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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Lightweight Thrust Chamber Assemblies using Multi-Alloy Additive Manufacturing and Composite Overwrap

Additive Manufacturing (AM) has brought significant design and fabrication opportunities for complex components with internal features such as liquid rocket engine thrust chambers not previously possible. This technology allows for significant cost savings and schedule reductions in addition to new performance optimization through weight reduction and increased margins. Specific to regeneratively-cooled combustion chambers and nozzles for liquid rocket engines, additive manufacturing offers the ability to form the complex internal coolant channels and the closeout of the channels to contain the high pressure liquid propellants with a single operation. Much of additive manufacturing development has focused on monolithic alloys using Laser Powder Bed Fusion (L-PBF), which do not allow for complete optimization of the structure. The National Aeronautics and Space Administration (NASA) completed feasibility of an AM bimetallic L-PBF GRCop-84 copper-alloy combustion chamber with an AM electron beam freeform Inconel 625 structural jacket under the Low Cost Upper Stage Propulsion (LCUSP) Project. A follow-on project called Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) is under development to further expand large-scale multi-alloy thrust chambers while maturing composite overwrap technology for significant weight savings opportunities. The RAMPT project has three primary objectives: 1) Advancing blown powder Directed Energy Deposition (DED) to fabricate integral-channel large scale nozzles, 2) Develop composite overwrap technology to reduce weight and provide structural capability for thrust chamber assemblies, and 3) Develop bimetallic and multi-metallic additively manufactured radial and axial joints to optimize material performance. In addition to these primary manufacturing developments, analytical modeling efforts compliment the process development to simulate the AM processes to reduce build failures and distortions. The RAMPT project is also maturing the supply chain for various manufacturing processes described above in addition to L-PBF of GRCop-42. This paper will present an overview of the RAMPT project, the process development and hardware progress to date, material and hot-fire testing results, along with future developments.

Additive Manufacturing↗
NASA NTRSDate not supplied

Recent Advances in Soft Matter Characterization Capabilities Developed at NASA GRC for Lunar Exploration: Differential Dynamic Microscopy to Spectroscopy to Computer Vision

In 1991, famous French scientist Pierre-Gilles de Genes was awarded Nobel prize for his impactful research in soft matter, more specifically polymers. He is defined as the founding father of soft matter. In his Nobel lecture (https://www.nobelprize.org/uploads/2018/06/gennes-lecture.pdf ) he described soft matter aka complex fluids as materials with two primary features – (a) complexity and (b) flexibility. The sub-categories of soft matter (e.g.- granular materials, polymers, foams, colloids etc.) are defined on the basis of Pierre-Gilles de Gennes’ definition. At NASA GRC, we are pushing the boundaries for fundamental study of soft matter on Lunar Surface. With regard to Lunar surface science, we are focusing on developing capabilities pertaining to granular materials and bio-soft/active matter to facilitate future efforts in ISRU and bio-ISRU capabilities. In order to achieve fundamental goals of soft matter research within the limitations of Lunar environment, the scientific capabilities need to be small, flexible, modular, off the shelf and the focus needs to be more on developing an interdisciplinary capability that leverages the recent growth in AI/ML and Computer Vision to augment our understanding of fundamental science. This strategy would allow us to reduce our resource requirement during launch, installation, and occupied real estate footprint on Lunar surface In this talk, we will go over 3 different capabilities that we have developed in house and in close collaboration – (a) Differential Dynamic Microscopy (DDM), (b) Portable In-situ Chemical Spectroscopy (PICS) and (c) Computer Vision Enabled Observation. At very high level, Differential Dynamic Microscopy (DDM) allows us to study the structure-property-process relation (microrheology) of bio-soft/active matter using optical microscope and improved image analysis capabilities. PICS uses AI/ML-based advanced signal deconvolution and analysis technique that can work with existing portable spectroscopy tools to perform materials analysis (e.g.- granular materials and bio-soft/active matter) inspection on the go. Finally, computer vision enabled analysis allows us to use simple camera images for 3D reconstruction of experimental process and tracking of objects of interest in an experiment. We expect that this detailed process will allow us reach a thorough understanding of soft matter in Lunar environment. The capabilities developed by us will help to validate and establish fundamental understanding in Lunar environment. This will, in turn, allow us to guide future space exploration missions and expand the knowledge base of the scientific and engineering communities.

