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All sourcesNASA NTRSDOE OSTI
NASA NTRS2020

Novel High Barrier Films for Packaging Food and Medicine

Long manned missions require food packaging to maintain food safety, nutrition, and acceptability for the length of 3-5 years1,2 while the shelf life assigned by NASA for current provisions is 18-24 months1. The focus of this design project was to make a polymer film specifically to function as a high oxygen barrier to later be included in an improved multi-layer packaging system of other specialized polymers with capabilities to allow for a 5-year shelf-life. To qualify as a high oxygen barrier film and to be a successful design for the future packaging, the resulting film is required to have an oxygen transmission rate (OTR) less than 0.06 cc/ m2/24 hr/atm, the standard for the current packaging3. This new film was designed to have a decreased permeability by increasing the “tortuous path” a gas molecule travels to permeate through a film. The increase in the “tortuous path” of a gas molecule is accomplished by introducing a 2D material additive. The additive chosen for this project was hexagonal boron nitride (h-BN) which exfoliates into boron nitride nanosheets (BNNs). Nylon 6 was chosen as the candidate for the matrix. This project is required to determine the best methods to synthesize the sample film and then to test the OTR of the film to determine if this design was successful. This project examined methods for pulverizing polymer resin pellets, h-BN exfoliation, and film fabrication using a hot press. This report includes the exfoliation and analysis of h-BN, procedural preparations for films, and a modeling study of estimated OTR of the h-BN/Nylon. The work in this report did not yield a high barrier composite film because of the laboratory closure in response to COVID -19 guidance but provides a concise method of the additive preparation and film synthesis. This gives a good starting point for future research in high barrier films by 2D additive composites.

Polymer, Nylon, PET, boron nitride, nanocomposite↗
NASA NTRS2004

Water-Based Pressure Sensitive Paint

Preparation and performance of a water-based pressure sensitive paint (PSP) is described. A water emulsion of an oxygen permeable polymer and a platinum porphyrin type luminescent compound were dispersed in a water matrix to produce a PSP that performs well without the use of volatile, toxic solvents. The primary advantages of this PSP are reduced contamination of wind tunnels in which it is used, lower health risk to its users, and easier cleanup and disposal. This also represents a cost reduction by eliminating the need for elaborate ventilation and user protection during application. The water-based PSP described has all the characteristics associated with water-based paints (low toxicity, very low volatile organic chemicals, and easy water cleanup) but also has high performance as a global pressure sensor for PSP measurements in wind tunnels. The use of a water-based PSP virtually eliminates the toxic fumes associated with the application of PSPs to a model in wind tunnels.

Oglesby, Donald M.↗
NASA NTRSDate not supplied

Airframe Noise Simulations of a Full-Scale Large Civil Transport in Landing Configuration

This paper summarizes the results obtained from an extensive computational campaign to accurately predict full-scale landing gear noise for large civil transports. A highly accurate digital model of a full-scale Boeing 777-300ER aircraft with as-flown nose and main landing gear components was developed for use in the simulations. Two aircraft configurations were selected: nose and main landing gear deployed with wing high-lift devices retracted, and nose and main landing gear deployed with wing high-lift devices deflected. The two configurations were simulated without and with toboggan fairings installed on the main gear to represent the principal configurations evaluated during the 2005 QTD2 flight test. All simulations were performed with the lattice Boltzmann solver PowerFLOW® to resolve and capture the highly complex, unsteady flow field in the immediate vicinity of the aircraft. The far-field noise sig-nature of the aircraft was computed via a Ffowcs-Williams and Hawkings integral approach, with flow quantities on a permeable surface enclosing the source regions used as input. Synthetic pressure records at ground array microphone locations used during the QDT2 test were employed to generate narrowband acoustic maps and integrated far-field noise spectra. With high-lift devices retracted, the predicted spectra showed that landing gear noise is equivalent to total airframe noise, with no other airframe sources appearing within 10 dB of gear peak levels. Application of a toboggan fairing to the main gear produced modest noise reductions of 1-2 dB across the resolved frequency range. With high-lift devices deflected, undercarriage noise was within 3-4 dB of the total airframe noise, thus comprising nearly half of the total airframe noise. For this configuration, the toboggan fairing did not produce a reduction in noise, corroborating trends previously observed in QTD2 flight test data.

airframe noise↗
NASA NTRS1989

Fluvial valleys and Martian palaeoclimates

Theoretical models of early Martian atmospheric evolution describe the maintenance of a dense CO2 atmosphere and a warm, wet climate until the end of the heavy-bombardment phase of impacting. However, the presence of very young, earthlike fluvial valleys on the northern flank of Alba Patera conflicts with this scenario. Whereas the widespread ancient Martian valleys generally have morphologies indicative of sapping erosion by the slow outflow of subsurface water, the local Alba valleys were probably formed by surface-runoff processes. Because subsurface water flow might be maintained by hydrothermal energy inputs and because surface-runoff valleys developed late in Martian history, it is not necessary to invoke drastically different planet-wide climatic conditions to explain valley development on Mars. The Alba fluvial valleys can be explained by hydrothermal activity or outflow-channel discharges that locally modified the atmosphere, including precipitation and local overland flow on low-permeability volcanic ash.

