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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 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
NASA NTRS2007

CHEM-Based Self-Deploying Planetary Storage Tanks

A document proposes self-deploying storage tanks, based on the cold elastic hibernated memory (CHEM) concept, to be used on remote planets. The CHEM concept, described in previous NASA Tech Briefs articles, involves the use of open-cell shape-memory-polymer (SMP) foam sandwich structures to make lightweight, space-deployable structures that can be compressed for storage and can later be expanded, then rigidified for use. A tank according to the proposal would be made of multiple SMP layers (of which at least one could be an SMP foam). The tank would be fabricated at full size in the rigid, deployed condition at ambient temperature, the SMP material(s) having been chosen so that ambient temperature would be below the SMP glass-transition temperature (T(sub g)). The tank would then be warmed to a temperature above T(sub g), where it would be compacted and packaged, then cooled to below T(sub g) and kept there during launch and transport to a distant planet. At the assigned position on the planet, the compacted tank would be heated above T(sub g) by the solar radiation making it rebound to its original size and shape. Finally, the tank would be rigidified through natural cooling to below T(sub g) in the planetary ambient environment.

Sokolowski, Witold↗
NASA NTRS2004

Design Analysis and Thermo-Mechanical Fatigue of a Polyimide Composite for Combustion Chamber Support

Polyimide composites are being evaluated for use in lightweight support structures designed to preserve the ideal flow geometry within thin shell combustion chambers of future space launch propulsion systems. Principles of lightweight design and innovative manufacturing techniques have yielded a sandwich structure with an outer face sheet of carbon fiber polyimide matrix composite. While the continuous carbon fiber enables laminated skin of high specific stiffness; the polyimide matrix materials ensure that the rigidity and durability is maintained at operation temperatures of 316 C. Significant weight savings over all metal support structures are expected. The protypical structure is the result of ongoing collaboration, between Boeing and NASA-GRC seeking to introduce polyimide composites to the harsh environmental and loads familiar to space launch propulsion systems. Design trade analyses were carried out using relevant closed form solutions, approximations for sandwich beams/panels and finite element analysis. Analyses confirm the significant thermal stresses exist when combining materials whose coefficients of thermal expansion (CTEs) differ by a factor of about 10 for materials such as a polymer composite and metallic structures. The ramifications on design and manufacturing alternatives are reviewed and discussed. Due to stringent durability and safety requirements, serious consideration is being given to the synergistic effects of temperature and mechanical loads. The candidate structure operates at 316 C, about 80% of the glass transition temperature T(sub g). Earlier thermomechanical fatigue (TMF) investigations of chopped fiber polyimide composites made this near to T(sub g), showed that cyclic temperature and stress promoted excessive creep damage and strain accumulation. Here it is important to verify that such response is limited in continuous fiber laminates.

Thesken, J. C.↗
DOE OSTI2014

Power optics

By using the theory we developed in the early 1970s, a broad range of phenomena is considered for an optical surface of a solid body that is exposed to radiation arbitrarily varying in time and producing temperature fields, thermoelastic stresses and thermal deformations on the surface layer. The examination is based on the relations (which are similar to Duhamel's integral formula from the theory of heat conduction) between the quantities characterising the thermal stress state in any nonstationary regimes of energy input into a solid. A peculiar feature of the analysis of the thermal stress state in this case consists in the fact that this relation comprises time as a parameter, which in turn is a consequence of incoherence of the quasi-stationary problem of thermoelasticity. This phenomenon is particularly important for the optics of high-power, high-pulse repetition rate lasers, which are being actively developed. In the review, we have recently published in Laser Physics, the thermal stress state of a solid is analysed. In this state, time is treated as an independent variable used in differentiation. Such an approach greatly reduces the applicability of the method. The review published contains data on the use of capillary porous structures made of various materials with different degrees of the surface development. Moreover, such structures can be efficiently employed to increase the heat exchange at a temperature below the boiling point of the coolant. In the present review we discuss the dependences of the limiting laser intensities on the duration of a pulse or a pulse train, corresponding to the three stages of the state of the reflecting surface and leading to unacceptable elastic deformations of the surface, to the plastic yield of the material accompanied by the formation of residual stresses and to the melting of the surface layer. We also analyse the problem of heat exchange in the surface layer with a liquid metal coolant pumped through it. The theoretical estimates are compared with the experimental data. We discuss the issues related to the technology of fabrication of power optics elements based on materials with a porous structure, of lightweight highly stable large optics based on highly porous materials, multi-layer honeycomb structures and silicon carbide, as well as problems of application of physical and technical fundamentals of power optics in modern cutting-edge technology. (invited paper)