Suman Sinha Ray↗
NASA NTRSDate not supplied

Recent Advances in Soft Matter Characterization Capabilities Developed at NASA GRC for Lunar Exploration: Differential Dynamic Microscopy to Spectroscopy to Computer Vision

In 1991, famous French scientist Pierre-Gilles de Genes was awarded Nobel prize for his impactful research in soft matter, more specifically polymers. He is defined as the founding father of soft matter. In his Nobel lecture (https://www.nobelprize.org/uploads/2018/06/gennes-lecture.pdf ) he described soft matter aka complex fluids as materials with two primary features – (a) complexity and (b) flexibility. The sub-categories of soft matter (e.g.- granular materials, polymers, foams, colloids etc.) are defined on the basis of Pierre-Gilles de Gennes’ definition. At NASA GRC, we are pushing the boundaries for fundamental study of soft matter on Lunar Surface. With regard to Lunar surface science, we are focusing on developing capabilities pertaining to granular materials and bio-soft/active matter to facilitate future efforts in ISRU and bio-ISRU capabilities. In order to achieve fundamental goals of soft matter research within the limitations of Lunar environment, the scientific capabilities need to be small, flexible, modular, off the shelf and the focus needs to be more on developing an interdisciplinary capability that leverages the recent growth in AI/ML and Computer Vision to augment our understanding of fundamental science. This strategy would allow us to reduce our resource requirement during launch, installation, and occupied real estate footprint on Lunar surface. In this talk, we will go over 3 different capabilities that we have developed in house and in close collaboration – (a) Differential Dynamic Microscopy (DDM), (b) Portable In-situ Chemical Spectroscopy (PICS) and (c) Computer Vision Enabled Observation. At very high level, Differential Dynamic Microscopy (DDM) allows us to study the structure-property-process relation (microrheology) of bio-soft/active matter using optical microscope and improved image analysis capabilities. PICS uses AI/ML-based advanced signal deconvolution and analysis technique that can work with existing portable spectroscopy tools to perform materials analysis (e.g.- granular materials and bio-soft/active matter) inspection on the go. Finally, computer vision enabled analysis allows us to use simple camera images for 3D reconstruction of experimental process and tracking of objects of interest in an experiment. We expect that this detailed process will allow us reach a thorough understanding of soft matter in Lunar environment. The capabilities developed by us will help to validate and establish fundamental understanding in Lunar environment. This will, in turn, allow us to guide future space exploration missions and expand the knowledge base of the scientific and engineering communities.

Suman Sinha-Ray↗
NASA NTRSDate not supplied

Recent Advances in Soft Matter Characterization Capabilities Developed at NASA GRC for Lunar Exploration: Differential Dynamic Microscopy to Spectroscopy to Computer Vision