Gulick, Virginia C.↗
NASA NTRSDate not supplied

Jet Noise Prediction for Chevron Nozzle Flows with Wall-Modeled Large-Eddy Simulation

This paper presents results from ongoing research on jet noise prediction with wall-modeled large eddy simulations (WMLES) performed with the LAVA computational framework. In particular the focus of this study is on mixing enhancements from a single stream chevron nozzle at Reynolds number of 1×10(exp 6). Although the concept of chevron nozzles to reduce jet noise is not new, our understanding of its impact on the overall noise is still not well understood. As a first step towards predicting noise reduction due to mixing enhancement concepts from first principles with WMLES, we simulate the noise generated by a single stream chevron nozzle SMC001 as well as its equivalent axisymmetric round jet nozzle SMC000. Detailed comparisons are made with a dedicated experiment conducted at NASA’s Glenn Research Center and good agreement was achieved. Two different approaches to introduce a turbulent boundary layer were compared but show no major impact on the results. This is especially important given future work were multi-stream nozzles are considered and extended costs of resolving the internal BL would have a bigger cost impact. A permeable Ffowcs Williams Hawkings (FWH) surface enclosing the jet is used to predict far-field noise from the simulated flow-field and excellent comparison to microphone array measurements is achieved within the resolved frequency band. Sensitivity of far-field noise predictions to grid resolution is systematically documented. Near-field comparisons to PIV data shows great agreement for both velocity and normal stresses, however a systematic TKE overshoot at the nozzle exit is seen in the shear-layer. The paper shows a cost reduction of an order of magnitude compared to an earlier study of this configuration due to algorithmic and software improvements and demonstrates that WMLES can be used as a cost-competitive approach for jet noise predictions.

CST↗
NASA NTRS2014

Towards Co-evolution of Membrane Transport and Metabolism

Protocellular boundaries were inextricably connected to the metabolism they encapsulated: to be inheritable, early metabolism must have led to an increased rate of growth and division of vesicles and, similarly, transport through vesicle boundaries must have supported the evolution of metabolism. Even though explaining how this coupling emerged and evolved in the absence of the complex machinery of modern cells is one of the key issues in studies on the origin of life, little is known about the biochemical and biophysical processes that might have been involved. This gap in our knowledge is a major impediment in efforts to construct scenarios for the origin of life and laboratory models of protocells. A combination of experimental and computational studies carried out by us and our collaborators is aimed at helping to close this gap. Properties of membranes might have contributed to the selection of RNA as an early biopolymer. A kinetic mechanism was proposed (Sacerdote & Szostak, 2005) in which ribose was supplied more quickly than other aldopentoses to primordial cells for preferential incorporation of ribonucleotides into nucleic acids. This proposal is based on a finding that ribose permeates membranes an order of magnitude faster than its diastereomers, arabinose and xylose. Our computer simulations, which yield permeation rates in excellent agreement with experiment, and kinetic modeling explain this phenomenon in terms of inter- and intramolecular interactions involving exocyclic hydroxyl groups attached to carbon atoms of the pyranose ring (Wei and Pohorille, 2009). They also constrain scenarios for the formation of the earliest nucleic acids (Wei and Pohorille, 2013). In one scenario, sugars permeate protocellular walls and subsequently are used to synthesize nucleic acids inside protocells. As long as this process proceeds at the rate faster than 6x10(exp -3)/s, ribose derivatives will be available for synthesis easier than their diastereomers. If nucleosides or their activated derivatives are synthesized outside protocells and subsequently transported across protocellular membranes the kinetic mechanism does not apply because all diastereomers, which have their sugars in the furanose rather than pyranose form, permeate the membrane at approximately the same rate. Properties of membranes might have been also coupled to metabolism involving peptides. Recently, Adamala and Szostak (2013) have shown that a dipeptide inside fatty-acid vesicles catalyzes the formation of another dipeptide that binds to vesicle walls and, by doing so, promotes their growth at the expense of other vesicles. This coupling of metabolism, permeability of vesicles and their growth is the first demonstration of evolutionary advantage imparted by small, membrane-bound peptides. Building on this work we have calculated the rate at which different blocked amino acids are delivered to a protocell for synthesis of dipeptides. We have further shown that the dipeptides are located at the water-membrane interface rather than in the center of the bilayer. On these basis it is anticipated that other dipeptides containing aromatic, but not necessarily hydrophobic amino acids (e.g. tyrosine) could have the same catalytic effects. Insight from these studies allows for estimating the rate of vesicle growth and the rates of dipeptide synthesis required to keep the system in balance. These results, in combination with our earlier studies, lead to a general scenario for evolution from membrane-bound dipeptides to ion channels in the origin of life.

