate not supplied

Icing Physics Studies Using the 3D SIDRM Test Article: Aerodynamic and Supercooled Liquid Icing Analysis

In-flight icing is an important safety issue and is a factor that affects aircraft design and performance. Newer regulations are driving a need for improvements in airframe and engine icing simulation capability. Experimental data is required for development of icing physics models and simulation validation. To that end, this paper discusses analyzed data from icing tests conducted with a 3D test article in 2022 at the NASA Icing Research Tunnel. The test article, whose geometry is representative of an inter-compressor duct and strut region of a turbofan engine, has been designed and constructed to study the physics of supercooled water icing and ice crystal icing. The surfaces of the Simulated Inter-compressor Duct Research Model (SIDRM) can be heated to simulate the warm surfaces of the turbofan inter-compressor duct. The test article is instrumented with pressure taps, heaters, heat flux gauges, and thermocouples, while a 3D laser scanner, cameras, and a scale to measure ice mass were utilized to characterize the icing behavior. The aim of these tests was to generate ice accretions on the SIDRM test article under well-characterized supercooled liquid icing and ice crystal icing conditions. This paper discusses measurements related to aerodynamic tests and supercooled liquid icing tests that were conducted. Aerodynamic measurements were analyzed and compared to computational simulations and were found to be in good agreement for the range of airspeeds (50 to 230 knots) and angles of attack (0 to 4°) tested. Various parametric sweeps were conducted during the supercooled liquid icing portion of the test entry (cloud median volumetric diameter ranged from 15 to 90 µm, total air temperature from -3 to -17 °C, angle of attack from 0 to 4°, and accretion time from 5 to 20 min). These sweeps were performed to measure that parameter’s impact on ice accretion size, location, characteristics (such as glaze/rime ice and shedding behavior), and test article surface temperature. Analysis of the test data showed that clouds composed of larger drops, colder air temperatures, smaller angles of attack, and longer spray times were the primary parameters that resulted in accretions with greater ice mass. Test article angle of attack and cloud droplet size influenced the location of ice accretion as these two parameters directly impact collection efficiency. With respect to icing characteristics, total air temperature dictated icing type, and smaller cloud drop size along with warmer air temperatures resulted in greater amounts of ice shedding. Surface temperature increased during ice accretion from the release of latent (fusion) heat, where total air temperature and cloud drop size impacted the amount of surface temperature change. The icing measurements collected during the SIDRM tests will be used to develop and validate 3D computational engine icing tools, such as GlennICE, that predictively assesses the onset and growth of ice. One of the goals of the sponsoring NASA project is to develop simulation models and tools that can assist in the design and certification of engines for flight in icing conditions in a cost‑effective way.

supercooled liquid icing↗
NASA NTRS1984

Origin of the Moon: Constraints from volatile elements

Supporting arguments for the lunar fusion hypothesis include the low density of the Moon corresponding to the density of the Earth's mantle and the low volatile content of the lunar rocks vs. those of terrestrial origin. Vapor pressures of the alkali elements and their oxides increase in the following order: Na, K, Rb and Cs. The Moon should, therefore, be more depleted in Cs relative to Rb, Rb relative to K, and K relative to Na than the Earth if the fission model is correct. Analyses of lunar mare basalts and terrestrial mid-ocean ridge and other young basalts indicate that this behavior is not observed. It is possible that monovalent alkali elements might be lost from silicate materials in a different order than that inferred from elemental and oxide vapor pressures, as a result of differences in the way they are bound in silicate materials. To test this hypothesis a series of experiments was conducted to investigate alkali loss at high temperatures. Analyses indicate that the behavior of volatiles dissolved in a silicate melt is similar to that inferred from elemental and oxide vapor pressures. It is concluded that alkali element ratios in the Earth and Moon are not readily interpreted in terms of the fission hypothesis.

