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At least 307 records · Page 17

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NASA NTRS2018

Space Technology Mission Directorate: Game Changing Development Program: Rapid Analysis and Manufacturing Propulsion Technology (RAMPT)

Technology Overview: The RAMPT (Rapid Analysis and Manufacturing Propulsion Technology) project will develop and advance large scale light-weight multi-metallic freeform manufacturing and composite overwrap techniques and analysis capabilities required to implement them to reduce design and fabrication cycles for regeneratively-cooled liquid rocket engine components; RAMPT will reduce design, fabrication, assembly schedules while allowing for reduced parts, increased reliability, significant weight reduction and a healthy American supply chain. Four technology areas developed: 1) Freeform Blown Powder Nozzle; 2) Composite overwrap structural jacket; 3) Bimetallic radial deposition for manifolds; 4) Modeling and analysis tools for Additive and Regen design. Exploration & Science Impact: Addresses longest lead, highest cost and heaviest component in engine; Applicable to Lunar Lander Engine, Booster Engines, Upper Stage Engines, and NTP (Nuclear Thermal Propulsion) Technology; Public-private partnerships with specialty industry vendors, government partners, Commercial Crew, and infusion into commercial space companies and manufacturers; SSTIP (NASA's Strategic Space Technology Investment Plan) Core Investment Area - Launch Propulsion Systems (TA01 (NASA Technology Area 01); Lightweight Space Structures and Materials (TA12); Manufacturing (TA12).

RAMPT↗

NASA NTRS2019

A Proposal for Standardized MMOD Shielding for Robotic Spacecraft

NASA robotic spacecraft are required to assess the potential for small debris induced failure for all disposal-critical components. Additional shielding might then be necessary in order to meet the acceptable risk requirement for the overall mission. Traditionally this requirement had been met with little or no additional shielding. Since the introduction of a high density debris population in ORDEM 3.0, some missions, especially those in higher portions of Low Earth Orbit, have needed additional MMOD-specific shielding in order for the mission to meet the requirement. This is a costly design effort when performed late in the project life cycle, which adds unexpected mass to the spacecraft components during the integration phase, and could disrupt thermal management.A proposal is discussed to develop a more cost-effective approach to MMOD-shielding, which can be employed earlier in the hardware design phase. The development and adoption of standardized shielding assemblies allows early tailoring of the shielding around a component, so that the mass is accounted for, as well as the small particle penetration risk, at a point in the design phase when the cost and schedule impact are more manageable. A set of several assemblies can be developed with a range of protection thresholds, in order to control mass where less shielding is needed. Such shielding assemblies would be developed in collaboration with blanket assembly specialists and thermal control engineers to ensure manufacturability and thermal performance challenges are known and acceptable. One clear benefit of such an approach is that hypervelocity testing can be performed on each of the standard shield assemblies to refine and confirm their performance prior to use.The challenges inherent in designing supplemental MMOD shielding will be discussed, including variations in the orbital debris environment and performance prediction. The benefits of a standardized shielding approach and example applications will also be presented.

Hull, Scott M.↗

NASA NTRS2019

A Proposal for Standardized MMOD Shielding for Robotic Spacecraft

NASA robotic spacecraft are required to assess the potential for small debris induced failure for all disposal-critical components. Additional shielding might then be necessary in order to meet the acceptable risk requirement for the overall mission. Traditionally this requirement had been met with little or no additional shielding. Since the introduction of a high density debris population in ORDEM 3.0, some missions, especially those in higher portions of Low Earth Orbit, have needed additional MMOD-specific shielding in order for the mission to meet the requirement. This is a costly design effort when performed late in the project life cycle, which adds unexpected mass to the spacecraft components during the integration phase, and could disrupt thermal management. A proposal is discussed to develop a more cost-effective approach to MMOD-shielding, which can be employed earlier in the hardware design phase. The development and adoption of standardized shielding assemblies allows early tailoring of the shielding around a component, so that the mass is accounted for, as well as the small particle penetration risk, at a point in the design phase when the cost and schedule impact are more manageable. A set of several assemblies can be developed with a range of protection thresholds, in order to control mass where less shielding is needed. Such shielding assemblies would be developed in collaboration with blanket assembly specialists and thermal control engineers to ensure manufacturability and thermal performance challenges are known and acceptable. One clear benefit of such an approach is that hypervelocity testing can be performed on each of the standard shield assemblies to refine and confirm their performance prior to use.The challenges inherent in designing supplemental MMOD shielding will be discussed, including variations in the orbital debris environment and performance prediction. The benefits of a standardized shielding approach and example applications will also be presented.