Metabolism↗
NASA NTRS2022

Analyzing Recharge Dynamics and Storage in a Thick, Karstic Vadose Zone

Karst vadose zone heterogeneity creates complex transmission and storage dynamics that affect the timing and magnitude of aquifer recharge. Young, high-matrix permeability eogenetic karst aquifers may have significantly higher matrix storage than older, lower matrix permeability counterparts. In vulnerable and water-limited karst regions, the timescales of storage may be important for seasonal and sub-seasonal water resource management. We create a framework to quantify storage dynamics in karst aquifers using high-resolution precipitation and groundwater levels from the Northern Guam Lens Aquifer in the US territory of Guam. We estimate recharge using the Water Table Fluctuation method, and then develop transfer functions between precipitation and recharge to quantify storage and release of water from the vadose zone. The transfer functions are partitioned into different flow pathways including conduit, conduit/matrix, and slowly draining matrix. Probability distributions are fit to each pathway to determine the average travel times of infiltrated waters. The results show that aquifer recharge through secondary porosity features typically occurs within a few hours of a rainfall event, but this rapid recharge accounts for only 12%–28% of total recharge. The majority of aquifer recharge (>70%) occurs within a month of a contributing storm event. An additional 10% of recharge, on average, took longer than a month to reach the water table. The framework established can help improve the hydrological modeling and freshwater management for karst aquifers.

Patricia Spellman↗
NASA NTRS1991

Lake Hoare, Antarctica: sedimentation through a thick perennial ice cover

Lake Hoare in the Dry Valleys of Antarctica is covered with a perennial ice cover more than 3 m thick, yet there is a complex record of sedimentation and of growth of microbial mats on the lake bottom. Rough topography on the ice covering the lake surface traps sand that is transported by the wind. In late summer, vertical conduits form by melting and fracturing, making the ice permeable to both liquid water and gases. Cross-sections of the ice cover show that sand is able to penetrate into and apparently through it by descending through these conduits. This is the primary sedimentation mechanism in the lake. Sediment traps retrieved from the lake bottom indicate that rates of deposition can vary by large amounts over lateral scales as small as 1 m. This conclusion is supported by cores taken in a 3 x 3 grid with a spacing of 1.5 m. Despite the close spacing of the cores, the poor stratigraphic correlation that is observed indicates substantial lateral variability in sedimentation rate. Apparently, sand descends into the lake from discrete, highly localized sources in the ice that may in some cases deposit a large amount of sand into the lake in a very short time. In some locations on the lake bottom, distinctive sand mounds have been formed by this process. They are primary sedimentary structures and appear unique to the perennially ice-covered lacustrine environment. In some locations they are tens of centimetres high and gently rounded with stable slopes; in others they reach approximately 1 m in height and have a conical shape with slopes at angle of repose. A simple formation model suggests that these differences can be explained by local variations in water depth and sedimentation rate. Rapid colonization of fresh sand surfaces by microbial mats composed of cyanobacteria, eukaryotic algae, and heterotrophic bacteria produces a complex intercalation of organic and sandy layers that are a distinctive form of modern stromatolites.

NASA Discipline Exobiology↗
NASA NTRS1997

The Age of the Surface of Venus

Impact craters on Venus appear to be uniformly and randomly scattered over a once, but no longer, geologically active planet. To first approximation, the planet shows a single surface of a single age. Here we use Monte Carlo cratering simulations to estimate the age of the surface of Venus. The simulations are based on the present populations of Earth-approaching asteroids, Jupiter-family, Halley-family, and long period comets; they use standard Schmidt-Housen crater scalings in the gravity regime; and they describe interaction with the atmosphere using a semi-analytic 'pancake' model that is calibrated to detailed numerical simulations of impactors striking Venus. The lunar and terrestrial cratering records are also simulated. Both of these records suffer from poor statistics. The Moon has few young large craters and fewer still whose ages are known, and the record is biased because small craters tend to look old and large craters tend to look young. The craters of the Earth provide the only reliable ages, but these craters are few, eroded, of uncertain diameter, and statistically incomplete. Together the three cratering records can be inverted to constrain the flux of impacting bodies, crater diameters given impact parameters, and the calibration of atmospheric interactions. The surface age of Venus that results is relatively young. Alternatively, we can use our best estimates for these three input parameters to derive a best estimate for the age of the surface of Venus. Our tentative conclusions are that comets are unimportant, that the lunar and terrestrial crater records are both subject to strong biases, that there is no strong evidence for an increasing cratering flux in recent years, and that that the nominal age of the surface of Venus is about 600 Ma, although the uncertainty is about a factor of two. The chief difference between our estimate and earlier, somewhat younger estimates is that we find that the venusian atmosphere is less permeable to impacting bodies than supposed by earlier studies. An older surface increases the likelihood that Venus is dead.