36 MATERIALS SCIENCE↗
NASA NTRS2003

Laser-Induced Fluorescence Photogrammetry for Dynamic Characterization of Transparent and Aluminized Membrane Structures

Photogrammetry has proven to be a valuable tool for static and dynamic profiling of membrane based inflatable and ultra-lightweight space structures. However, the traditional photogrammetric targeting techniques used for solid structures, such as attached retro-reflective targets and white-light dot projection, have some disadvantages and are not ideally suited for measuring highly transparent or reflective membrane structures. In this paper, we describe a new laser-induced fluorescence based target generation technique that is more suitable for these types of structures. We also present several examples of non-contact non-invasive photogrammetric measurements of laser-dye doped polymers, including the dynamic measurement and modal analysis of a 1m-by-1m aluminized solar sail style membrane.

Dorrington, Adrian A.↗
DOE OSTI2025

Multi-Functional Smart Structures for Smart Vehicles

This report summarizes the development of a new class of recyclable multi-functional composite materials for production of lightweight smart structures and surfaces. Functional high stiffness conductive composites were processed using molding methods that integrated continuous fiber and additively manufactured features. Methods for integration of sensing functionality and controls were also developed to reduce system cost while providing a new capability for structural health monitoring. This new class of composites is applicable to a broad range of vehicle interior, exterior and battery enclosure systems. By way of demonstration, a vehicle instrument panel cross car beam was developed that provided a 38% mass savings compared to steel while maintaining a cost penalty competitive to alternate lightweight material solutions. These technologies were validated for implementation by a uniquely qualified project team comprising a US automotive OEM, Tier 1 and Tier 2 supplier, with key contributions from Oak Ridge National Lab, Purdue University and Michigan State University.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS2012

Composite Payload Fairing Structural Architecture Assessment and Selection

This paper provides a summary of the structural architecture assessments conducted and a recommendation for an affordable high performance composite structural concept to use on the next generation heavy-lift launch vehicle, the Space Launch System (SLS). The Structural Concepts Element of the Advanced Composites Technology (ACT) project and its follow on the Lightweight Spacecraft Structures and Materials (LSSM) project was tasked with evaluating a number of composite construction technologies for specific Ares V components: the Payload Shroud, the Interstage, and the Core Stage Intertank. Team studies strived to address the structural challenges, risks and needs for each of these vehicle components. Leveraging off of this work, the subsequent Composites for Exploration (CoEx) effort is focused on providing a composite structural concept to support the Payload Fairing for SLS. This paper documents the evaluation and down selection of composite construction technologies and evolution to the SLS Payload Fairing. Development of the evaluation criteria (also referred to as Figures of Merit or FOMs), their relative importance, and association to vehicle requirements are presented. A summary of the evaluation results, and a recommendation of the composite concept to baseline in the Composites for Exploration (CoEx) project is presented. The recommendation for the SLS Fairing is a Honeycomb Sandwich architecture based primarily on affordability and performance with two promising alternatives, Hat stiffened and Fiber Reinforced Foam (FRF) identified for eventual program block upgrade.

Krivanek, Thomas M.↗
NASA NTRS1983

Metal matrix composite structural panel construction

Lightweight capped honeycomb stiffeners for use in fabricating metal or metal/matrix exterior structural panels on aerospace type vehicles and the process for fabricating same are disclosed. The stiffener stringers are formed in sheets, cut to the desired width and length and brazed in spaced relationship to a skin with the honeycomb material serving directly as the required lightweight stiffeners and not requiring separate metal encasement for the exposed honeycomb cells.

Mcwithey, R. R.↗
NASA NTRS1993

Validation of a unique concept for a low-cost, lightweight space-deployable antenna structure

An experiment conducted in the framework of a NASA In-Space Technology Experiments Program based on a concept of inflatable deployable structures is described. The concept utilizes very low inflation pressure to maintain the required geometry on orbit and gravity-induced deflection of the structure precludes any meaningful ground-based demonstrations of functions performance. The experiment is aimed at validating and characterizing the mechanical functional performance of a 14-m-diameter inflatable deployable reflector antenna structure in the orbital operational environment. Results of the experiment are expected to significantly reduce the user risk associated with using large space-deployable antennas by demonstrating the functional performance of a concept that meets the criteria for low-cost, lightweight, and highly reliable space-deployable structures.