Kreutzberger, M. E.↗
NASA NTRS2004

Strategy Developed for Selecting Optimal Sensors for Monitoring Engine Health

Sensor indications during rocket engine operation are the primary means of assessing engine performance and health. Effective selection and location of sensors in the operating engine environment enables accurate real-time condition monitoring and rapid engine controller response to mitigate critical fault conditions. These capabilities are crucial to ensure crew safety and mission success. Effective sensor selection also facilitates postflight condition assessment, which contributes to efficient engine maintenance and reduced operating costs. Under the Next Generation Launch Technology program, the NASA Glenn Research Center, in partnership with Rocketdyne Propulsion and Power, has developed a model-based procedure for systematically selecting an optimal sensor suite for assessing rocket engine system health. This optimization process is termed the systematic sensor selection strategy. Engine health management (EHM) systems generally employ multiple diagnostic procedures including data validation, anomaly detection, fault-isolation, and information fusion. The effectiveness of each diagnostic component is affected by the quality, availability, and compatibility of sensor data. Therefore systematic sensor selection is an enabling technology for EHM. Information in three categories is required by the systematic sensor selection strategy. The first category consists of targeted engine fault information; including the description and estimated risk-reduction factor for each identified fault. Risk-reduction factors are used to define and rank the potential merit of timely fault diagnoses. The second category is composed of candidate sensor information; including type, location, and estimated variance in normal operation. The final category includes the definition of fault scenarios characteristic of each targeted engine fault. These scenarios are defined in terms of engine model hardware parameters. Values of these parameters define engine simulations that generate expected sensor values for targeted fault scenarios. Taken together, this information provides an efficient condensation of the engineering experience and engine flow physics needed for sensor selection. The systematic sensor selection strategy is composed of three primary algorithms. The core of the selection process is a genetic algorithm that iteratively improves a defined quality measure of selected sensor suites. A merit algorithm is employed to compute the quality measure for each test sensor suite presented by the selection process. The quality measure is based on the fidelity of fault detection and the level of fault source discrimination provided by the test sensor suite. An inverse engine model, whose function is to derive hardware performance parameters from sensor data, is an integral part of the merit algorithm. The final component is a statistical evaluation algorithm that characterizes the impact of interference effects, such as control-induced sensor variation and sensor noise, on the probability of fault detection and isolation for optimal and near-optimal sensor suites.

Source record↗
NASA NTRSDate not supplied

Contamination, Transportation or Transmutation in LENR Material Analyses

LENR experiments using various loading and triggering mechanisms rely on a variety of elemental and isotopic assays to determine LENR effects. These assays include optical microscopy, Scanning Electron Microscopy with Energy Dispersive X-Ray Analysis (SEM/EDX), X-Ray Photoelectron Spectroscopy (XPS) and Transmission Electron Microscopy (TEM). All of these methods observe the surface of a material. By dissolving or vaporizing the sample, Inductively Coupled Plasma Optical Element Spectroscopy (ICP-OES) can determine elemental composition (ppb) or with mass spectroscopy, isotopes (ICP/MS). One can use a focused ion beam (FIB) to cut open a sample and observe the “cut” with either SEM/EDX, or Time-of-Flight Secondary Ion Mass Spectroscopy (TOF-SIMS). High Purity Gamma Ray Spectroscopy (HPGe) and alpha/ beta Liquid Scintillator spectroscopy can be used. We’ve employed these assay methods in our NASA GRC research under both the Advanced Energy Conversion and Lattice Confinement Fusion Projects. However, there are limitations associated with each of these methods ranging from handling contamination, instrumental limitations including sensitivity and field of view, and sample preparation.