Zahnle, K. J.↗
NASA NTRSDate not supplied

Recent Developments to the Porous Microstructure Analysis (PuMA) Software

Introduction The Porous Microstructure Analysis (PuMA) software is an open source framework for image-based simulation, primarily used to determine effective properties based on material microstructure. PuMA was originally developed for the study of NASA thermal protection materials; however, many of the solvers in PuMA have applicability to a broad range of materials science applications. PuMA version 3.2 computes material surface area, pore diameters, effective thermal conductivity, continuum and rarefied tortuosity, and permeability. For anisotropic materials, PuMA can estimate material orientation and compute anisotropic thermal conductivity and elasticity. In this talk, a brief overview of the PuMA software and underlying methods will be presented, as well as some recent and ongoing developments, including the use of immersed boundary methods for image-based simulation and the development of a new weave segmentation tool, called TomoSAM. Cut-Cell method for heat and mass transfer For simulations on complex microstructures, traditional unstructured meshing techniques often prove to be difficult and time-intensive. Voxel-based solvers, which represent the surface as a staircase structure, are relatively simple to implement but can lose accuracy when feature resolution is poor. In this work, we present a novel 3D cut-cell method for solving the variable coefficient Poisson equation on complex microstructures, suitable for the determination of effective thermal conductivity or tortuosity of a material. The method uses a Marching Cubes/Marching Squares surface reconstruction to create cut-cells and determine geometric quantities. A flux-correction method is extended to 3D, with least squares gradient reconstruction, to solve for the boundary fluxes in the cut-cells. Verification cases show the solver achieves globally 2nd order accuracy on complex microstructures. TomoSAM TomoSAM, a module of the PuMA software, has been developed as a plugin for 3D Slicer, a software platform used for 3D image processing and visualization. It utilizes the Segment Anything Model (SAM), a deep learning model capable of identifying objects and generating image masks based on minimal user input. This feature enables efficient segmentation of complex 3D datasets, particularly of woven materials, from tomography or similar imaging methods, reducing the need for manual segmentation.

Tomography↗
NASA NTRSDate not supplied

Recent Developments to the Porous Microstructure Analysis (PuMA) Software

The Porous Microstructure Analysis (PuMA) software is an open source framework for image-based simulation, primarily used to determine effective properties based on material microstructure. PuMA was originally developed for the study of NASA thermal protection materials; however, many of the solvers in PuMA have applicability to a broad range of materials science applications. PuMA version 3.2 computes material surface area, pore diameters, effective thermal conductivity, continuum and rarefied tortuosity, and permeability. For anisotropic materials, PuMA can estimate material orientation and compute anisotropic thermal conductivity and elasticity. In this talk, a brief overview of the PuMA software and underlying methods will be presented, as well as some recent and ongoing developments, including the use of immersed boundary methods for image-based simulation and the development of a new weave segmentation tool, called TomoSAM. Cut-Cell method for heat and mass transfer For simulations on complex microstructures, traditional unstructured meshing techniques often prove to be difficult and time-intensive. Voxel-based solvers, which represent the surface as a staircase structure, are relatively simple to implement but can lose accuracy when feature resolution is poor. In this work, we present a novel 3D cut-cell method for solving the variable coefficient Poisson equation on complex microstructures, suitable for the determination of effective thermal conductivity or tortuosity of a material. The method uses a Marching Cubes/Marching Squares surface reconstruction to create cut-cells and determine geometric quantities. A flux-correction method is extended to 3D, with least squares gradient reconstruction, to solve for the boundary fluxes in the cut-cells. Verification cases show the solver achieves globally 2nd order accuracy on complex microstructures. TomoSAM TomoSAM, a module of the PuMA software, has been developed as a plugin for 3D Slicer, a software platform used for 3D image processing and visualization. It utilizes the Segment Anything Model (SAM), a deep learning model capable of identifying objects and generating image masks based on minimal user input. This feature enables efficient segmentation of complex 3D datasets, particularly of woven materials, from tomography or similar imaging methods, reducing the need for manual segmentation.

