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At least 253 records · Page 14
All sourcesNASA NTRSDOE OSTI
NASA NTRS2018

Impact of Powder Variability on the Microstructure and Mechanical Behavior of Selective Laser Melted Alloy 718

Powder-bed additive manufacturing processes use fine powders to build parts layer-by-layer. Alloy 718 powder feedstocks for selective laser melting (SLM) additive manufacturing are produced commercially by both gas and rotary atomization and are available typically in the 10-45 or 15-45 microns size ranges. A comprehensive investigation was conducted to understand the impact of powder variability on the microstructure and mechanical behavior of SLM 718 heat treated to Aerospace Material Specification (AMS) 5664. This study included sixteen virgin powders and three once-recycled powders within the 10-45 and 15-45 microns size ranges that were obtained from seven direct source suppliers and one reseller. Although alike as highly regular spheroids, these powders showed distinct differences in composition (especially Al, C and N contents), particle size distributions, and powder features such as degree of agglomeration, fusion and surface roughness. Compositional differences expectedly had the strongest impact on microstructure. High N and C contents formed TiN-nitrides and/or (Nb,Ti,Mo)-C carbides on the grain boundaries, prevented recrystallization during heat treatment, and resulted in retained (001)-scalloped shaped grains that ranged from 19 to 41 microns in average size. In the absence of this particle pinning, the average grain size of the heat treated SLM 718 ranged from 51 microns to 90 microns. Room temperature tensile and high cycle fatigue (HCF) testing compared as-fabricated (AF) and low stress ground (LSG) surface conditions. Tensile testing revealed consistent behavior between the two surface conditions and amongst the powder lots. The finer grained SLM 718 builds displayed the lowest tensile properties. A SLM 718 build fabricated from a powder with eight times lower C content showed statistically better tensile properties presumably due to enhanced coarsening of (delta)-Ni3Nb precipitates. The specimens from once-recycled powders had slightly higher tensile strengths and slightly higher ductility compared to their virgin equivalents; once-recycling also did not substantially degrade the mean HCF life. The LSG fatigue lives agreed with conventionally manufactured 718 data, while AF lives exhibited a knock-down due to surface roughness. The fatigue lives of AF specimens were statistically equivalent across powder lots except for one and failures typically initiated at stress concentrators associated with SLM surface asperities. Fatigue testing of low stress ground specimens result in both transgranular and within facet crack initiations. More than half of the cracks initiated from these facets for the machined condition; however, these facets appeared to be within grains that were larger-than-average in size. A nitrogen-atomized powder with fine prior particles of TiN-nitrides and M(Ti,Nb,Mo)C carbides from atomization on powder surfaces resulted in the best fatigue performance with segregation of these particles to the SLM 718 grain boundaries leading to higher resistance to early-stage crack propagation. Typically the fine-grained builds with minor phases along the grain boundaries did not perform well in fatigue, whereas a larger-grain build with lower carbon content and coarser delta-Ni3Nb precipitates showed the next best HCF response. Further details of the build microstructure and its impact on tensile and fatigue behavior was considered.