Hull, Scott M.↗

NASA NTRS1980

Thermal-structural design study of an airframe-integrated Scramjet

The development and evaluation of a design concept for the cooled structures assembly for the Scramjet engine is discussed. Development concepts for engine subsystems and design concepts for the aircraft/engine interface are included. A thermal protection system was defined which makes it possible to attain a life of 100 hr and 1000 cycles, the specified goal. The coolant equivalence ratio at the Mach 10 maximum thermal loading condition is 0.6, indicating a capacity for airframe cooling. The mechanical design is feasible for manufacture using conventional materials. For the cooled structures in a six module engine, the mass per unit capture area is 1256 kg/sq m. The total mass of a six module engine assembly including the fuel system is 1502 kg.

Killackey, J. J.↗

DOE OSTI2023

Evaluation of HPK n + - p planar pixel sensors for the CMS Phase-2 upgrade

To cope with the challenging environment of the planned high luminosity upgrade of the Large Hadron Collider (HL-LHC), scheduled to start operation in 2029, CMS will replace its entire tracking system. The requirements for the tracker are largely determined by the long operation time of 10 years with an instantaneous peak luminosity of up to 7.5 × 10 34 cm –2 s –1 in the ultimate performance scenario. Depending on the radial distance from the interaction point, the silicon sensors will receive a particle fluence corresponding to a non-ionizing energy loss of up to $\Phi_{\text {eq}}$ = 3.5 × 10 16 cm –2 . Here this paper focuses on planar pixel sensor design and qualification up to a fluence of $\Phi_{\text {eq}}$ = 1.4 × 10 16 cm –2 . For the development of appropriate planar pixel sensors an R&D program was initiated, which includes $n^+ -p$ sensors on 150 mm (6”) wafers with an active thickness of 150 μm with pixel sizes of 100 × 25 μm 2 and 50 × 50 μm 2 manufactured by Hamamatsu. Single chip modules with ROC4Sens and RD53A readout chips were made. Irradiation with protons and neutrons, as well was an extensive test beam campaign at DESY were carried out. This paper presents the investigation of various assemblies mainly with ROC4Sens readout chips. It demonstrates that multiple designs fulfill the requirements in terms of breakdown voltage, leakage current and efficiency. The single point resolution for 50 × 50 μm 2 pixels is measured as 4.0 μm for non-irradiated samples, and 6.3 μm after irradiation to $\Phi_{\text {eq}}$ = 7.2 × 10 15 cm –2 .

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

NASA NTRS1978

Thermal-structural design study of an airframe-integrated Scramjet

Design concepts are developed and evaluated for a cooled structures assembly for the Scramjet engine, for engine subsystems mass, volume, and operating requirements, and for the aircraft/engine interface. A thermal protection system was defined that makes it possible to attain a life of 100 hours and 1000 cycles. The coolant equivalence ratio at the Mach 10 maximum thermal loading condition is 0.6, indicating a capacity for airframe cooling. The mechanical design is feasible for manufacture using conventional materials. For the cooled structures in a six-module engine, the mass per unit capture area is 12.4 KN/sq m. The total weight of a six-module engine assembly including the fuel system is 14.73 KN.

Killackey, J. J.↗

DOE OSTI2022

Experimental studies of a high-gradient X-band welded hard-copper split accelerating structure

We report on recent research on high-gradient radio frequency (RF) accelerating structures indicates that the use of hard copper alloys provides improvement in high gradient performance over annealed copper. Such structures are made by bonding individually manufactured parts. However, there are no well-established bonding techniques that preserve the hardness, surface finish and cleanliness required for high gradient operation. To preserve the copper hardness, RadiaBeam has developed a novel high-gradient split accelerating structure, based on electron beam welding joining technique. This technique provides efficient bonding with strong, clean welds and minimal thermal loading, while maintaining a clean inner RF environment. Our RF design and fabrication methodology limits the small heat affected zone to the outer cavity envelop, with virtually no distortions or thermal loading of critical RF surfaces. It also incorporates provisions to precisely control the gap despite conventional issues with weld joint shrinkage. To date we have manufactured and validated an RF accelerating structure joined by electron-beam welding that incorporates a novel open split design to significantly reduce the assembly complexity and cost. In this paper, we will present the electromagnetic design of this structure, discuss bonding, and present the results of high-power tests, where the accelerating gradients of 140 MV m -1 with surface peak fields of 400 MV m -1 were achieved for flat-top pulse length of 600 ns with an RF breakdown rate of 10 -4 1/(pulsecm).