Freeland, R. E.↗
NASA NTRS1973

Structural considerations in design of lightweight glass-fiber composite pressure vessels

The design concepts used for metal-lined glass-fiber composite pressure vessels are described, comparing the structural characteristics of the composite designs with each other and with homogeneous metal pressure vessels. Specific design techniques and available design data are identified. The discussion centers around two distinctly different design concepts, which provide the basis for defining metal lined composite vessels as either (1) thin-metal lined, or (2) glass fiber reinforced (GFR). Both concepts are described and associated development problems are identified and discussed. Relevant fabrication and testing experience from a series of NASA-Lewis Research Center development efforts is presented.

Faddoul, J. R.↗
DOE OSTI2016

Manufacturing Energy Intensity and Opportunity Analysis for Fiber-Reinforced Polymer Composites and Other Lightweight Materials

With their high strength-to-weight ratios, fiber-reinforced polymer (FRP) composites are important materials for lightweighting in structural applications; however, manufacturing challenges such as low process throughput and poor quality control can lead to high costs and variable performance, limiting their use in commercial applications. One of the most significant challenges for advanced composite materials is their high manufacturing energy intensity. This study explored the energy intensities of two lightweight FRP composite materials (glass- and carbon-fiber-reinforced polymers), with three lightweight metals (aluminum, magnesium, and titanium) and structural steel (as a reference material) included for comparison. Energy consumption for current typical and state-of-the-art manufacturing processes were estimated for each material, deconstructing manufacturing process energy use by sub-process and manufacturing pathway in order to better understand the most energy intensive steps. Energy saving opportunities were identified and quantified for each production step based on a review of applied R&D technologies currently under development in order to estimate the practical minimum energy intensity. Results demonstrate that while carbon fiber reinforced polymer (CFRP) composites have the highest current manufacturing energy intensity of all materials considered, the large differences between current typical and state-of-the-art energy intensity levels (the 'current opportunity') and between state-of-the-art and practical minimum energy intensity levels (the 'R&D opportunity') suggest that large-scale energy savings are within reach.

36 MATERIALS SCIENCE↗
NASA NTRS1993

In situ processing methods for composite fuselage sandwich structures

Conventional sandwich structure fabrication methods are labor intensive and high in cost. A low cost method is needed to produce lightweight sandwich structures. Sundstrand has developed a series of in situ composite fabrication methods in which the raw materials (skin and core materials) are placed in a closed mold, and the component is produced in one heating cycle. Internal pressure is generated by chemical agents during the thermal cycles, which consolidates the skins and produces the foam core. The finished part is a net-shape composite sandwich structure with skins and a foamed core. The in situ process reduces cost by eliminating several secondary operations that are used in conventional fabrication methods. Further, a strong molecular bond is produced between the core and skin, which eliminates adhesive bonding and prevents a weak bond section in the sandwich structure. In this investigation, we evaluated the feasibility of the in situ process using thermoset materials currently under consideration for commercial airplane fuselage applications, such as keel sections. The materials used were Hercules 855340 toughened epoxy resin in both liquid and powder forms, and 3M Scotchply PR500 resin, manufactured by 3M Corporation, in powder form. We successfully foamed these resins and produced experimental panels with AS-4/855340 Hercules prepreg skins. Chopped fibers were added to the core to increase performance of the foam. Mechanical property testing on these panels showed properties competitive with other foams. Additional experiments are required to optimize the in situ foam core sandwiches for specific properties and applications.

Saatchi, Hossein↗
NASA NTRS2012

Face-Sheet Quality Analysis and Thermo-Physical Property Characterization of OOA and Autoclave Panels

Increased application of polymer matrix composite (PMC) materials in large vehicle structures requires consideration of non-autoclave manufacturing technology. The NASA Composites for Exploration project, and its predecessor, Lightweight Spacecraft Structures and Materials project, were tasked with the development of materials and manufacturing processes for structures that will perform in a heavy-lift-launch vehicle environment. Both autoclave and out of autoclave processable materials were considered. Large PMC structures envisioned for such a vehicle included the payload shroud and the interstage connector. In this study, composite sandwich panels representing 1/16th segments of the barrel section of the Ares V rocket fairing were prepared as 1.8 m x 2.4 m sections of the 10 m diameter arc segment. IM7/977-3 was used as the face-sheet prepreg of the autoclave processed panels and T40-800B/5320-1 for the out of autoclave panels. The core was 49.7 kilograms per square meters (3.1 pounds per cubic feet (pcf)) aluminum honeycomb. Face-sheets were fabricated by automated tape laying 153 mm wide unidirectional tape. This work details analysis of the manufactured panels where face-sheet quality was characterized by optical microscopy, cured ply thickness measurements, acid digestion, and thermal analysis.