laser deposition↗
NASA NTRS2018

Microgravity Experiments of Solid Waste Conversion into Useful Commodities

This Summer I participated in two projects at Kennedy Space Center in Cape Canaveral, Florida. The projects focus on the NASA's Deep Space Gateway applications for future Mars travel. All of these projects use recycling technology to use resources found on Earth and on other planets for fuel and other environmental applications. The first project I took the lead on is “Plasma Arc Gasification.” Plasma is a high temperature and very efficient way to process waste to create usable byproducts. The plasma chamber in temperature is comparable to that of the sun and this energy will help create an environment in which the waste can be recycled properly for not only plant support, but also for possible fuel application as well. I preformed the tests in a quartz tube, which is used to hold the waste (cotton, plastics, nylon, paper and a human waste simulant) and the waste is then combusted using O2 (present in air) into gases such as H2, H2O, CH4 and CO2. I determined which gases are present using a Fourier-transform infrared spectroscopy (FTIR) machine, which analyzes the peaks of the gases using liquid nitrogen. Problems arose in the beginning from the reactor emitting electromagnetic waves (EMI) that interfered with the technology of the experiment, specifically the thermocouples. This was solved through multiple tests with the positioning of the thermocouple power supply further away from the plasma reactor. I worked with another intern, Daniel Santander, who developed a space plant chamber which uses CO2 and H2O (harvested from the plasma reactor) to grow plants in space. The chamber possess a CO2 monitor, which controls the amount of gas that enters the chamber, along with a water integration system to supply the amount of water needed for proper plan growth. This technology will then be used for plant growth in space for the Astronauts on future space flights and possibly on the International Space Station (ISS). The second project I worked on is the “Orbital Syngas / Commodity Augmentation Reactor (OSCAR)” which focuses on the issues experienced in long-duration space flight regarding waste disposal. In previous space flight missions, waste was stored on board and returned to Earth for disposal. This technique is not applicable to long space flight missions to Mars due to the rocket being months away from Earth. OSCAR is using microgravity waste disposal techniques to produce fuels from the recycled waste. The waste is converted to syngas through a thermal degradation process. This process helps create an environmentally friendly way to dispose and reuse trash on board the space craft. Currently waste is being tested in the form of cotton and plastics. OSCAR is designed as a microgravity reactor that is currently being tested in a drop tower rig at Glenn Research Center. I helped design the 3D model for the insulation that will line the reactor. The first few trials, I dissolved the plastic of the mold in acetone. This method worked, but was very costly. I then received a silicone material to construct the mold from Swamp Works here at Kennedy. Through multiple trials with the silicone, this method worked best for developing the end pieces of the insulation for the chamber.

Plasma↗
NASA NTRS2019

Program Promotion Can Distort Space Systems Engineering and Deny Risk

NASA's spectacular success in the Apollo moon landings was achieved against the odds by an obsessive dedication to reducing the great risk. But risk analysis predicted so many astronaut fatalities that it was thought to be unreasonably pessimistic and potentially damaging to the Apollo program. Risk analysis was discontinued, risk was neglected in space shuttle engineering, and so the space shuttle design was unnecessarily dangerous. Since the Apollo era it has been understood that long human space missions would recycle oxygen and water to avoid the very high launch cost of directly supplying them. The development of recycling systems was justified by the need to increase material closure and reduce launch mass. When it was recognized that increasing closure leads to rapidly diminishing returns, the program goal was changed to reducing launch mass and reliability, cost, and risk were considered irrelevant. Systems engineering and especially the discouraging problems of risk and cost have been deliberately ignored because they detract from program promotion, with unfortunate results. Current human launch system design does account for risk and the result strongly resembles Apollo. Current life support design continues to assume recycling, even though the recent great reduction in launch cost now allows direct supply of oxygen and water with significantly better quality, reliability, cost, and risk.

Advocacy↗
NASA NTRS2019

Moon Base Life Support Design Depends on Launch Cost, Crew Size, and Mission Duration

Brief human space missions such as Apollo and the Space Shuttle used material storage for life support but a long mission such as a space station uses a recycling life support system. The upcoming Moon visits will probably be brief with few crew at first but in the future there may be a long-term or even permanent Moon base with a large crew. The initial life support system will probably use storage and resupply of materials from Earth, but it could be replaced later by recycling, especially if launch cost per kilogram is high. Moon base life support design is investigated considering requirements, performance, reliability, cost, and risk. The launch cost, crew size, and mission duration are variable parameters that affect the life support design choice. Greater launch cost, crew size, or mission duration all tend to make recycling more cost-effective than resupply.

Jones, Harry W.↗
NASA NTRS2019

Powering OSCAR

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

Cauvel, Thomas↗
NASA NTRSDate not supplied

From 3D Printing Lunar and Mars Habitats to Affordable Sustainable Housing on Earth