43 PARTICLE ACCELERATORS↗

NASA NTRS2002

Observations of the Performance of the U.S. Laboratory Architecture

The United States Laboratory Module "Destiny" was the product of many architectural, technology, manufacturing, schedule and cost constraints which spanned 15 years. Requirements for the Space Station pressurized elements were developed and baselined in the mid to late '80's. Although the station program went through several design changes the fundamental requirements that drove the architecture did not change. Manufacturing of the U.S. Laboratory began in the early 90's. Final assembly and checkout testing completed in December of 2000. Destiny was launched, mated to the International Space Station and successfully activated on the STS-98 mission in February of 2001. The purpose of this paper is to identify key requirements, which directly or indirectly established the architecture of the U.S. Laboratory. Provide an overview of how that architecture affected the manufacture, assembly, test, and activation of the module on-orbit. And finally, through observations made during the last year of operation, provide considerations in the development of future requirements and mission integration controls for space habitats.

Jones, Rod↗

NASA NTRSDate not supplied

Design of a Manufacturing Demonstration Unit for a Composite Lunar Landing Gear Strut

The goal of the current work was to develop an analytical framework for design of composite struts using various levels of model fidelity. Rapid optimization trade studies were performed using low fidelity two-dimensional (2D) axisymmetric models with smeared composite properties. The optimum 2D model was compared with three-dimensional (3D) models with higher levels of fidelity in material property representation. Good agreement was found with all models. The buckling performance of the highest fidelity 3D model was found to be satisfactory for the intended loading conditions. An additional goal of this work was to perform an initial assessment of using automated fiber placement (AFP) and other advanced manufacturing methods to explore their feasibility for the fabrication of struts for lunar landers, strut-braced wings, and other aerospace components. The designs produced during this study are intended to be used to develop manufacturing demonstration units (MDU) that can be fabricated at the Integrated Structural Assembly of Advanced Composites (ISAAC) facility at Langley Research Center (LaRC) and tested in lab facilities at LaRC.

carbon-epoxy↗

NASA NTRSDate not supplied

Design of a Manufacturing Demonstration Unit for a Composite Lunar Landing Gear Strut

carbon-epoxy↗

NASA NTRS2022

Radial Loading of Hydrodynamic Bearings Due to Magnetic Variation

Anomalies during integration of a small-scale hydrodynamic pump motor prompted an investigation into all sources of radial loading on the bearings, and revealed that overall loads were insufficiently characterized. Experimental measurements demonstrated that magnetic forces in the pump motor contributed to significant amounts of radial loading on the bearings, potentially causing wear over long periods of operation and premature failures. The magnitude of these magnetic forces was determined for the rotor and stator separately, as well as for the rotor-stator assembly by designing various experimental setups able to recreate the pump motor without hydrodynamic bearings. Characterization of these magnetic forces led to changes in manufacturing processes and enabled selective choices of components, improving the pump motor hardware in order to meet NASA’s Europa Clipper project requirements.

Underhill, Micheal↗

NASA NTRS2016

Design and Fabrication of Oxygen/RP-2 Multi-Element Oxidizer-Rich Staged Combustion Thrust Chamber Injectors

