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At least 343 records · Page 19

Additive Manufacturing and Experimental Characterization of Nickel-Titanium Shape-Memory Alloy Wick Structures and Heat Pipes for Spacecraft Thermal Control

Shape memory alloys (SMA), such as those based on nickel-titanium (NiTi), are increasingly being applied as multifunctional spacecraft components. For thermal management applications, NiTi flow tubing hinges and self-deploying loop heat pipes have been demonstrated. Emerging additive manufacturing (AM) processes are enabling more complex SMA devices than can be formed from conventional plain wire, tubing, and sheet stock materials. This paper presents our progress toward applying powder bed fusion AM to producing porous NiTi wicks and NiTi-H2O heat pipes, which could be embedded in thermally deploying radiators for spacecraft thermal management. AM near-equiatomic NiTi (55.1 wt% Ni) porous wick specimens were produced with a range of deposition parameters. Transient acetone rate-of-rise experiments were performed to estimate wick permeability (K) and average pore radius (r_pore) values and identify parameter sets with high capillary performance. Surface treatments were evaluated to achieve hydrophilic wick structures. Evaluated treatments included chemical oxide growth with H2O2, oxide and sodium titanate growth with NaOH solution, and ultrasonic cleaning with specialty detergents that can remove hydrocarbon contaminants. The most durable hydrophilic surface conditions were obtained with the NaOH treatment. High performing wick deposition parameters were used to produce a full AM NiTi heat pipe, which was treated with NaOH solution to activate the wick. This heat pipe was operated on a test stand in the inverted configuration (upper evaporator and lower condenser), and demonstrated stable nearly isothermal operation for 150 hrs.

Thermal management↗

Additive Manufacturing and Experimental Characterization of Nickel-Titanium Shape-Memory Alloy Wick Structures and Heat Pipes for Spacecraft Thermal Control

Shape memory alloys (SMA), such as those based on nickel-titanium (NiTi), are increasingly being applied as multifunctional spacecraft components. For thermal management applications, NiTi flow tubing hinges and self-deploying loop heat pipes have been demonstrated. Emerging additive manufacturing (AM) processes are enabling more complex SMA devices than can be formed from conventional plain wire, tubing, and sheet stock materials. This paper presents our progress toward applying powder bed fusion AM to producing porous NiTi wicks and NiTi-H2O heat pipes, which could be embedded in thermally deploying radiators for spacecraft thermal management. AM near-equiatomic NiTi (55.1 wt% Ni) porous wick specimens were produced with a range of deposition parameters. Transient acetone rate-of-rise experiments were performed to estimate wick permeability (K) and average pore radius (r_pore) values and identify parameter sets with high capillary performance. Surface treatments were evaluated to achieve hydrophilic wick structures. Evaluated treatments included chemical oxide growth with H2O2, oxide and sodium titanate growth with NaOH solution, and ultrasonic cleaning with specialty detergents that can remove hydrocarbon contaminants. The most durable hydrophilic surface conditions were obtained with the NaOH treatment. High performing wick deposition parameters were used to produce a full AM NiTi heat pipe, which was treated with NaOH solution to activate the wick. This heat pipe was operated on a test stand in the inverted configuration (upper evaporator and lower condenser), and demonstrated stable nearly isothermal operation for 150 hrs.

Thermal management↗

Large Scale and Multi-Alloy Rocket Engine Component Development using Various Metal Additive Manufacturing Techniques

The NASA Marshall Space Flight Center (MSFC) has been involved with various forms of metallic additive manufacturing (AM) for use in liquid rocket engine component design, development, and testing since 2010. These AM techniques have been demonstrated to significantly reduce hardware cost, shorten fabrication schedules, increase reliability by reducing the number of joints, and improve hardware performance by allowing fabrication of designs not feasible by conventional means. The focus at the NASA MSFC for these metal additive manufacturing techniques include laser powder-bed fusion (L-PBF), blown powder directed energy deposition (DED), arc-based deposition, and Laser Wire Direct Closeout (LWDC). A variety of components have been evaluated and tested including thrust chamber injectors, injector components such as faceplates, regeneratively-cooled combustion chambers, regeneratively-cooled nozzles, gas generator and preburner hardware, and augmented spark igniters. To support these component applications in harsh environments, NASA has advanced a variety of “standard” additive manufacturing alloys such as those in the superalloy-family and also evolved new alloys including GRCop-84, GRCop-42, NASA HR-1, and JBK-75. The purpose of this presentation is to discuss the various component programs at the NASA MSFC using AM to develop, fabricate, and test combustion devices hardware and the evolution of the new additive alloys. One of these projects that will be highlighted is Rapid Analysis and Manufacturing Propulsion Technology (RAMPT), which includes new process development for large scale AM components, multi-metallic AM components, including unique component designs using additive manufacturing. Additional information will be provided on the development of other components, hot-fire testing, post-processing of AM techniques including surface enhancements (polishing) techniques, material and process characterization, future development programs, and dissemination of data to industry partners.

