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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 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
NASA NTRS1986

The pultrusion process for structures on advanced aerospace transportation systems

The pultrusion process, which has the potential for use in the manufacture of structures for aerospace hardware, is described. In this process, reinforcing fibers are pulled continuously through a resin system for wetting and subsequently through a heated die for polymerization. By using this process, fabrication of very long lengths of high strength, lightweight structures with consistently high quality for aerospace applications is possible. The more conventional processes involve hand lay-up, vacuum bagging, autoclaving or oven curing techniques such that lengths of structural elements produced are limited by the lengths of autoclaves or curing ovens. Several types of developmental structural elements are described in which fiberglass, aramid, graphite, and hybrid fiber systems have been used as reinforcements in an epoxy matrix and their flexural properties compared. Reinforcement fibers having tailor-made orientations which achieve tailor-made strength in the pultrusions are described. The potential aerospace applications for the pultruded products are described with advantages cited over conventional hand lay-up methods.

Wilson, Maywood L.↗
NASA NTRS1991

Sensor-model in-situ control of the RTM composite process

The paper reports on the use of in situ frequency dependent electromagnetic sensors (FDEMS) and the Loos resin transfer model to select and control the processing properties of an epoxy resin during RTM impregnation and cure. Once correlated with viscosity and degree of cure, FDEMS monitors the advancement of the resin, viscosity, and the impregnation of the fabric, allowing a direct means of monitoring in situ in the mold throughout the fabrication process the effects of time, temperature, vacuum, and pressure.

Kranbuehl, D. E.↗
NASA NTRS1996

Chill-Bar Assembly For Cooling Areas Adjacent To Welds

Assembly of custom-shaped water-cooled chill bars developed for use during repair process in which cracks and pinholes in rocket-engine combustion chamber welded closed. Held in required relative geometric relationships by rigid framework, chill bars pressed against surface of chamber to conduct heat away from areas surrounding welds, preventing damage caused by overheating of areas not meant to be welded. Design features beneficial in other welding applications; for example, manufacture and repair of pressure vessels, chemical-processing vessels, and complexly shaped laboratory vacuum vessels.

Hoffman, David S.↗
NASA NTRS1996

More About Brazing Or Welding NiAl Without Filler

Two reports present additional information about two processes for joining, brazing, or welding workpieces made of nickel aluminide alloys, without use of filler metal. Joining processes involve uniform heating in vacuum-controlled furnace. Eliminates internal thermal gradients in workpieces joined and greatly reduces tendency toward cracking.

Moore, Thomas J.↗
NASA NTRS2002

Variability Analysis in Vacuum Assisted Resin Transfer Molding

The vacuum assisted resin transfer molding (VARTM) process is a low-cost, innovative method that is being considered for manufacture of large aircraft-quality components where high mechanical properties and dimensional tolerance are essential. In the present work a rigorous science-based approach is used to study the VARTM processing of high performance complex shape components. A process model, COMPRO, is used to simulate the cure of panels produced by VARTM. It was found that the presence of the distribution media significantly affects the magnitude of the exotherm particularly for thick panels. For C-shaped laminates, the part distortion was a function of fiber volume fraction distribution and was affected by the presence of the distribution media.

Hubert, Pascal↗
NASA NTRS2004

H2O2 Synthesis Induced by Irradiation of H2O with Energetic H(+) and Ar(+) Ions at Various Temperatures

The detection of H2O2 on Jupiter's icy satellite Europa by the Galileo NIMS instrument presented a strong evidence for the importance of radiation effects on icy surfaces. A few experiments have investigated whether solar flux of protons incident on Europa ice could cause a significant if any H2O2 production. These published results differ as to whether H2O2 can be formed by ions impacting water at temperatures near 80 K, which are appropriate to Europa. This discrepancy may be a result of the use of different incident ion energies, different vacuum conditions, or different ways of processing the data. The latter possibility comes about from the difficulty of identifying the 3.5 m peroxide OH band on the long wavelength wing of the much stronger water 3.1 m band. The problem is aggravated by using straight line baselines to represent the water OH band with a curvature, in the region of the peroxide band, that increases with temperature. To overcome this problem, we use polynomial baselines that provide good fits to the water band and its derivative.