As part of the Combustion Stability Tool Development project funded by the Air Force Space and Missile Systems Center, the NASA Marshall Space Flight Center was contracted to assemble and hot-fire test a multi-element integrated test article demonstrating combustion characteristics of an oxygen/hydrocarbon propellant oxidizer-rich staged-combustion engine thrust chamber. Such a test article simulates flow through the main injectors of oxygen/kerosene oxidizer-rich staged combustion engines such as the Russian RD-180 or NK-33 engines, or future U.S.-built engine systems such as the Aerojet-Rocketdyne AR-1 engine or the Hydrocarbon Boost program demonstration engine. On the current project, several configurations of new main injectors were considered for the thrust chamber assembly of the integrated test article. All the injector elements were of the gas-centered swirl coaxial type, similar to those used on the Russian oxidizer-rich staged-combustion rocket engines. In such elements, oxidizer-rich combustion products from the preburner/turbine exhaust flow through a straight tube, and fuel exiting from the combustion chamber and nozzle regenerative cooling circuits is injected near the exit of the oxidizer tube through tangentially oriented orifices that impart a swirl motion such that the fuel flows along the wall of the oxidizer tube in a thin film. In some elements there is an orifice at the inlet to the oxidizer tube, and in some elements there is a sleeve or "shield" inside the oxidizer tube where the fuel enters. In the current project, several variations of element geometries were created, including element size (i.e., number of elements or pattern density), the distance from the exit of the sleeve to the injector face, the width of the gap between the oxidizer tube inner wall and the outer wall of the sleeve, and excluding the sleeve entirely. This paper discusses the design rationale for each of these element variations, including hydraulic, structural, thermal, combustion performance, and combustion stability considerations. This paper also discusses the fabrication and assembly of the injector components, including the injector body/interpropellant plate, the additive manufactured GRCop-84 faceplate, and the pieces that make up the injector elements including the oxidizer tube, an inlet to the oxidizer tube, and a facenut that includes the fuel tangential inlets and forms the initial recessed volume where oxidizer and fuel first interact. Hot-fire test results of these main injector designs in an integrated test article that includes an oxidizer-rich preburner are described in companion papers at this JANNAF meeting.

Garcia, C. P.↗

DOE OSTI2025

Self-assembly of wood-based shape memory composites triggered by solar-thermal energy

Transporting and assembling large, complex structures poses significant challenges due to their size, geometry, and cost. Additionally, the installation sites are often inaccessible or hazardous for humans, necessitating self-assembling capabilities in these structures. To mitigate these challenges, we propose using 3D printing materials with shape memory effect (SME) for both transport and construction. This approach involves developing 3D modular components into flat sheets for easier transportation, and then self-assembling into 3D structures on-site using solar energy. To gain a deeper understanding of the factors influencing material memory performance, we have chosen a composite PLA/WF, which is polylactic acid (PLA) with 20 wt% wood flour (WF) for this purpose, leveraging its high tensile modulus at 0.966 GPa, low cost, and sustainability. Printed shapes with this material can maintain a recovery ratio over 90% after 3 cycles. While traditional composites fillers (e.g. glass or carbon fiber) are added to enhance mechanical and thermal properties, the addition of bio-based fillers like WF accomplish similar goals without compromising sustainability. We conducted multiple experiments to demonstrate how environmental conditions (i.e. temperature) maximize the material’s SME. Although still at an early stage, this study provides initial insights into bridging the gap between the small-scale nature of shape memory polymers (SMPs) and their potential for large-scale additive manufacturing, addressing a critical need for efficient and sustainable construction. In the long term, we hope our study contributes to the design vision of utilizing SMPs for transportation, assembly, and deployment of complex structures, providing a new pathway for sustainable construction and transportation of large-scale structures to hard-to-access locations such as disaster-affected areas and remote deserts, etc.

4D printing↗

NASA NTRS1988

Advanced satellite servicing facility studies

A NASA-sponsored systems analysis designed to identify and recommend advanced subsystems and technologies specifically for a manned Sun-synchronous platform for satellite management is discussed. An overview of system design, manned and unmanned servicing facilities, and representative mission scenarios are given. Mission areas discussed include facility based satellite assembly, checkout, deployment, refueling, repair, and systems upgrade. The ferrying of materials and consumables to and from manufacturing platforms, deorbit, removal, repositioning, or salvage of satellites and debris, and crew rescue of any other manned vehicles are also examined. Impacted subsytems discussed include guidance navigation and control, propulsion, data management, power, thermal control, structures, life support, and radiation management. In addition, technology issues which would have significant impacts on the system design are discussed.