In 2015, the NASA Centennial Challenges program launched the 3D-Printed Habitat (3DPH) competition to develop housing solutions for extended-duration missions on planetary surfaces using advanced additive construction technology. The challenge was executed in three phases with increasing complexities and requirements. The main goal of the competition was to use of planetary indigenous materials and mission recyclables as feedstock for large-scale, autonomous 3D printers to construct a habitat on the Moon or Mars. Phase 1 challenged teams to develop state-of-the-art architecture concepts that took advantage of unique capabilities offered by 3D-printing. In Phase 2, teams autonomously 3D-printed structural components using terrestrial/space-based materials and recyclables. Phase 3 tasked competitors to fabricate sub-scale habitats using indigenous materials with or without mission-generated recyclables and ended in a head-to-head competition. The developments from this challenge are applicable both to the fulfillment of NASA’s Moon to Mars mission and to the creation of affordable and sustainable housing solutions on Earth. This paper will summarize the results of the four-year challenge and provide an overview of team achievements as a result of the competition. Results from the competition include humanitarian and business opportunities created/negotiated and the development of 3D-printed housing solutions for people such those in need of shelter in Austin, Texas and 3D-printing houses at the United Nations habitat headquarters in Nairobi, Keyna. The Phase 3: Level 5 winner, AI. SpaceFactory, is currently 3D-printing an ecofriendly house in New York called Terra, a full-size habitat design for Mars and available on Earth.

M C Roman↗
NASA NTRSDate not supplied

Can water mined on the moon save cost for life support?

The water needed for space life support has been so far provided by direct supply from Earth on most missions or by recycling on the International Space Station (ISS). With the recent reduction in launch cost, Earth resupply has become more attractive than recycling for lunar missions with smaller crews and briefer missions requiring less than 1,000 crew days. The third alternative supply method would use water mined from the lunar regolith. Continuing lunar research suggests that the moon may have more water, more widely distributed than previously expected. The cost of water mined on the moon will depend on its form and concentration, the machinery and operations required, and the overall demand for water. The use of oxygen and hydrogen for propulsion may greatly exceed the need for crew life support. The conditions under which water mined on the moon would be less expensive that water provided by resupply or recycling are described.

Harry W Jones↗
NASA NTRS2021

A data–model approach to interpreting speleothem oxygen isotope records from monsoon regions

Reconstruction of past changes in monsoon climate from speleothem oxygen isotope (δ 18 O) records is complex because δ 18 O signals can be influenced by multiple factors including changes in precipitation, precipitation recycling over land, temperature at the moisture source, and changes in the moisture source region and transport pathway. Here, we analyse >150 speleothem records of the Speleothem Isotopes Synthesis and AnaLysis (SISAL) database to produce composite regional trends in δ 18 O in monsoon regions; compositing minimises the influence of site-specific karst and cave processes that can influence individual site records. We compare speleothem δ 18 O observations with isotope-enabled climate model simulations to investigate the specific climatic factors causing these regional trends. We focus on differences in δ 18 O signals between the mid-Holocene, the peak of the Last Interglacial (Marine Isotope Stage 5e) and the Last Glacial Maximum as well as on δ 18 O evolution through the Holocene. Differences in speleothem δ 18 O between the mid-Holocene and the Last Interglacial in the East Asian and Indian monsoons are small, despite the larger summer insolation values during the Last Interglacial. Last Glacial Maximum δ 18 O values are significantly less negative than interglacial values. Comparison with simulated glacial–interglacial δ 18 O shows that changes are principally driven by global shifts in temperature and regional precipitation. Holocene speleothem δ 18 O records show distinct and coherent regional trends. Trends are similar to summer insolation in India, China and southwestern South America, but they are different in the Indonesian–Australian region. Redundancy analysis shows that 37 % of Holocene variability can be accounted for by latitude and longitude, supporting the differentiation of records into individual monsoon regions. Regression analysis of simulated precipitation δ 18 O and climate variables show significant relationships between global Holocene monsoon δ 18 O trends and changes in precipitation, atmospheric circulation and (to a lesser extent) source area temperature, whereas precipitation recycling is non-significant. However, there are differences in regional-scale mechanisms: there are clear relationships between changes in precipitation and δ 18 O for India, southwestern South America and the Indonesian–Australian regions but not for the East Asian monsoon. Changes in atmospheric circulation contribute to δ 18 O trends in the East Asian, Indian and Indonesian–Australian monsoons, and a weak source area temperature effect is observed over southern and central America and Asia. Precipitation recycling is influential in southwestern South America and southern Africa. Overall, our analyses show that it is possible to differentiate the impacts of specific climatic mechanisms influencing precipitation δ 18 O and use this analysis to interpret changes in speleothem δ 18 O.

speleothem oxygen isotope records↗
NASA NTRSDate not supplied

Closing the Loop on Space Trash / Is a Circular Economy Possible?

