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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
NASA NTRS2015

Method and System for Weakening Shock Wave Strength at Leading Edge Surfaces of Vehicle in Supersonic Atmospheric Flight

A method and system are provided to weaken shock wave strength at leading edge surfaces of a vehicle in atmospheric flight. One or more flight-related attribute sensed along a vehicle's outer mold line are used to control the injection of a non-heated, non-plasma-producing gas into a local external flowfield of the vehicle from at least one leading-edge surface location along the vehicle's outer mold line. Pressure and/or mass flow rate of the gas so-injected is adjusted in order to cause a Rankine-Hugoniot Jump Condition along the vehicle's outer mold line to be violated.

Daso, Endwell O.↗
NASA NTRS2016

Fiber-Reinforced Epoxy Composites and Methods of Making Same Without the Use of Oven or Autoclave

Method embodiments for producing a fiber-reinforced epoxy composite comprise providing a mold defining a shape for a composite, applying a fiber reinforcement over the mold, covering the mold and fiber reinforcement thereon in a vacuum enclosure, performing a vacuum on the vacuum enclosure to produce a pressure gradient, insulating at least a portion of the vacuum enclosure with thermal insulation, infusing the fiber reinforcement with a reactive mixture of uncured epoxy resin and curing agent under vacuum conditions, wherein the reactive mixture of uncured epoxy resin and curing agent generates exothermic heat, and producing the fiber-reinforced epoxy composite having a glass transition temperature of at least about 100.degree. C. by curing the fiber reinforcement infused with the reactive mixture of uncured epoxy resin and curing agent by utilizing the exothermically generated heat, wherein the curing is conducted inside the thermally insulated vacuum enclosure without utilization of an external heat source or an external radiation source.

Barnell, Thomas J.↗
NASA NTRS2017

Process for Forming a High Temperature Single Crystal Canted Spring

A process for forming a high temperature single crystal canted spring is provided. In one embodiment, the process includes fabricating configurations of a rapid prototype spring to fabricate a sacrificial mold pattern to create a ceramic mold and casting a canted coiled spring to form at least one canted coil spring configuration based on the ceramic mold. The high temperature single crystal canted spring is formed from a nickel-based alloy containing rhenium using the at least one coil spring configuration.

DeMange, Jeffrey J↗
NASA NTRS2018

Systems and Methods for Fabricating Structures Including Metallic Glass-Based Materials Using Low Pressure Casting

Systems and methods to fabricate objects including metallic glass-based materials using low-pressure casting techniques are described. In one embodiment, a method of fabricating an object that includes a metallic glass-based material includes: introducing molten alloy into a mold cavity defined by a mold using a low enough pressure such that the molten alloy does not conform to features of the mold cavity that are smaller than 100 microns; and cooling the molten alloy such that it solidifies, the solid including a metallic glass-based material.

Hofmann, Douglas C.↗
NASA NTRS2018

Determination of Uncertainties for Analytically Derived Material Properties to Be Used in Monte Carlo Based Orion Heatshield Sizing

Ablative materials are often used for spacecraft heatshields to protect underlying structures from the extreme environments associated with atmospheric reentry. NASA's Orion EM-1 capsule has been designed to use a molded Avcoat material system. In order to determine the required heatshield thickness, a Monte Carlo approach to the sizing process was proposed. To perform the Monte Carlo simulation, statistical uncertainties on all material property input parameters were required. Obtaining these values for measured properties is straightforward, however input parameters that are derived analytically have historically used uncertainties based on engineering judgment. A MATLAB program was created to use laboratory generated thermogravimetric analysis (TGA) data to calculate uncertainties on the Arrhenius parameters for molded Avcoat. Uncertainties associated with the normalized ablation rate and pyrolysis gas enthalpy were also generated using a wrapper script and the ACE code. These uncertainties could then be tied directly to measured values of individual elemental constituents. The resulting uncertainty values will allow for a probabilistic sizing approach on molded Avcoat with a higher level of confidence in the input parameters.

material property uncertainties↗
NASA NTRSDate not supplied

Assessment of the Impact of an Advanced Power System on a Turboelectric Single-Aisle Concept Aircraft

Electrified aircraft propulsion concepts show potential in using propulsion airframe inte-gration in order to increase efficiency in flight and therefore decrease fuel burn and emissions.Electrification offers component efficiency values greater than 90 percent, but the loss is in the form of low grade waste heat. A major challenge of electrified aircraft propulsion is managing that heat while minimizing any penalties associated with a thermal management system. This paper explores the effect of two innovations in the management of waste heat at the aircraft system level for a turboelectric single aisle concept. The first innovation is achieving a 3 times reduction in heat by developing high-efficiency components rather than managing the high levels of heat. The second takes advantage of the outer mold line of the aircraft to reject heat directly to the environment passively instead of adding active cooling loops that negatively impact the weight, power, and drag of the aircraft. In order to fully grasp the impact of the advanced power system, we develop methods of modeling the power and thermal management systems to be integrated in the full aircraft conceptual model. We then model the aircraft with a state of the art DC transmission system and active cooling loops as a baseline for our study. Our second model includes the advanced power system with active cooling, which results in a fuel burn reduction of 2.5 percent. Finally, in our third model we assess the benefit of an outer mold line cooling scheme with the advanced power system. The outer mold line cooling scheme with an advanced power system yields an additional 0.8 percent reduction in fuel burn,for an overall fuel burn reduction potential of 3.3 percent in addition to aerodynamic benefits of electrified aircraft propulsion.