Qualls, Garry D.↗

DOE OSTI2022

3D Printed Carbon Aerogels for Polymer-Electrolyte Fuel Cells

Carbon aerogels (CA) are known for ultra-low density, very high surface area, fine porous structure, and excellent electrical conductivity. Recent advances in high resolution 3D printing at LLNL enable the manufacturing of complex structured CA electrodes which have been demonstrated in electrolysis, flow battery, and supercapacitor applications. Polymer-electrolyte fuel cells (PEFC) may be an excellent candidate for these materials/methods as designers seek to optimize membrane-electrode assemblies to achieve higher efficiencies. A major challenge to PEFC design is two-phase flow due to water production which causes pore flooding and leads to cell instability and degradation. To mitigate these effects, groups have investigated the creation of liquid specific pathways in the porous layers to alleviate liquid buildup and enhance gas diffusion. While some progress has been made, traditionally manufactured GDLs, which consist of randomly distributed carbon fibers, are limiting. 3D printed CAs are a promising solution as complex macroporous electrode structures can be manufactured out of micro and nano porous filaments with a high level of control. Additionally, the process may allow for the consolidation of multiple layers (MPL, GDL, & flow channels) into a single printed architecture. In this work various CA lattice structures were printed using a direct ink write (DIW) method and liquid breakthrough pressures were measured to demonstrate the ability to tune the water pathways to achieve specific pressure thresholds. Furthermore, a discussion of the prospects for printed CA electrodes in PEFC will focus on material properties, synthesis techniques, and current challenges.

36 MATERIALS SCIENCE↗

NASA NTRS1989

The partnership: Space shuttle, space science, and space station

An overview of the NASA Space Station Program functions, design, and planned implementation is presented. The discussed functions for the permanently manned space facility include: (1) development of new technologies and related commercial products; (2) observations of the Earth and the universe; (3) provision of service facilities for resupply, maintenance, upgrade and repair of payloads and spacecraft; (4) provision of a transportation node for stationing, processing and dispatching payloads and vehicles; (5) provision of manufacturing and assembly facilities; (6) provision of a storage depot for parts and payloads; and (7) provision of a staging base for future space endeavors. The fundamental concept for the Space Station, as given, is that it be designed, operated, and evolved in response to a broad variety of scientific, technological, and commercial user interests. The Space Shuttle's role as the principal transportation system for the construction and maintenance of the Space Station and the servicing and support of the station crew is also discussed.

Culbertson, Philip E.↗

DOE OSTI2022

A systematic approach to resolve high impedance of multifunctional energy storage composites

Previous work has proposed and characterized the structural and electrical performance of Multifunctional Energy Storage Composite (MESC) structures: structural elements with embedded lithium-ion batteries which were developed by the Structures and Composite Laboratory (SACL) at Stanford University. This work conducts a comprehensive parametric study over the design variables in the manufacturing process to determine the root cause of increased DC impedance compared to commercial pouch cell batteries. Several MESC samples were assembled under various controlled environmental temperatures and pressures. The samples underwent Hybrid Peak Pulse Characterization (HPPC) to approximate the DC impedance as a function of state of charge (SOC). Failure limits of the battery with respect to assembly temperature and pressure were tested, and an MESC manufacturing simulation model was constructed in Abaqus to validate the manufacturing limits. Samples assembled without enough temperature or pressure failed due to a lack of structural integrity or hermetic seal. Conversely, samples which underwent elevated temperatures and pressures resulted in high DC impedance due to nonuniform electrolyte wetting. This work resolves the primary concern of MESC by achieving comparable DC impedance to commercial pouch cells of the same chemistry and testing procedure.

25 ENERGY STORAGE↗

DOE OSTI2020

Use of Commercial Off-The-Shelf Parts with 3-D Printed Connectors for Powered Air Purifying Respirators

This report presents preliminary results from the performance evaluation of a powered air purifying respirator (PAPR) assembled from commercial off-the-shelf (COTS) parts. Cost is a major limiting factor to PAPR adoption in healthcare. Moreover, the lack of standardization for filters and batteries poses a challenge for clinics and hospitals. Rapid prototyping of connectors, both mechanical and electrical, offers a possible solution in addressing both issues. We used 3-D printed connectors to assemble COTS components into a prototype PAPR. Large-scale manufacturing of 3-D printed connectors may be accomplished by converting the computer-aided design (CAD) drawings to pressure-injection molds.

42 ENGINEERING↗