Tomography↗
NASA NTRS2001

Numerical Simulation of One- and Two-Phase Flows in Propulsion Systems

In this report, we present some results of problems investigated during joint research between the Hampton University Fluid Mechanics and Acoustics Laboratory (HU/FM&AL), NASA GRC, and the LaRC Hyper-X Program. This work is supported by joint research between the NASA GRC and the Institute of Mechanics at Moscow State University (IM/MSU) in Russia under a CRDF grant. The main areas of current scientific interest of the HU/FM&AL include an investigation of the proposed and patented advanced methods for aircraft engine thrust and noise benefits. These methods are based on nontraditional 3D corrugated and composite nozzle, inlet, propeller and screw designs such as a Bluebell and Telescope nozzle, Mobius-shaped screw, etc. This is the main subject of our other projects, of which one is presented at the current conference. Here we analyze additional methods for exhaust jet noise reduction without essential thrust loss and even with thrust augmentation. Such additional approaches are: (1) to add some solid, fluid, or gas mass at discrete locations to the main supersonic gas stream to minimize the negative influence of strong shock waves formed in propulsion systems. This mass addition may be accompanied by heat addition to the main stream as a result of the fuel combustion or by cooling of this stream as a result of the liquid mass evaporation and boiling; (2) Use of porous or permeable nozzles and additional shells at the nozzle exit for preliminary cooling of the hot jet exhaust and pressure compensation for off-design conditions (so-called continuous ejector with small mass flow rate); and (3) to propose and analyze new effective methods of fuel injection into the flow stream in air-breathing engines. The research is focused on a wide regime of problems in the propulsion field as well as in experimental testing and theoretical and numerical simulation analyses for advanced aircraft and rocket engines. The FM&AL Team uses analytical methods, numerical simulations, and experimental tests at the Hampton University campus, NASA, and IM/MSU. The main outcomes during this reporting period are: (1) Publications: The AIAA Paper #01-1893 has been accepted for the AIAA/NAL-NASDA-ISAS 10th International Space Planes and Hypersonic Systems and Technologies Conference, 24-27 April 2001, Kyoto, Japan. The AIAA Paper #01-3204 has been accepted for presentation at the 37th AIAA/ASME/SAE/ASEE Joint Propulsion Conference being held on 08-11 July, in Salt Lake City, UT; (2) Grants and proposals: The HU/FM&AL was awarded the NASA grant NAG3-2495 in October 2000 and the CRDF award was granted to the NASA GRC-HU FM&AL and IM/MSU (Russia) in July 2000. A solicited proposal was submitted for the NASA NRA-01GRC-02 competition and two unsolicited proposals to NASA are in preparation; (3) Theory and numerical simulations: Analytical theory, numerical simulation, comparison of theoretical with experimental results, and modification of theoretical approaches, models, grids, etc. Such investigations have been conducted for three main problems: (a) Combustion efficiency optimization in the half-duct combustor system; (b) Drag reduction effects for blunt bodies with solid needles; and (c) Solid particle injection from the butt-end against a supersonic flow. The NASA CFL3D, HU/FM&AL, and IM/MSU GODUNOV codes were used and modified for solution of these problems. The codes are based on full Euler and Navier-Stokes solvers with and without nonequilibrium oxygen-nitrogen and air-hydrogen chemical reactions in laminar and turbulent gas flow regimes; (4) Experimental tests: In the IM/MSU supersonic wind tunnel, experimental tests were conducted with different number, location, and geometric parameters of solid needles mounted at the front of the butt-end in supersonic flow. Optimal parameters were determined that provide minimal butt-end drag in the stationary flow regime. Experimental and numerical simulation results are in good agreement; (5) Student Research Activity: Involvement of one graduate and two undergraduate students as research assistants in the current project.

Gilinsky, Mikhail↗
NASA NTRS1994

Detection of Cracks at Welds in Steel Tubing Using Flux Focusing Electromagnetic Probe

The inspection of weldments in critical pressure vessel joints is a major concern in the nuclear power industry. Corrosive environments can speed the fatigue process and access to the critical area is often limited. Eddy current techniques have begun to be used to help overcome these obstacles [1]. As direct contact and couplants are not required, remote areas can be inspected by simply snaking an eddy current coil into the intake tube of the vessel. The drawback of the eddy current method has been the high sensitivity to small changes in the conductivity and permeability of the test piece which are known to vary at weldments [1]. The flaw detection mechanism of the flux focusing electromagnetic probe can help alleviate these difficulties and provide a unique capability for detecting longitudinal fatigue cracks in critical tube structures. The Flux Focusing Electromagnetic Flaw Detector, originally invented for the detection of fatigue and corrosion damage in aluminum plates [2-3], has been adapted for use in testing steel tubing for longitudinal fatigue cracks. The modified design allows for the probe to be placed axisymmetrically into the tubing, inducing eddy currents in the tube wall. The pickup coil of the probe is fixed slightly below the primary windings and is rotated 90 so that its axis is normal to the tube wall. The magnetic flux of the primary coil is focused through the use of ferromagnetic material so that in the absence of fatigue damage there will be no flux linkage with the pickup coil. The presence of a longitudinal fatigue crack will cause the eddy currents induced in the tube wall to flow around the flaw and directly under the pickup coil. The magnetic field associated with these currents will then link the pickup coil and an unambiguous increase in the output voltage of the probe will be measured. The use of the flux focusing electromagnetic probe is especially suited for the detection of flaws originating at or near tube welds. The probe is shown to discriminate against signals due solely to the weld joint so that flaw signals are not hidden in the background in these locations. Experimental and finite element modeling results are presented for the flaw detection capabilities of the probe in stainless steel tubes.