Low Energy Nuclear Reactions↗
NASA NTRS1991

Fuzzy set methods for object recognition in space applications

Progress on the following tasks is reported: (1) fuzzy set-based decision making methodologies; (2) feature calculation; (3) clustering for curve and surface fitting; and (4) acquisition of images. The general structure for networks based on fuzzy set connectives which are being used for information fusion and decision making in space applications is described. The structure and training techniques for such networks consisting of generalized means and gamma-operators are described. The use of other hybrid operators in multicriteria decision making is currently being examined. Numerous classical features on image regions such as gray level statistics, edge and curve primitives, texture measures from cooccurrance matrix, and size and shape parameters were implemented. Several fractal geometric features which may have a considerable impact on characterizing cluttered background, such as clouds, dense star patterns, or some planetary surfaces, were used. A new approach to a fuzzy C-shell algorithm is addressed. NASA personnel are in the process of acquiring suitable simulation data and hopefully videotaped actual shuttle imagery. Photographs have been digitized to use in the algorithms. Also, a model of the shuttle was assembled and a mechanism to orient this model in 3-D to digitize for experiments on pose estimation is being constructed.

Keller, James M.↗
NASA NTRSDate not supplied

Experimental Characterization of Surface Roughness and Geometric Evaluations of Thin-Wall Laser Powder Directed Energy Deposition

Additive Manufacturing (AM) has offered many new design and manufacturing opportunities for components across various industries. As AM evolves there is a need to better understand outputs of the process including geometric limitations and surface roughness based on specific application requirements. One possible application area of AM are components using thin-wall (<2 mm) microchannel heat exchangers for subsystems across aerospace, and industrial applications. AM offers the opportunity to significantly reduce the cost and lead time associated with fabricating these complex parts with internal features such as an array of cooling channels. Laser Powder Bed Fusion (L-PBF) has been continuously demonstrated as a technique to fabricate heat exchangers with internal geometric complexities. However, L-PBF is limited in the scale at which parts can be fabricated. Laser Powder Directed Energy Deposition (LP-DED) has been demonstrated as an AM technology to significantly increase the scale of which thin-wall microchannel heat exchangers could be manufactured. Successful deployment of the LP-DED technology requires critical understanding of the resulting features from the build process. Surface roughness is one of the critical areas that effects the friction factor and pressure drop within a heat exchanger and must be well understood. This presentation will provide an overview of the characterization work completed to understand the LP-DED process for thin-walls representative of hydrogen resistant alloy NASA HR-1 that would be used in a Hydrogen-environment application. An overview of the experiments conducted with varying LP-DED parameters, evaluation of various geometric channel and geometric build features and resulting surface finish will be provided along with a summary of conclusions from these experiments. Results indicate that powder size is a major contributor and surface roughness varies between closed channel shapes and external surfaces.

Directed Energy Deposition↗
NASA NTRSDate not supplied

Thin-wall Internal Channel Geometry and Surface Enhancements for Heat Exchangers using Laser Powder Directed Energy Deposition

Additive Manufacturing (AM) has offered many new design and manufacturing opportunities for components across various industries. As AM evolves there is a need to better understand outputs of the process including geometric limitations, surface texture, and post-processing surface enhancements for specific application requirements. One possible application area of AM are components using thin-wall (~1 mm) microchannel heat exchangers for subsystems across aerospace and industrial applications. Laser Powder Bed Fusion (L-PBF) is a common process for complex internal channels but the build diameter is limited to approximately 600 mm. Laser Powder Directed Energy Deposition (LP-DED) is being evaluated to produce thin-wall microchannel heat exchangers at scales beyond the L-PBF process. Successful deployment of the LP-DED technology requires characterization of geometric features from the process and potential improvements to the surface using post-processing. Surface texture, inclusive of roughness and waviness, is one of the critical attributes of AM that effects the friction factor and pressure drop within a heat exchanger and lacks data for the LP-DED process. This presentation will provide an overview of the characterization work completed of the LP-DED process for thin-walls and small channel geometry representative of various high performance alloys including NASA HR-1 and GRCop-42. An overview of the experiments conducted with varying LP-DED parameters, evaluation of various internal channel geometry, geometric build features, and resulting surface texture will be provided along with a summary of conclusions from these experiments. This study presents characterization of 2.5 mm microchannels using LP-DED, mechanisms that cause the surface texture which include powder adherence and material droop, and angled walls have a significant impact on the thickness and surface texture. Results will also be presented on various surface enhancement processes that allow for tuning of the wetting surface for friction factor, heat transfer, or fatigue life performance requirements.