Electric Aircraft↗
NASA NTRS2023

Spaceflight Autonomous Multigenerational Microbial Sequencer (SAMMS) in Support of Plant-Growth Systems

As the National Aeronautics and Space Association (NASA) begins to pursue long-duration space flights, they will need to be able to provide astronauts with a nutritious and reliable food source. To meet the administration’s goal of traveling to the Moon and Mars, astronauts will need to begin to grow their own food in space. To protect their food source, extensive monitoring will occur to test for the effects of a space flight environment (e.g., radiation) as well as for early pathogen and disease detection. Genomic sequencing allows for both concerns to be tested on a regular basis. However, NASA’s current sequencer is unable to process plant tissues. Therefore, a novel method for plant DNA extraction using microneedle (MN) patches that will be able to feed into NASA’s existing system, but also require minimal human input is proposed. To support this, the design was broken down into four components (1) MN patch fabrication (2) MN patch extraction, (3) automated sampling motion control, and (4) a processing module. The MN patch is fabricated using a custom mold with conically shaped needles. The mold is filled with Polyvinyl alcohol (PVA) solution and placed in a vacuum desiccator. The mold is left in the vacuum overnight until the patch is dry and ready for use. The protocol was tested with varying pressures, drying times, volume amounts, and preparation methods to determine if highquality needles can be produced. A MN is a method of DNA extraction where the patch is applied to a leaf, the needles penetrate the leaf, breaking the rigid plant cell wall to isolate the DNA. A protocol for this method of extraction was tested to ensure the patch could produce the needed yield and purity. The tests varied by the number of patches, number of applications, and plant type. To automate the MN extraction method, motion control will utilize two separate axis tables which move in the x and y directions. The y-axis table will have an end effector that fits a MN patch and will have the ability to apply the patch to the leaf sample. This end effector will also act as a lid for a downstream processing module. The other axis will position the leaf sample and processing container so that the patch can be applied accurately. The Joint Comprehensive Sequencing System (JCSS) module integrates all the components together. The output of this module feeds into the NASA Charged Information-Storage Polymer Preparation System (CHIPPS) for genomic sequencing. The extraction module operates using a series of syringes and tubing to pump the varying reagents needed for the extraction protocol. The results of the study proved that MN patches are a viable method of DNA extraction. While fabrication of high-quality needles was unsuccessful, the protocol was able to be further developed using centrifugation. The integrated design between the motion control and the JCSS enabled the potential for automation with a complete conceptual design and prototype. Future research and development for this study would include (1) further testing for fabrication (2) expanding the range of plant species compatible with the MN patch, and (3) building a working prototype for the integrated system.

Peter Ling↗
NASA NTRS2023

BOLT II Forebody Surface Measurement Analysis

Surface impression molds of the nosetip/forebody interface, discrete tripping elements, and other surface imperfections were formed on the BOLT II flight vehicle prior to its launch in March 2022. The silicon-rubber molds cast on the interface between the nickel nosetip and the stainless steel forebody were measured using a 3D optical measurement system and a stylus profilometer and were evaluated for step direction and height. The step around the nosetip/forebody interface was found to vary in both magnitude and direction, but values were generally modest with most samples below 60 μm across the span and only two samples, both cast in the gutter, with step values larger than 100 μm. Impressions of the secondary-side tripping elements were strictly scanned with the optical device and similar methods were used to calculate trip height as step height. The measured centerline trip height was 2623 ±12 μm, while the leading-edge, quadrant 2 and 3, trip heights were 897 ±5 μm and 891 ±18 μm, respectively. Surface imperfections on the nose and forebody were also evaluated. Surface roughness values and spectra were estimated, and profiles were extracted across the imperfections to quantify the magnitude of those features.

Trip height↗
NASA NTRS1966

Split glass tube assures quality in electron beam brazing

Sealed enclosure of heat-resistant glass tubing and silicone rubber molds provide good visibility for electron beam brazing of metal tubes in an inert gas atmosphere. The glass tubing and rubber molds, which are bonded together, are easily applied to and removed from the brazing area by operation of a clamp.

Kressin, W. J.↗
NASA NTRS1970

New hyperthermal thermosetting heterocyclic polymers

Polyimidazopyrrolone polymers, formed by the condensation of aromatic dianhydrides with aromatic tetraamines in various solvents, form moldings that resist degradation in air and retain great strength at 400 to 700 degrees F. The resins have good insulating properties, are easy to mold, and make good protective coatings.