Wincheski, Buzz↗
NASA NTRSDate not supplied

Microwave Structure Construction Capability Year One Accomplishments

The Microwave Structure Construction Capability (MSCC) element, part of the Moon to Mars Planetary Autonomous Construction Project (MMPACT) was initiated in 2020. MSCC is responsible for creating horizontal and vertical infrastructure on the moon using microwave energy. Microwave energy was selected since it is the only method to volumetrically heat the regolith. All other sintering/melting methods rely on thermal conduction through the very low conductivity surface, resulting in an inefficient process. Advances were achieved in materials characterization and understanding, microwave sintering in vacuum, and microwave design and analyses. Two dielectric property testing systems have been developed at Radiance Technologies and JPL. These will examine dielectric properties at cryogenic temperatures and over a broad frequency range. Permittivity and permeability testing at -60 ̊C in vacuum from 0.05 to 3 GHz has been generated at JPL. Additional modifications will be made to go to -190 ̊C (LN2). Radiance Technologies created a test system to measure dielectric properties at greater than 10 GHz and initiated work on developing a vacuum capable, portable test system to measure dielectric properties of Apollo regolith and simulants from 100 MHz to 18 GHz. These tests are to identify optimal heating frequencies and protocols. During microwave sintering at about 1100 ̊C, volatiles were creating difficulty in achieving a reasonably dense specimen. Due to processing in vacuum and the nature of the lunar regolith, some volatiles and porosity are expected. However, the Earth produced simulants have non-lunar materials in them that create volatiles that aren’t representative of lunar regolith. Therefore, a five month effort was conducted to establish a heat treat method to remove these non-lunar materials. Tests were conducted using TGA mass spectrometry, heating in vacuum and conducting mass spectrometry, dielectric and DTA, Raman, BET, particle size analysis, morphological analysis, carbon and sulfur chemical content determination and microscopy. The process has been scaled-up to 6 kg batch size and undergoing evaluation. A 36 kg batch size is the target for JSC-1A and other limited availability simulants. These calcining protocols will be standard for NASA and beyond. MSCC has also created scalable processes for fabricating synthetic lunar materials. Processes to fabricate Anorthite (plagioclase CaAl2Si2O8), Diopside (pyroxene CaMgSi₂O₆), and Enstatite (pyroxene Mg2Si2O6) have been generated. These materials will enable generation of microwave sintering models to bound various composition ranges anticipated on the Moon, therefore mitigating the need for a precise simulant with respect to location on the Moon. Successful microwave sintering in air using a horn applicator was demonstrated. All previous microwave vacuum sintering in the literature was at small scale and in a contained enclosure thus taking advantage of reflections. This is the first to use a lunar like microwave applicator to sinter ceramic in a bed as it would be done on the Moon. Small scale and inert sintering were conducted to assist in developing protocols with quicker turnaround times than larger scale testing. Testing has anchored thermal analysis predicting heat flow in vacuum during microwave sintering. Thermal conductivity testing was also initiated. Microwave coupling to the regolith has been modeled by multiple organizations and with different software packages. At least six horn designs and applicator configurations for both magnetron and solid state sources are being examined. Optimal simulant container designs for microwaves have also been generated. The power and electronics design for the solid state microwave system has been initiated. Concept designs for a lander based microwave sintering have been evaluated.

microwave↗
NASA NTRS1993

Properties and processing characteristics of low density carbon cloth phenolic composites

Ply-lift and pocketing are two critical anomalies of carbon cloth phenolic composites (CCPC) in rocket nozzle applications. Ply lift occurs at low temperatures when the A/P and in-plane permeabilities of the composite materials are still very low and in-plane porous paths are blocked. Pocketing occurs at elevated temperatures when in-plane permeability is reduced by the A/P compressive stress. The thermostructural response of CCPC in a rapid heating environment involves simultaneous heat, mass, and momentum transfer along with the degradation of phenolic resin in a multiphase system with temperature- and time-dependent material properties as well as dynamic processing conditions. Three temperature regions represent the consequent chemical reactions, material transformations, and property transitions, and provide a quick qualitative method for characterizing the thermostructural behavior of a CCPC. In order to optimize the FM5939 LDCCP (low density carbon cloth phenolic) for the nozzle performance required in the Advanced Solid Rocket Motor (ASRM) program, a fundamental study on LDCCP materials was conducted. The cured composite has a density of 1.0 +/- 0.5 gm/cc which includes 10 to 25 percent void volume. The weight percent of carbon microballoon is low (7-15 percent). However, they account for approximately one third of the volume and historically their percentages have not been controlled very tightly. In addition, the composite properties show no correlation with microballoon weight percent or fiber properties (e.g. fiber density or fiber moisture adsorption capacity). Test results concerning the ply-lift anomaly in the MNASA motor firings were: (1) Steeper ply angle (shorter path lenght) designs minimized/eliminated by lifting, (2) material with higher void volume ply lifted less frequently, (3) materials with high (greater than 9 percent) microballoon content had a higher rate of ply lifting, and (4) LDCCP materials failed at microballoon-resin interfaces. The objectives of this project are: (1) to investigate the effects of carbon microballoon and cabosil fillers as well as fiber heat treatment on plylift-related mechanical properties, (2) to develop a science-based thermostructural process model for the carbon phenolics. The model can be used in the future for the selection of the improved ASRM materials, (3) to develop the micro-failure mechanisms for the ply-lift initiation and propagation processes during the thermoelastic region of phenolic degradation, i.e. postcuring and devolatilization.