Miller, Sandi G.↗
NASA NTRS2012

Face-Sheet Quality Analysis and Thermo-Physical Property Characterization of OOA and Autoclave Panels

Increased application of polymer matrix composite (PMC) materials in large vehicle structures requires consideration of non-autoclave manufacturing technology. The NASA Composites for Exploration project, and its predecessor, Lightweight Spacecraft Structures and Materials project, were tasked with the development of materials and manufacturing processes for structures that will perform in a heavy-lift-launch vehicle environment. Both autoclave and out of autoclave processable materials were considered. Large PMC structures envisioned for such a vehicle included the payload shroud and the interstage connector. In this study, composite sandwich panels representing 1/16th segments of the barrel section of the Ares V rocket fairing were prepared as 1.8 m x 2.4 m sections of the 10 m diameter arc segment. IM7/977-3 was used as the face-sheet prepreg of the autoclave processed panels and T40-800B/5320-1 for the out of autoclave panels. The core was 49.7 kg/sq m (3.1 lb/cu ft (pcf)) aluminum honeycomb. Face-sheets were fabricated by automated tape laying 153 mm wide unidirectional tape. This work details analysis of the manufactured panels where face-sheet quality was characterized by optical microscopy, cured ply thickness measurements, acid digestion, and thermal analysis.

Miller, Sandi G.↗
NASA NTRS2006

Structurally Integrated Antenna Concepts for HALE UAVs

This technical memorandum describes work done in support of the Multifunctional Structures and Materials Team under the Vehicle Systems Program's ITAS (Integrated Tailored Aero Structures) Project during FY 2005. The Electromagnetics and Sensors Branch (ESB) developed three ultra lightweight antenna concepts compatible with HALE UAVs (High Altitude Long Endurance Unmanned Aerial Vehicles). ESB also developed antenna elements that minimize the interaction between elements and the vehicle to minimize the impact of wing flexure on the EM (electromagnetic) performance of the integrated array. In addition, computer models were developed to perform phase correction for antenna arrays whose elements are moving relative to each other due to wing deformations expected in HALE vehicle concepts. Development of lightweight, conformal or structurally integrated antenna elements and compensating for the impact of a lightweight, flexible structure on a large antenna array are important steps in the realization of HALE UAVs for microwave applications such as passive remote sensing and communications.

Cravey, Robin L.↗
NASA NTRS1982

Strong thin membrane structure for use as solar sail comprising substrate with reflective coating on one surface and an infra red emissivity increasing coating on the other surface

Production of strong lightweight membrane structure by applying a thin reflective coating such as aluminum to a rotating cylinder, applying a mesh material such as nylon over the aluminum coating, coating the mesh overlying the aluminum with a polymerizing material such as a para-xylylene monomer gas to polymerize as a film bound to the mesh and the aluminum, and applying an emissivity increasing material such as chromium and silicon monoxide to the polymer film to disperse such material colloidally into the growing polymer film, or applying such material to the final polymer film, and removing the resulting membrane structure from the cylinder. Alternatively, such membrane structure can be formed by etching a substrate in the form of an organic film such as a polyimide, or a metal foil, to remove material from the substrate and reduce its thickness, applying a thin reflective coating such as aluminum on one side of the substrate and applying an emissivity increasing coating such as chromium and silicon monoxide on the reverse side of the substrate.