A crew member will nominally consume 2.5 kg of water per crew-member per day, rejectapproximately 0.032 kg of dry fecal solid waste per crew member per day (dry basis)and generate approximately 2,122 kg of logistical waste per year on a long-durationcrewed mission. This topic seeks to push the conversation towards completing a closedloop system and circular economy for all materials and recoverable resources withregard to waste management, regenerative water use, and recycling. In all aspects,reduction of crew maintenance time, mass, power and volume are at the forefront oftechnology development. In addition, the longevity and hardware robustness is important(lasting >3 years). Overall water recovery of >98% is desired, as well as, condensingheat exchangers that remove water from air with collection rates up to 1.45 kg of waterper hour. There are many technologies on the ground being developed for recycling andtrash management or regenerative water use that have yet to introduce themselves forspace development and infusion. Here we look to open the conversation and cross cutthese platforms to bring out some innovation and exposure into the hidden crevasses ofthe waste that humans create and how to minimize it/repurpose it, for all of humanity.

ISRU↗
NASA NTRSDate not supplied

Computationally Guided Design of Polymer-Coated Microparticles as Reusable Materials

Long-duration space exploration missions and sustained lunar or Martian surface operations present greater demands for multifunctional and reusable materials. By scaling down the amount of material to be launched from Earth, both mission cost and risk can be reduced. In this regard, leveraging in-space manufacturing capabilities with reusable feedstock materials is an attractive option, as it will allow for articles to be generated on demand, utilized, and then recycled for additional use. NASA’s Enabling Sustained Presence Using Recyclables (ESPUR) project aims to develop reusable materials using polymer-coated microparticles that are bonded via reversible Diels-Alder reactions, where only modest heat is needed to trigger the reverse reaction and enable reuse. For proof-of-concept demonstration, research is currently focused on the fabrication of epoxy microparticles that contain a copoly(carbonate urethane) coating with maleimide and furan functionalities. Here, we discuss the integration of computational materials modeling approaches to help navigate the large design space in this development effort. We perform molecular dynamics (MD) simulations with atomistic and coarse-grained models of the copolymer, which allow us to evaluate the effects of design parameters like the molecular weight and composition on the molecular interactions and chain dynamics. We show how the properties change with the reversible bonds. We also leverage discrete element method (DEM) simulations to assess how microparticle design parameters like the size ratio and volume fraction can be tuned to increase the packing density and number of microparticle contacts to improve the mechanical properties. Our results demonstrate how computational tools can be used in close collaboration with experimental efforts to accelerate material design.

reusable materials↗
NASA NTRS1971

Rotary relay for space power transfer

The power clutch presented is designed for the transfer of electrical signals and power across rotating joints. Radio noise, friction, and wear are virtually eliminated. The design, construction, and applications are discussed. This clutch eliminates the need of recycling solar arrays once each orbit by recycling only a low-inertia component of the power system.

Haynie, H. T.↗
NASA NTRS1972

Superalloy material test in a plasma arc tunnel

Seven superalloy models were tested in a plasma arc tunnel at the peak heating condition existing on the space shuttle orbiter's lower surface during a low cross-range entry. The models were 3 x 3 in. flat surfaces, nominally 0.01 to 0.02 in. thick, and were held in a water-cooled wedge holder at a 60 deg angle of attack. Five test models were recycled 25 times for 10 min periods (two were recycled 50 times) in a Mach 4.6 test stream, with the model's leading edge temperature maintained at 2200 F (2000 F in one case).

Land, D. W.↗
NASA NTRS1972

The Bosch process.