In 1991, famous French scientist Pierre-Gilles de Genes was awarded Nobel prize for his impactful research in soft matter, more specifically polymers. He is defined as the founding father of soft matter. In his Nobel lecture (https://www.nobelprize.org/uploads/2018/06/gennes-lecture.pdf ) he described soft matter aka complex fluids as materials with two primary features – (a) complexity and (b) flexibility. The sub-categories of soft matter (e.g.- granular materials, polymers, foams, colloids etc.) are defined on the basis of Pierre-Gilles de Gennes’ definition. At NASA GRC, we are pushing the boundaries for fundamental study of soft matter on Lunar Surface. With regard to Lunar surface science, we are focusing on developing capabilities pertaining to granular materials and bio-soft/active matter to facilitate future efforts in ISRU and bio-ISRU capabilities. In order to achieve fundamental goals of soft matter research within the limitations of Lunar environment, the scientific capabilities need to be small, flexible, modular, off the shelf and the focus needs to be more on developing an interdisciplinary capability that leverages the recent growth in AI/ML and Computer Vision to augment our understanding of fundamental science. This strategy would allow us to reduce our resource requirement during launch, installation, and occupied real estate footprint on Lunar surface In this talk, we will go over 3 different capabilities that we have developed in house and in close collaboration – (a) Differential Dynamic Microscopy (DDM), (b) Portable In-situ Chemical Spectroscopy (PICS) and (c) Computer Vision Enabled Observation. At very high level, Differential Dynamic Microscopy (DDM) allows us to study the structure-property-process relation (microrheology) of bio-soft/active matter using optical microscope and improved image analysis capabilities. PICS uses AI/ML-based advanced signal deconvolution and analysis technique that can work with existing portable spectroscopy tools to perform materials analysis (e.g.- granular materials and bio-soft/active matter) inspection on the go. Finally, computer vision enabled analysis allows us to use simple camera images for 3D reconstruction of experimental process and tracking of objects of interest in an experiment. We expect that this detailed process will allow us reach a thorough understanding of soft matter in Lunar environment. The capabilities developed by us will help to validate and establish fundamental understanding in Lunar environment. This will, in turn, allow us to guide future space exploration missions and expand the knowledge base of the scientific and engineering communities.

Suman Sinha Ray↗
NASA NTRSDate not supplied

Recent Advances in Soft Matter Characterization Capabilities Developed at NASA GRC

In 1991, famous French scientist Pierre-Gilles de Genes was awarded Nobel prize for his impactful research in soft matter, more specifically polymers. He is defined as the founding father of soft matter. In his Nobel lecture (https://www.nobelprize.org/uploads/2018/06/gennes-lecture.pdf ) he described soft matter aka complex fluids as materials with two primary features – (a) complexity and (b) flexibility. The sub-categories of soft matter (e.g.- granular materials, polymers, foams, colloids etc.) are defined on the basis of Pierre-Gilles de Gennes’ definition. At NASA GRC, we are pushing the boundaries for fundamental study of soft matter on Lunar Surface. With regard to Lunar surface science, we are focusing on developing capabilities pertaining to granular materials and bio-soft/active matter to facilitate future efforts in ISRU and bio-ISRU capabilities. In order to achieve fundamental goals of soft matter research within the limitations of Lunar environment, the scientific capabilities need to be small, flexible, modular, off the shelf and the focus needs to be more on developing an interdisciplinary capability that leverages the recent growth in AI/ML and Computer Vision to augment our understanding of fundamental science. This strategy would allow us to reduce our resource requirement during launch, installation, and occupied real estate footprint on Lunar surface In this talk, we will go over 3 different capabilities that we have developed in house and in close collaboration – (a) Differential Dynamic Microscopy (DDM), (b) Portable In-situ Chemical Spectroscopy (PICS) and (c) Computer Vision Enabled Observation. At very high level, Differential Dynamic Microscopy (DDM) allows us to study the structure-property-process relation (microrheology) of bio-soft/active matter using optical microscope and improved image analysis capabilities. PICS uses AI/ML-based advanced signal deconvolution and analysis technique that can work with existing portable spectroscopy tools to perform materials analysis (e.g.- granular materials and bio-soft/active matter) inspection on the go. Finally, computer vision enabled analysis allows us to use simple camera images for 3D reconstruction of experimental process and tracking of objects of interest in an experiment. We expect that this detailed process will allow us reach a thorough understanding of soft matter in Lunar environment. The capabilities developed by us will help to validate and establish fundamental understanding in Lunar environment. This will, in turn, allow us to guide future space exploration missions and expand the knowledge base of the scientific and engineering communities.