Additive Manufacturing↗
NASA NTRS1978

Electron beam injection experiments - The beam-plasma discharge at low pressures and magnetic field strengths

The paper describes electron beam injection experiments which clarify observational results obtained in rocket flights. A column of enhanced density plasma, exceeding the density expected from ionization by primary beam electrons, was observed in a large vacuum system at low magnetic fields (1 to 1.5 G) and low ambient pressures (10 to the minus 6 to 10 to the minus 5 torr). The peak luminosity of the discharge was about 10 times that of the beam alone, and the radius increased by a factor of three. In the absence of the discharge, RF emission is observed at 1.1 to 1.2 times the cyclotron frequency, and a strong band of RF noise with upper frequency cutoff at about the cyclotron frequency is observed in the discharge mode, along with higher frequency noise at or near the plasma frequency. The onset of the plasma discharge is critically dependent on beam current. The described results agree with observations obtained at much higher densities and magnetic fields in fusion research studies.

Bernstein, W.↗
NASA NTRS1999

Effects of spaceflight conditions on fertilization and embryogenesis in the sea urchin Lytechinus pictus

Calcium loss and muscle atrophy are two of the main metabolic changes experienced by astronauts and crew members during exposure to microgravity in space. Calcium and cytoskeletal events were investigated within sea urchin embryos which were cultured in space under both microgravity and 1 g conditions. Embryos were fixed at time-points ranging from 3 h to 8 days after fertilization. Investigative emphasis was placed upon: (1) sperm-induced calcium-dependent exocytosis and cortical granule secretion, (2) membrane fusion of cortical granule and plasma membranes; (3) microfilament polymerization and microvilli elongation; and (5) embryonic development into morula, blastula, gastrula, and pluteus stages. For embryos cultured under microgravity conditions, the processes of cortical granule discharge, fusion of cortical granule membranes with the plasma membrane, elongation of microvilli and elevation of the fertilization coat were reduced in comparison with embryos cultured at 1 g in space and under normal conditions on Earth. Also, 4% of all cells undergoing division in microgravity showed abnormalities in the centrosome-centriole complex. These abnormalities were not observed within the 1 g flight and ground control specimens, indicating that significant alterations in sea urchin development processes occur under microgravity conditions. Copyright 1999 Academic Press.

STS-77 Shuttle Project↗
NASA NTRS2012

NASA/SPoRT's GOES-R Activities in Support of Product Development, Management, and Training

The NASA Short-term Prediction Research and Transition (SPoRT) Center supports many activities within the GOES-R Proving Grounds (PG). These include the development of imagery from existing instrumentation as a proxy to future Advanced Baseline Imager (ABI) capabilities on GOES-R. The Moderate Resolution Imaging Spectroradiometer (MODIS) and the Visible/Infrared Imager/Radiometer Suite (VIIRS) instruments are used to provide a glimpse of the multi-spectral capabilities that will become the norm as the number of channels and data rate dramatically increase with GOES-R. The NOAA/NWS has plans to provide operational users with all ABI channels at the highest resolution. Data fusion of individual channels into composite red, green, and blue imagery products will assist the end user with this future wave of information. While increasing the efficiency in the operational use of ABI channels, these composites provide only qualitative information. Within the GOES-R PG, SPoRT and other partners are exploring ways to include quantitative information as part of the composite imagery. However, limitations in local hardware processing and/or data bandwidth for users of the GOES-R data stream are challenges to overcome. This presentation will discuss the creation of these composite images as well as possible solutions to address these processing challenges. In a similar manner the Geostationary Lightning Mapper (GLM) to be launched on GOES-R presents several data management challenges. The GLM is a pioneering instrument to quantify total lightning from a geostationary platform. The expected data frequency from the GLM is to be at a sub-minute interval. Users of such a data set may have little experience in handling such a rapid update of information. To assist users, SPoRT is working with the NWS to develop tools within the user fs decision support system to allow tracking and analysis of total lightning from a storm-based perspective. This presentation will discuss the challenges and progress of this tool development work. With new data and products comes the need for user Training. Within the GOES-R PG SPoRT is supporting the demonstration of these future products by providing various training materials to end users. A summary of training provided to operational users will be discussed.