Wang, C. Jeff↗
NASA NTRS2016

Additive Manufacturing, Design, Testing, and Fabrication: A Full Engineering Experience at JSC

I worked on several projects this term. While most projects involved additive manufacturing, I was also involved with two design projects, two testing projects, and a fabrication project. The primary mentor for these was Richard Hagen. Secondary mentors were Hai Nguyen, Khadijah Shariff, and fabrication training from James Brown. Overall, my experience at JSC has been successful and what I have learned will continue to help me in my engineering education and profession long after I leave. My 3D printing projects ranged from less than a 1 cubic centimeter to about 1 cubic foot and involved several printers using different printing technologies. It was exciting to become familiar with printing technologies such as industrial grade FDM (Fused Deposition Modeling), the relatively new SLA (Stereolithography), and PolyJet. My primary duty with the FDM printers was to model parts that came in from various sources to print effectively and efficiently. Using methods my mentor taught me and the Stratasys Insight software, I was able to minimize imperfections, hasten build time, improve strength for specific forces (tensile, shear, etc...), and reduce likelihood of a print-failure. Also using FDM, I learned how to repair a part after it was printed. This is done by using a special kind of glue that chemically melts the two faces of plastic parts together to form a fused interface. My first goal with SLA technology was to bring the printer back to operational readiness. In becoming familiar with the Pegasus SLA printer, I researched the leveling, laser settings, and different vats to hold liquid material. With this research, I was successfully able to bring the Pegasus back online and have successfully printed multiple sample parts as well as functional parts. My experience with PolyJet technology has been focused on an understanding of the abilities/limits, costs, and the maintenance for daily use. Still upcoming will be experience with using a composite printer that uses FDM technology to print plastic while laying an internal filament of Kevlar or carbon-fiber inside the printed material. It has been incredible being exposed to this range of technologies and I feel very fortunate to be ready for virtually any kind of printing technology I come across in the future. Design work played a part in my internship this term as well. Working with Hai Nguyen, I was able to design a set of testing tips and a test frame for use with an Arcjet. The testing tips will be made of several different materials that will possibly be used in the heat shield of the Orion space craft. These designs included technical drawings that were presented to the fabrication shop. The frame design was created from 80/20 (a popular brand of frame construction equipment) and included an order form with pricing for fabrication. An independent design was also done for the virtual reality lab. This design was to create a hand-controller based on a previous design. This final design was sent directly to a 3D printer without technical drawings. Overall, my design work has given me experience with using 80/20, helped improve my CAD (Computer Aided Design) proficiency, and increased my knowledge of how to set up technical drawings for fabrication. The final role I have played in this internship has been to assist with testing of the inflatable technology materials working Khadijah Shariff. I began the internship assisting with permeability testing with the initial plan to continue the testing independently after training. Unfortunately, the testing apparatus suffered a technical failure and had funding pulled which cancelled that portion of the project. Further testing with inflatable technology continued with tensile testing of various stitching methods. This testing took place over a two-days and concluded successfully. Final testing was to be more tensile testing but of straps used to connect various inflatable sections. Unfortunately, the needed grips for the tensile tests could not be located and put the testing on hold. It is possible this round of testing will still take place by the end of the internship if the grips can be found. Overall, this portion of the internship has helped me become familiar with one kind of permeability test as well as a popular tensile/compression testing machine. Finally, I also had the chance to be trained using a metal lathe for making very small tips for a soldering iron. These tips will be used to melt threaded brass inserts into 3D printed plastic. Working with James Brown, I was able to successfully machine a brass rod down to as little as 0.064 inches plus or minus 0.001 inches. It was very rewarding to learn how to best use the machine and become familiar with a skill that will undoubtedly be used again in the future. I have been told by several professional engineers that learning to use a lathe and mill will be invaluable skills in the field. This knocks 50 percent of that goal off and I look forward to learning the mill at some point in the future. As is apparent with this list of projects, my internship was not focused on a single over-arching goal. Instead, I was able to gain experience in a myriad of very different areas. I feel like my time here was spent bouncing from one project to the next. Though sometimes difficult to switch gears, it was very rewarding to be a part of so much in so little time. My career and education will be positively impacted by what I have learned at JSC. My experience with 3D printing has improved my ability to handle many issues that may come up in the future with multiple different technologies. The design work I took part in, especially creating technical drawings, will help me better present designs to any engineer or shop I will encounter. My testing experience has helped me become familiar with a popular kind of tensile test machine that will likely be similar to the kinds I will encounter in the future. Finally, my experience with fabrication has given me a rare opportunity, as an engineer, to take part in the fabrication of a part. This experience will help me better tailor my future designs for the manufacturing process and has given me an appreciation for detailed/delicate machining work. My experience at JSC has been successful and will continue to assist me for a long time within the engineering field.