Suman Sinha Ray↗
NASA NTRSDate not supplied

Particle-Based Fiber Models of Woven Materials for Earth Entry Thermal Protection

Applications requiring materials with layer-to-layer strength, from basketry to thermal protection systems, use interlaced, three-dimensional woven materials. NASA is developing and deploying woven material heat shields for missions, including Artemis I (3D-MAT for compression pads) and potentially Mars Sample Return - Earth Entry System. These materials are complex, hierarchical and must protect from extreme environments and phenomena, such as deformation, impact and high-enthalpy heating. Woven material performance depends on microstructure, damage and weave geometry. Therefore, fiber-specific models are needed to simulate fiber contacts within the weave hierarchical geometry (fiber to tow to yarn to weave) and the inherent directionality of fibers. Explicit fiber models can simulate how weave microstructure evolution affects thermal and mechanical properties. We parameterize a discrete element bonded particle models (DEM-BPM) of fibers to capture thermal and mechanical behavior within and between fibers, with bonded and contact forces, respectively. We study the proportion of heat transfer and stress via the contact network, fiber bonds and the weave geometry, for example, with respect to yarn warp-weft identity (whether it interlaces weave layers). Our results demonstrate the importance of explicit fiber modeling for connecting microstructure with thermal and mechanical properties.

woven material↗
NASA NTRSDate not supplied

Particle-Based Fiber Models of Woven Materials for Earth Entry Thermal Protection

Applications requiring materials with layer-to-layer strength, from basketry to thermal protection systems, use interlaced, three-dimensional woven materials. NASA is developing and deploying woven material heat shields for missions, including Artemis I (3D-MAT for compression pads) and potentially Mars Sample Return - Earth Entry System. These materials are complex, hierarchical and must protect from extreme environments and phenomena, such as deformation, impact and high-enthalpy heating. Woven material performance depends on microstructure, damage and weave geometry. Therefore, fiber-specific models are needed to simulate fiber contacts within the weave hierarchical geometry (fiber to tow to yarn to weave) and the inherent directionality of fibers. Explicit fiber models can simulate how weave microstructure evolution affects thermal and mechanical properties. We parameterize a discrete element bonded particle models (DEM-BPM) of fibers to capture thermal and mechanical behavior within and between fibers, with bonded and contact forces, respectively. We study the proportion of heat transfer and stress via the contact network, fiber bonds and the weave geometry, for example, with respect to yarn warp-weft identity (whether it interlaces weave layers). Our results demonstrate the importance of explicit fiber modeling for connecting microstructure with thermal and mechanical properties.

woven material↗
NASA NTRS1994

Vibration Isolation Technology (VIT) ATD Project

A fundamental advantage for performing material processing and fluid physics experiments in an orbital environment is the reduction in gravity driven phenomena. However, experience with manned spacecraft such as the Space Transportation System (STS) has demonstrated a dynamic acceleration environment far from being characterized as a 'microgravity' platform. Vibrations and transient disturbances from crew motions, thruster firings, rotating machinery etc. can have detrimental effects on many proposed microgravity science experiments. These same disturbances are also to be expected on the future space station. The Microgravity Science and Applications Division (MSAD) of the Office of Life and Microgravity Sciences and Applications (OLMSA), NASA Headquarters recognized the need for addressing this fundamental issue. As a result an Advanced Technology Development (ATD) project was initiated in the area of Vibration Isolation Technology (VIT) to develop methodologies for meeting future microgravity science needs. The objective of the Vibration Isolation Technology ATD project was to provide technology for the isolation of microgravity science experiments by developing methods to maintain a predictable, well defined, well characterized, and reproducible low-gravity environment, consistent with the needs of the microgravity science community. Included implicitly in this objective was the goal of advising the science community and hardware developers of the fundamental need to address the importance of maintaining, and how to maintain, a microgravity environment. This document will summarize the accomplishments of the VIT ATD which is now completed. There were three specific thrusts involved in the ATD effort. An analytical effort was performed at the Marshall Space Flight Center to define the sensitivity of selected experiments to residual and dynamic accelerations. This effort was redirected about half way through the ATD focusing specifically on the sensitivity of protein crystals to a realistic orbital environment. The other two thrusts of the ATD were performed at the Lewis Research Center. The first was to develop technology in the area of reactionless mechanisms and robotics to support the eventual development of robotics for servicing microgravity science experiments. This activity was completed in 1990. The second was to develop vibration isolation and damping technology providing protection for sensitive science experiments. In conjunction with the this activity, two workshops were held. The results of these were summarized and are included in this report.