Baragiola, R. A.↗
NASA NTRS2004

VARTM Model Development and Verification

In this investigation, a comprehensive Vacuum Assisted Resin Transfer Molding (VARTM) process simulation model was developed and verified. The model incorporates resin flow through the preform, compaction and relaxation of the preform, and viscosity and cure kinetics of the resin. The computer model can be used to analyze the resin flow details, track the thickness change of the preform, predict the total infiltration time and final fiber volume fraction of the parts, and determine whether the resin could completely infiltrate and uniformly wet out the preform.

Cano, Roberto J.↗
NASA NTRS2008

Improved Gas Filling and Sealing of an HC-PCF

An improved packaging approach has been devised for filling a hollow-core photonic-crystal fiber (HC-PCF) with a gas, sealing the HC-PCF to retain the gas, and providing for optical connections and, optionally, a plumbing fitting for changing or augmenting the gas filling. Gas-filled HC-PCFs can be many meters long and have been found to be attractive as relatively compact, lightweight, rugged alternatives to conventional gas-filled glass cells for use as molecular-resonance frequency references for stabilization of lasers in some optical-metrology, lidar, optical-communication, and other advanced applications. Prior approaches to gas filling and sealing of HC-PCFs have involved, variously, omission of any attempt to connectorize the PCF, connectorization inside a vacuum chamber (an awkward and expensive process), or temporary exposure of one end of an HC-PCF to the atmosphere, potentially resulting in contamination of the gas filling. Prior approaches have also involved, variously, fusion splicing of HC-PCFs with other optical fibers or other termination techniques that give rise to Fresnel reflections of about 4 percent, which results in output intensity noise.

Poberezhskiy, Ilya↗
NASA NTRS2014

Operation of an ADR Using Helium Exchange Gas as a Substitute for a Failed Heat Switch

The Soft X-ray Spectrometer (SXS) is one of four instruments on the Japanese Astro-H mission, which is currently planned for launch in late 2015. The SXS will perform imaging spectroscopy in the soft X-ray band (0.3-12 keV) using a 6 6 pixel array of microcalorimeters cooled to 50 mK. The detectors are cooled by a 3-stage adiabatic demagnetization refrigerator (ADR) that rejects heat to either a superfluid helium tank (at 1.2 K) or to a 4.5 K Joule-Thomson (JT) cryocooler. Four gas-gap heat switches are used in the assembly to manage heat flow between the ADR stages and the heat sinks. The engineering model (EM) ADR was assembled and performance tested at NASA/GSFC in November 2011, and subsequently installed in the EM dewar at Sumitomo Heavy Industries, Japan. During the first cooldown in July 2012, a failure of the heat switch that linked the two colder stages of the ADR to the helium tank was observed. Operation of the ADR requires some mechanism for thermally linking the salt pills to the heat sink, and then thermally isolating them. With the failed heat switch unable to perform this function, an alternate plan was devised which used carefully controlled amounts of exchange gas in the dewar's guard vacuum to facilitate heat exchange. The process was successfully demonstrated in November 2012, allowing the ADR to cool the detectors to 50 mK for hold times in excess of 10 h. This paper describes the exchange-gas-assisted recycling process, and the strategies used to avoid helium contamination of the detectors at low temperature.