Bilow, N.↗
NASA NTRS1971

Circuit breaker cases

A flammable plastic part was duplicated dimensionally using a nonflammable material in place of the flammable plastic. The material used was L-3203-6 with a 16-hour post-cure at 400 F. Initial efforts were made to determine shrinkage tolerances required to produce a mold which would produce a finished, workable part. The final twenty-five circuit breaker cases were shipped and the metal inserts when installed, produced a workable breaker. Initial submissions of cases were rejected as lacking sufficient rigidity though they met all other requirements. The plastic cases weighed 16.5 grams, whereas the Refset cases weighed 17 grams, not meeting the less-weight requirement. The data on shrinkage determinations, and mold and part dimensions are shown. The method of manufacture is also reported.

Holmes, R. L.↗
NASA NTRS1972

Thermally stable laminating resins

Improved thermally stable laminating resins were developed based on the addition-type pyrolytic polymerization. Detailed monomer and polymer synthesis and characterization studies identified formulations which facilitate press molding processing and autoclave fabrication of glass and graphite fiber reinforced composites. A specific resin formulation, termed P10P was utilized to prepare a Courtaulds HMS reinforced simulated airfoil demonstration part by an autoclave molding process.

Jones, R. J.↗
NASA NTRS1973

Electro-optical device for monitoring wire size

Device recognizes variations in wire size and is being used during computer memory-plane fabrication. Decrease in wire diameter, due to stretching, permits removal of wire from memory-plant mold. Monitoring provides means of detecting imperfect wire and permits fabrication of computer memory plane to be stopped prior to its insertion into mold.

Burcher, E. E.↗
NASA NTRS1974

Inexpensive lightweight mirror

Aluminized Mylar film is bonded to polyurethane foam mold; Mylar is then removed, leaving highly reflective coating of aluminum on foam. Mold may be used repeatedly to make mirrors for several optical instruments. Large mirrors of almost any shape may be made singularly or in quantity.

Badhwar, G. D.↗
NASA NTRS1973

Integrated circuit package with lead structure and method of preparing the same

A beam-lead integrated circuit package assembly including a beam-lead integrated circuit chip, a lead frame array bonded to projecting fingers of the chip, a rubber potting compound disposed around the chip, and an encapsulating molded plastic is described. The lead frame array is prepared by photographically printing a lead pattern on a base metal sheet, selectively etching to remove metal between leads, and plating with gold. Joining of the chip to the lead frame array is carried out by thermocompression bonding of mating goldplated surfaces. A small amount of silicone rubber is then applied to cover the chip and bonded joints, and the package is encapsulated with epoxy resin, applied by molding.

Kennedy, B. W.↗
NASA NTRS1974

Resin/graphite fiber composites

Techniques were developed that provided thermo-oxidatively stable A-type polyimide/graphite fiber composites using the approach of in situ polymerization of monomeric reactants directly on reinforcing fibers, rather than employing separately prepared prepolymer varnish. This was accomplished by simply mixing methylene dianiline and two ester-acids and applying this solution to the fibers for subsequent molding. Five different formulated molecular weight resins were examined, and an optimized die molding procedure established for the 1500 formulated molecular weight system. Extensive ultrasonic inspection of composites was successfully utilized as a technique for monitoring laminate quality. Composite mechanical property studies were conducted with this polyimide resin at room temperature and after various time exposures in a thermo-oxidative environment at 561 K (550 F), 589 K (600 F) and 617 K (650 F). It was determined that such composites have a long term life in the temperature range of 561 K to 589 K. The final phase involved the fabrication and evaluation of a series of demonstration airfoil specimens.

Cavano, P. J.↗
NASA NTRS1973

Experiments on stiffened conical shell structures using cast epoxy models

Description of a casting technique for fabricating high-quality plastic structural models, and review of results regarding the use of such specimens to parametrically study the effect of base ring stiffness on the critical buckling pressure of a ring-stiffened conical shell. The fabrication technique involves machining a metal mold to the desired configuration and vacuum-drawing the plastic material into the mold. A room-temperature curing translucent thermoset epoxy was the casting material selected. A shell of revolution computer program which employs a nonlinear axisymmetric prebuckling strain field to obtain a bifurcation buckling solution was used to guide the selection of congifurations tested. The shell experimentally exhibited asymmetric collapse behavior, and the ultimate load was considerably higher than the analytical bifurcation prediction. The asymmetric buckling mode shape, however, initially appeared at a pressure near the analysis bifurcation solution.

Williams, J. G.↗
NASA NTRS1975

Flame resistant nontoxic polymer development

A number of homopolymers, copolymers, and terpolymers were synthesized employing styrene and four derivatives of diphenyl-p-styrylphosphine. The various polymeric compositions were prepared by two processes, (1) monomer bulk polymerizations and (2) substitution of preformed polydiphenyl-p-styrylphosphine. Results indicate that the majority of the compositions exhibit superior melting and flame retardant characteristics as compared to polystyrene, but are inferior in molding and film forming capability. Terpolymerization appears to result in the materials with the best overall combination of properties. Toxicological evaluation of three representative basic compositions in the form of molded washers showed that no mortalities occurred among the test animals exposed to the products of the oxidative thermal decomposition of the three materials.

Paciorek, K. L.↗