Many previous studies have been carried out to elucidate certain aspects of the Bosch process wherein CO2 is reacted over an iron catalyst to form carbon and water at temperatures around 1100 F. These results are assembled, and with the aid of new experimental data, are used to analyze the various reactions involved. It is shown that CO2 and H2 will not usually react to deposit carbon unless water is removed in a recycle loop. The critical importance of large catalyst areas is stressed relative to catalyst pretreatment processes. It is shown that in most operating Bosch reactions, mass transfer controls the rate of reaction, and it is suggested that the carbon filaments found are the expected result of such a rate limiting process. Typical recycle gas mixtures are considered, and maximum water yields are determined from various cases. A few suggestions are made to improve Bosch reaction performance, and a number of unresolved problems are noted.

Meissner, H. P.↗
NASA NTRS1973

Control of a 30 cm diameter mercury bombardment thruster

Control logic functions were established for three automatic modes of operation of a 30-cm thruster using a power conditioner console with flight-like characteristics. The three modes provide: (1) automatic startup to reach thermal stability, (2) steady-state closed-loop control, and (3) the reliable recycling of the high voltages following an arc breakdown to reestablish normal operation. Power supply impedance characteristics necessary for stable operation and the effect of the magnetic baffle on the reliable recycling was studied.

Terdan, F. F.↗
NASA NTRS1975

Carbon dioxide reduction by the Bosch process

Prototype units for carrying out the reduction of carbon dioxide to elementary carbon have been built and operated successfully. In some cases, however, startup difficulties have been reported. Moreover, the recycle reactor product has been reported to contain only small amounts of water and undesirably high yields of methane. This paper presents the results of the first phase of an experimental study that was carried out to define the mechanisms occurring in the reduction process. Conclusions are drawn and possible modifications to the present recycle process are suggested.

Manning, M. P.↗
NASA NTRS1977

An analysis of the back end of the nuclear fuel cycle with emphasis on high-level waste management, volume 1

The programs and plans of the U.S. government for the "back end of the nuclear fuel cycle" were examined to determine if there were any significant technological or regulatory gaps and inconsistencies. Particular emphasis was placed on analysis of high-level nuclear waste management plans, since the permanent disposal of radioactive waste has emerged as a major factor in the public acceptance of nuclear power. The implications of various light water reactor fuel cycle options were examined including throwaway, stowaway, uranium recycle, and plutonium plus uranium recycle. The results of this study indicate that the U.S. program for high-level waste management has significant gaps and inconsistencies. Areas of greatest concern include: the adequacy of the scientific data base for geological disposal; programs for the the disposal of spent fuel rods; interagency coordination; and uncertainties in NRC regulatory requirements for disposal of both commercial and military high-level waste.

Source record↗
NASA NTRS1977

Conceptual design for spacelab two-phase flow experiments

KC-135 aircraft tests confirmed the gravity sensitivity of two phase flow correlations. The prime component of the apparatus is a 1.5 cm dia by 90 cm fused quartz tube test section selected for visual observation. The water-cabin air system with water recycle was a clear choice for a flow regime-pressure drop test since it was used satisfactorily on KC-135 tests. Freon-11 with either overboard dump or with liquid-recycle will be used for the heat transfer test. The two experiments use common hardware. The experimental plan covers 120 data points in six hours with mass velocities from 10 to 640 kg/sec-sq m and qualities 0.01 to 0.64. The apparatus with pump, separator, storage tank and controls is mounted in a double spacelab rack. Supporting hardware, procedures, measured variables and program costs are defined.

Bradshaw, R. D.↗
NASA NTRS1979

The role of phosphorus in the upper atmosphere of Jupiter

The reaction of elemental phosphorus and H atoms to form PH3 was observed and should be a major factor in the recycling of PH3 in the stratosphere of Jupiter. The formation of PH3 in this manner should predominate at high altitudes where, due to the very low temperatures, reactions that require higher activation energies than these atom reactions cannot occur. At lower altitudes, in the troposphere, the rapid formation of H atoms from the strong absorption of light by NH3 will contribute to phosphine production also in this same manner. Recent experiments have also shown that elemental phosphorus reacts readily with aqueous ammonia to form PH3. This reaction may also be important in the recycling of PH3 in the upper troposphere of Jupiter if water-ammonia clouds, as had been previously thought, exist. Considerations of the coloration of the Great Red Spot have been made based upon the nature of the phosphorus obtained by decomposition of the phosphine.

Howland, G. R.↗