Adiabatic demagnetization↗
NASA NTRS2019

Structural Dynamic Testing Results for Air-Independent Proton Exchange Membrane (PEM) Fuel Cell Technologies for Space Applications

In 2016, the NASA Advanced Exploration Systems (AES) project office funded research at the NASA Glenn Research Center to evaluate the maturity of the Proton Exchange Membrane (PEM) fuel cell technology and its viability for supporting launch vehicle and space applications. This technology evaluation included vibration, reactant purity, and vacuum exposure sensitivity testing. The evaluation process did not include microgravity testing. This paper discusses the vibration sensitivity testing of two air-independent fuel cell stacks provided by different vendors to assess the ability of currently available fuel cell stack hardware to survive the projected random vibrational environment that would be encountered in an upper stage launch vehicle. Baseline performance testing was utilized to quantify stack performance and overboard leak rate at standard atmospheric conditions in order to provide a reference for post-test comparison. Both fuel cell stacks were tested at a random vibration qualification level of 10.4 grms for five minutes in each axis. Low-level sinusoidal sweeps were conducted before and after each random vibration level run to see if any significant change in resonances were detected. Following vibration facility testing, the baseline performance testing was repeated. Test results demonstrated no measurable change in fuel cell electrochemical or mechanical performance, indicating that the two evaluated PEM fuel cell stacks may be suitable for space applications pending microgravity testing.

Gilligan, Ryan P.↗
NASA NTRSDate not supplied

Heat Treatment Optimization of Laser Powder Bed Fusion Additive Manufacture C103

Laser Powder Bed Fusion (L-PBF) and Laser Powder Directed Energy Deposition (LP-DED) additive manufacture C103 is in development for propulsion applications that operate under extreme environments. The standard post-process heat treatment has called for vacuum stress relief, however, depending on the application or certification requirements hot isostatic press (HIP) may be required. Although C103 density responds well to HIP the associated grain growth results in a reduction in mechanical properties. An investigation was conducted to look at the potential benefit of leveraging HIP followed by rapid cooling to minimize grain growth. A series of heat treatment schedules varying temperature and pressure were conducted followed by microstructural and mechanical characterization.

Additive Manufacturing↗
NASA NTRS2024

Pull-off Behavior of Stitched Composite T-Joints

T-joints are key structural elements that connect opposing surfaces, thereby providing the load path between flat or curved panels (i.e., upper and lower wing skins) and transverse components (i.e., stiffeners). Due to the low interlaminar strength of polymer matrix composites and their geometrical discontinuities, these joints are vulnerable to pull-off loads. To address these issues, through-thickness reinforcements can be employed to enhance the interlaminar capability of these type of joints. In this study, T-joints were manufactured using through-thickness stitching in dry carbon preforms and cured using the vacuum-assisted resin transfer molding (VARTM) process. Stitched and unstitched T-joints were tested under pull-off loading conditions, and surface strain fields were obtained using a 3D digital image correlation system. The ultimate load, displacement, and absorbed energy of the stitched T-joints were greater than their unstitched counterparts by approximately 16%, 34%, and 58%, respectively. Failure mechanisms were identified by examining fracture surfaces using optical microscopy. Results demonstrate that through-thickness stitching significantly improves the damage tolerance of T-joints, which highlights the effectiveness of stitching to enhance the structural integrity of large aerospace components.

VARTM↗
NASA NTRS1987

A more perfect vacuum

Design and operational features, problems and benefits of a Space Ultravacuum Research Facility (SURF), a wake shield, are discussed. SURF is primarily targeted at providing vacuums exceeding 10 to the -14th torr for performing materials processing experiments and, eventually, commercial-scale production. The materials to be processed would be at the apex of a convex shield, with the quality of vacuum limited mainly by the backscattering toward the wake surface of atmospheric molecules which have collided with molecules leaving the SURF surface. A stainless steel skin on the SURF, cured in orbit, is proposed as a means to minimize the molecules outgassed from the surface. Applications of SURF could include coating mirrors or other optical equipment, containerless melting and solidification of materials, and ultrapurification processing.