Zusack, Steven↗
NASA NTRS2010

Foldable Instrumented Bits for Ultrasonic/Sonic Penetrators

Long tool bits are undergoing development that can be stowed compactly until used as rock- or ground-penetrating probes actuated by ultrasonic/sonic mechanisms. These bits are designed to be folded or rolled into compact form for transport to exploration sites, where they are to be connected to their ultrasonic/ sonic actuation mechanisms and unfolded or unrolled to their full lengths for penetrating ground or rock to relatively large depths. These bits can be designed to acquire rock or soil samples and/or to be equipped with sensors for measuring properties of rock or soil in situ. These bits can also be designed to be withdrawn from the ground, restowed, and transported for reuse at different exploration sites. Apparatuses based on the concept of a probe actuated by an ultrasonic/sonic mechanism have been described in numerous prior NASA Tech Briefs articles, the most recent and relevant being "Ultrasonic/ Sonic Impacting Penetrators" (NPO-41666) NASA Tech Briefs, Vol. 32, No. 4 (April 2008), page 58. All of those apparatuses are variations on the basic theme of the earliest ones, denoted ultrasonic/sonic drill corers (USDCs). To recapitulate: An apparatus of this type includes a lightweight, low-power, piezoelectrically driven actuator in which ultrasonic and sonic vibrations are generated and coupled to a tool bit. The combination of ultrasonic and sonic vibrations gives rise to a hammering action (and a resulting chiseling action at the tip of the tool bit) that is more effective for drilling than is the microhammering action of ultrasonic vibrations alone. The hammering and chiseling actions are so effective that the size of the axial force needed to make the tool bit advance into soil, rock, or another material of interest is much smaller than in ordinary twist drilling, ordinary hammering, or ordinary steady pushing. Examples of properties that could be measured by use of an instrumented tool bit include electrical conductivity, permittivity, magnetic field, magnetic permeability, temperature, and any other properties that can be measured by fiber-optic sensors. The problem of instrumenting a probe of this type is simplified, relative to the problem of attaching electrodes in a rotating drill bit, in two ways: (1) Unlike a rotating drill bit, a bit of this type does not have flutes, which would compound the problem of ensuring contact between sensors and the side wall of a hole; and (2) there is no need for slip rings for electrical contact between sensor electronic circuitry and external circuitry because, unlike a rotating drill, a tool bit of this type is not rotated continuously during operation. One design for a tool bit of the present type is a segmented bit with a segmented, hinged support structure (see figure). The bit and its ultrasonic/sonic actuator are supported by a slider/guiding fixture, and its displacement and preload are controlled by a motor. For deployment from the folded configuration, a spring-loaded mechanism rotates the lower segment about the hinges, causing the lower segment to become axially aligned with the upper segment. A latching mechanism then locks the segments of the bit and the corresponding segments of the slider/guiding fixture. Then the entire resulting assembly is maneuvered into position for drilling into the ground. Another design provides for a bit comprising multiple tubular segments with an inner alignment string, similar to a foldable tent pole comprising multiple tubular segments with an inner elastic cable connecting the two ends. At the beginning of deployment, all segments except the first (lowermost) one remain folded, and the ultrasonic/sonic actuator is clamped to the top of the lowermost segment and used to drive this segment into the ground. When the first segment has penetrated to a specified depth, the second segment is connected to the upper end of the first segment to form a longer rigid tubular bit and the actuator is moved to the upper end of the second segnt. The process as described thus far is repeated, adding segments until the desired depth of penetration has been attained. Yet other designs provide for bits in the form of bistable circular- or rectangular- cross-section tubes that can be stowed compactly like rolls of flat tape and become rigidified upon extension to full length, in a manner partly similar to that of a common steel tape measure. Albeit not marketed for use in tool bits, a bistable reeled composite product that transforms itself from a flat coil to a rigid tube of circular cross section when unrolled, is commercially available under the trade name RolaTube(TradeMark) and serves as a model for the further development of tool bits of this subtype.

Bar-Cohen, Yoseph↗