Lubomski, Joseph F.↗
NASA NTRS1973

Multidimensional analysis of fast-spectrum material replacement measurements for systematic estimation of cross section uncertainties

A series of central core and core-reflector interface sample replacement experiments for 16 materials performed in the NASA heavy-metal-reflected, fast spectrum critical assembly (NCA) were analyzed in four and 13 groups using the GAM 2 cross-section set. The individual worths obtained by TDSN and DOT multidimensional transport theory calculations showed significant differences from the experimental results. These were attributed to cross-section uncertainties in the GAM 2 cross sections. Simultaneous analysis of the measured and calculated sample worths permitted separation of the worths into capture and scattering components which systematically provided fast spectrum averaged correction factors to the magnitudes of the GAM 2 absorption and scattering cross sections. Several Los Alamos clean critical assemblies containing Oy, Ta, and Mo as well as one of the NCA compositions were reanalyzed using the corrected cross sections. In all cases the eigenvalues were significantly improved and were recomputed to within 1 percent of the experimental eigenvalue. A comparable procedure may be used for ENDF cross sections when these are available.

Klann, P. G.↗
NASA NTRS1979

Laboratory test methods for evaluating the fire response of aerospace materials

The test methods which were developed or evaluated were intended to serve as means of comparing materials on the basis of specific responses under specific sets of test conditions, using apparatus, facilities, and personnel that would be within the capabilities of perhaps the majority of laboratories. Priority was given to test methods which showed promise of addressing the pre-ignition state of a potential fire. These test methods were intended to indicate which materials may present more hazard than others under specific test conditions. These test methods are discussed and arranged according to the stage of a fire to which they are most relevant. Some observations of material performance which resulted from this work are also discussed.

Hilado, C. J.↗
NASA NTRS1982

Low-Gravity Investigations in Cast-Iron Processing

Report on the state of the art in cast-iron processing identifies possible improvements that might result from processing in absence of gravity. Report suggests areas in which the knowledge of gravitational effects could eventually lead to practical improvements in material performance.

Frankhouser, W. L.↗
NASA NTRS1981

Flaw growth of 7075, 7475, 7050 and 7049 aluminum alloy plate in stress corrosion environments: 4-year marine atmosphere results

After nearly 53 months of exposure to marine atmosphere, crack growth in SL DCB specimens from 7075, 7475, 7050, and 7049-T7X plate has slowed to the arbitrary 10 to the -10 power m/sec used to define threshold stress intensity. Because some specimens appear to be approaching crack arrest, the importance of self-loading from corrosion product wedging as a significant driving force for crack propagation in overaged materials is questioned. Crack length-time data were analyzed using a computer curve fitting program which minimized the effects of normal data scatter, and provided a clearer picture of material performance. Precracked specimen data are supported by the results of smooth specimen tests. Transgranular stress corrosion cracking was observed in TL DCB specimens from all four alloys. This process is extremely slow and is characterized by a striated surface morphology.

Hasse, K. R.↗
NASA NTRS1982

Maypole (Hoop/Column) concept development program

The program is divided into six tasks: preliminary design and performance; materials development; advanced concepts; economic assessment; demonstration/verification models; and a 15 meter engineering model. All support the main objective of the program which is the technology development necessary to evaluate, design, manufacture, package, transport and deploy the Hoop/Column reflector by means of a ground-based test program. Progress for each task is reported.

Sullivan, M. R.↗