Naumann, Robert J.↗
NASA NTRS1976

Silicon solar cells by ion implantation and pulsed energy processing

A new method for fabrication of silicon solar cells is being developed around ion implantation in conjunction with pulsed electron beam techniques to replace conventional furnace processing. Solar cells can be fabricated totally in a vacuum environment at room temperature. Cells with 10% AM0 efficiency have been demonstrated. High efficiency cells and effective automated processing capabilities are anticipated.

Kirkpatrick, A. R.↗
NASA NTRSDate not supplied

Advanced Al Mirrors Protected with LiF Overcoat to Realize Stable Mirror Coatings for Astronomical Telescopes

Pure Aluminum (Al) exhibits intrinsic high reflectance over the proposed Large UV/Optical/IR (LUVOIR) Surveyor observatory target spectral range (90-2500 nm). However, Al coatings have to be protected from oxygen exposure in order to prevent the formation of the naturally occurring Al2O3 oxide layer, which limit performance for use only above 160 nm. Aluminum protected with fluorides such as LiF or MgF2 have been the most commonly used solutions. But below 102 nm and down to 90 nm, no transparent material is available to protect Al and coating mirror reflectance stays below 40%. But even above 102 nm, the reflectance of protected Al is limited by the residual absorption of the fluoride overcoats. Hence, this paper will report on recent advances in producing enhanced Al-based mirror coatings with the highest possible far-ultraviolet (FUV) reflectance, while exhibiting a more stable LiF protection layer. The process starts with a bare optically smooth glass substrate that is coated with Al in an ultra-high vacuum chamber by using the physical vapor deposition (PVD) process, which has been shown to provide the best aluminum thin-films when compared to other approaches. The next step is done by in-situ exposure of the freshly made Al film to a reactive XeF2 gas that will grant a thin AlF3 overcoat (2-3 nm) to the Al film that prevents further oxidation. This fluorinated Al film is then coated with a final layer of a LiF metal-fluoride overcoat. The coating process is finalized with a second exposure to the XeF2 precursor gas. The preparation of these mirror coatings will be studied and analyzed as a function of the XeF2 exposure time and deposition rate of the LiF layer during the PVD process. This paper will present and discuss characterization of a number of Al+XeLiF witness coupons produced with this reactive PVD (rPVD) process. These studies include characterization of specular reflectance in the 90-2500 nm spectral range, micro-roughness, long-term stability, as well as polarization characteristics in the visible and near-infrared spectral regions. These studies have been performed in order to demonstrate the improved reflectance performance, longer durability, and less hygroscopic nature of protected Al mirrors produced with the rPVD process (through exposure to XeF2) and in comparison with the standard PVD process.

optics↗
NASA NTRS1980

Book Preservation

Books produced since 1850, held in the Library of Congress, have a very high acid content, hence a shorter life expectancy than prior-published volumes. A means of "deacidifying" books on a large, economically-viable scale is of great interest, particularly to the research library community, which stores millions of valuable, often irreplaceable documents. The General Electric vacuum chamber used in deacidification tests serves a dual purpose. It creates an environment in which DEZ can do its job without presence of oxygen and also dries the books. After the drying phase, DEZ is introduced to the chamber as a paper-penetrating vapor. The complete process typically takes eight days, four days for vacuum drying and four days of book exposure to DEZ. Accelerated aging tests showed that the process can extend paper life almost fourfold, even on color illustrations.

Source record↗
NASA NTRS1992

Use of space ultra-vacuum for high quality semiconductor thin film growth

The utilization of space for materials processing is being expanded through a unique concept of epitaxial thin film growth in the ultra-vacuum of low earth orbit (LEO). This condition can be created in the wake of an orbiting space vehicle; and assuming that the vehicle itself does not pertub the environment, vacuum levels of better than 10 exp -14 torr can be attained. This vacuum environment has the capacity of greatly enhancing epitaxial thin film growth and will be the focus of experiments conducted aboard the Wake Shield Facility (WSF) currently being developed by the Space Vacuum Epitaxy Center (SVEC), Industry, and NASA.

Ignatiev, A.↗