Fuell, Kevin K.↗
NASA NTRS2017

Linear Transformer Drivers for Z-pinch Based Propulsion

The MSFC/UAH team has been developing of a novel power management and distribution system called a Linear Transformer Driver (LTD). LTD's hold the promise of dramatically reducing the required mass to drive a z-pinch by replacing the capacitor banks which constitute half the mass of the entire system. The MSFC?UAH tea, is developing this technology in hope of integrating it with the Pulsed Fission Fusion (PuFF) propulsion concept. High-Voltage pulsed power systems used for Z-Pinch experimentation have in the past largely been based on Marx Generators. Marx generators deliver the voltage and current required for the Z-Pinch, but suffer from two significant drawbacks when applied to a flight system: they are very massive, consisting of high-voltage capacitor banks insulated in oil-filled tanks and they do not lend themselves to rapid pulsing. The overall goal of Phase 2 is to demonstrate the construction of a higher voltage stack from a number of cavities each of the design proven in Phase 1 and to characterize and understand the techniques for designing the stack. The overall goal of Phase 3 is to demonstrate the feasibility of constructing a higher energy cavity from a number of smaller LTD stacks, to characterize and understand the way in which the constituent stacks combine, and to extend this demonstration LTD to serve as the basis for a 64 kJ pulse generator for Z-Pinch experiments.

Adams, Robert↗
NASA NTRS2026

Beyond Melting: Amorphous Bonding for Joining and Consolidation

Crystallization may be the hidden constraint in thermoplastic composite manufacturing. It requires tightly controlled cooling, induces residual stresses through shrinkage, and introduces path-dependent behavior that complicates predictive modeling yet remains essential for structural performance. This work asks: can bonding be achieved without relying on melt-driven crystallization? To address this, thin (5–20 μm) polyetherimide (PEI) interlayers are pre-healed to slow-cooled polyaryletherketone (PAEK) in two contexts. The first, Thermabond®, is sub-melt joining of low melt-PAEK laminates. Results show that bond quality is governed primarily by processing (i.e., adequate healing and film handling) rather than modest changes in interlayer thickness. This concept is then extended to laminate-scale manufacturing through an architecture known as OATMEAL (Out-of-autoclave Amorphous/semicrystalline Thermoplastic Material for Energy-efficient Aerospace-grade Laminates). PEI is healed to carbon fiber reinforced polyetheretherketone (PEEK) at the prepreg and excess PEI is then ablated from the surface. Crystallinity is developed off-line during prepreg fabrication, while subsequent consolidation occurs below the melt temperature to preserve it. Cross-ply warpage experiments show that, contrary to intuition, repeated amorphous interfaces reduce global curvature by lowering the effective stress lock-in temperature and eliminating crystallization shrinkage from the lamina response. Correspondingly, laminate behavior is accurately predicted using classical laminate theory (CLT) with a single effective stress-free temperature, whereas conventional CF/PEEK requires accounting for crystallization-driven effects. By decoupling interfacial healing from crystallization, OATMEAL enables sub-melt consolidation, reduces energy consumption by up to 75%, and increases manufacturing throughput by fivefold. These results demonstrate that amorphous bonding is not only a joining strategy, but a pathway to more predictable and scalable thermoplastic composite manufacturing.

solidification↗