Frazer, Robert E.↗
NASA NTRS2009

Improved Fabrication of Ceramic Matrix Composite/Foam Core Integrated Structures

The use of hybridized carbon/silicon carbide (C/SiC) fabric to reinforce ceramic matrix composite face sheets and the integration of such face sheets with a foam core creates a sandwich structure capable of withstanding high-heatflux environments (150 W/cm2) in which the core provides a temperature drop of 1,000 C between the surface and the back face without cracking or delamination of the structure. The composite face sheet exhibits a bilinear response, which results from the SiC matrix not being cracked on fabrication. In addition, the structure exhibits damage tolerance under impact with projectiles, showing no penetration to the back face sheet. These attributes make the composite ideal for leading edge structures and control surfaces in aerospace vehicles, as well as for acreage thermal protection systems and in high-temperature, lightweight stiffened structures. By tailoring the coefficient of thermal expansion (CTE) of a carbon fiber containing ceramic matrix composite (CMC) face sheet to match that of a ceramic foam core, the face sheet and the core can be integrally fabricated without any delamination. Carbon and SiC are woven together in the reinforcing fabric. Integral densification of the CMC and the foam core is accomplished with chemical vapor deposition, eliminating the need for bond-line adhesive. This means there is no need to separately fabricate the core and the face sheet, or to bond the two elements together, risking edge delamination during use. Fibers of two or more types are woven together on a loom. The carbon and ceramic fibers are pulled into the same pick location during the weaving process. Tow spacing may be varied to accommodate the increased volume of the combined fiber tows while maintaining a target fiber volume fraction in the composite. Foam pore size, strut thickness, and ratio of face sheet to core thickness can be used to tailor thermal and mechanical properties. The anticipated CTE for the hybridized composite is managed by the choice of constituents, varying fiber tow sizes and constituent part ratios. This structural concept provides high strength and stiffness at low density 1.06 g/cm3 in panels tested. Varieties of face sheet constructions are possible, including variations in fiber type and weave geometry. The integrated structures possible with this composite could eliminate the need for non-load-bearing thermal protection systems on top of a structural component. The back sheet can readily be integrated to substructures through the incorporation of ribs. This would eliminate weight and cost for aerospace missions.

Hurwitz, Frances I.↗
NASA NTRS2009

Inert Welding/Brazing Gas Filters and Dryers

The use of hybridized carbon/silicon carbide (C/SiC) fabric to reinforce ceramic matrix composite face sheets and the integration of such face sheets with a foam core creates a sandwich structure capable of withstanding high-heat-flux environments (150 W/sq cm) in which the core provides a temperature drop of 1,000 C between the surface and the back face without cracking or delamination of the structure. The composite face sheet exhibits a bilinear response, which results from the SiC matrix not being cracked on fabrication. In addition, the structure exhibits damage tolerance under impact with projectiles, showing no penetration to the back face sheet. These attributes make the composite ideal for leading-edge structures and control surfaces in aerospace vehicles, as well as for acreage thermal protection systems and in high-temperature, lightweight stiffened structures. By tailoring the coefficient of thermal expansion (CTE) of a carbon fiber containing ceramic matrix composite (CMC) face sheet to match that of a ceramic foam core, the face sheet and the core can be integrally fabricated without any delamination. Carbon and SiC are woven together in the reinforcing fabric. Integral densification of the CMC and the foam core is accomplished with chemical vapor deposition, eliminating the need for bond-line adhesive. This means there is no need to separately fabricate the core and the face sheet, or to bond the two elements together, risking edge delamination during use. Fibers of two or more types are woven together on a loom. The carbon and ceramic fibers are pulled into the same "pick" location during the weaving process. Tow spacing may be varied to accommodate the increased volume of the combined fiber tows while maintaining a target fiber volume fraction in the composite. Foam pore size, strut thickness, and ratio of face sheet to core thickness can be used to tailor thermal and mechanical properties. The anticipated CTE for the hybridized composite is managed by the choice of constituents, varying fiber tow sizes and constituent part ratios. This structural concept provides high strength and stiffness at low density 1.06 g/cu cm in panels tested. Varieties of face sheet constructions are possible, including variations in fiber type and weave geometry. The integrated structures possible with this composite could eliminate the need for non-load-bearing thermal protection systems on top of a structural component. The back sheet can readily be integrated to substructures through the incorporation of ribs. This would eliminate weight and cost for aerospace missions.

Goudy, Jerry↗
NASA NTRS2012

Materials, Structures and Manufacturing: An Integrated Approach to Develop Expandable Structures

Membrane dominated space structures are lightweight and package efficiently for launch; however, they must be expanded (deployed) in-orbit to achieve the desired geometry. These expandable structural systems include solar sails, solar power arrays, antennas, and numerous other large aperture devices that are used to collect, reflect and/or transmit electromagnetic radiation. In this work, an integrated approach to development of thin-film damage tolerant membranes is explored using advanced manufacturing. Bio-inspired hierarchical structures were printed on films using additive manufacturing to achieve improved tear resistance and to facilitate membrane deployment. High precision, robust expandable structures can be realized using materials that are both space durable and processable using additive manufacturing. Test results show this initial work produced higher tear resistance than neat film of equivalent mass. Future research and development opportunities for expandable structural systems designed using an integrated approach to structural design, manufacturing, and materials selection are discussed.

Belvin, W. Keith↗