Additive Manufacturing↗

Three-Axis Attitude Estimation With a High-Bandwidth Angular Rate Sensor

A continuing challenge for modern instrument pointing control systems is to meet the increasingly stringent pointing performance requirements imposed by emerging advanced scientific, defense, and civilian payloads. Instruments such as adaptive optics telescopes, space interferometers, and optical communications make unprecedented demands on precision pointing capabilities. A cost-effective method was developed for increasing the pointing performance for this class of NASA applications. The solution was to develop an attitude estimator that fuses star tracker and gyro measurements with a high-bandwidth angular rotation sensor (ARS). An ARS is a rate sensor whose bandwidth extends well beyond that of the gyro, typically up to 1,000 Hz or higher. The most promising ARS sensor technology is based on a magnetohydrodynamic concept, and has recently become available commercially. The key idea is that the sensor fusion of the star tracker, gyro, and ARS provides a high-bandwidth attitude estimate suitable for supporting pointing control with a fast-steering mirror or other type of tip/tilt correction for increased performance. The ARS is relatively inexpensive and can be bolted directly next to the gyro and star tracker on the spacecraft bus. The high-bandwidth attitude estimator fuses an ARS sensor with a standard three-axis suite comprised of a gyro and star tracker. The estimation architecture is based on a dual-complementary filter (DCF) structure. The DCF takes a frequency- weighted combination of the sensors such that each sensor is most heavily weighted in a frequency region where it has the lowest noise. An important property of the DCF is that it avoids the need to model disturbance torques in the filter mechanization. This is important because the disturbance torques are generally not known in applications. This property represents an advantage over the prior art because it overcomes a weakness of the Kalman filter that arises when fusing more than one rate measurement. An additional advantage over prior art is that, computationally, the DCF requires significantly fewer real-time calculations than a Kalman filter formulation. There are essentially two reasons for this: the DCF state is not augmented with angular rate, and measurement updates occur at the slower gyro rate instead of the faster ARS sampling rate. Finally, the DCF has a simple and compelling architecture. The DCF is exactly equivalent to flying two identical attitude observers, one at low rate and one at high rate. These attitude observers are exactly of the form currently flown on typical three-axis spacecraft.

Bayard, David S.↗

Advanced Welding Applications

Some of the applications of advanced welding techniques are shown in this poster presentation. Included are brief explanations of the use on the Ares I and Ares V launch vehicle and on the Space Shuttle Launch vehicle. Also included are microstructural views from four advanced welding techniques: Variable Polarity Plasma Arc (VPPA) weld (fusion), self-reacting friction stir welding (SR-FSW), conventional FSW, and Tube Socket Weld (TSW) on aluminum.

Ding, Robert J.↗

Studies for improved high temperature coatings for Space Shuttle application

Improvement of the current Class 2 Space Shuttle Orbiter RCG coating was experimentally investigated.Coatings, which are applied to LI-900 or LI-2200 tiles, were prepared to provide increased performance in thermal expansion, impact, residual strain and increased viscosity. Turbulent duct arc-plasma tests at NASA/Ames Research Center are continuing on two candidates that show improved low residual strain and increased high temperature viscosity. A coating system with lower fusion-temperature (1950 F) was identified which has the potential of improving tile yield through reduced LI-900 shrinkage and distortion since it can be fused at 250 F lower than the present Class 2 coating.

Creedon, J.↗

A contribution to laser range imaging technology

The goal of the project was to develop a methodology for fusion of a Laser Range Imaging Device (LRID) and camera data. Our initial work in the project led to the conclusion that none of the LRID's that were available were sufficiently adequate for this purpose. Thus we spent the time and effort on the development of the new LRID with several novel features which elicit the desired fusion objectives. In what follows, we describe the device developed and built under contract. The Laser Range Imaging Device (LRID) is an instrument which scans a scene using a laser and returns range and reflection intensity data. Such a system would be extremely useful in scene analysis in industry and space applications. The LRID will be eventually implemented on board a mobile robot. The current system has several advantages over some commercially available systems. One improvement is the use of X-Y galvonometer scanning mirrors instead of polygonal mirrors present in some systems. The advantage of the X-Y scanning mirrors is that the mirror system can be programmed to provide adjustable scanning regions. For each mirror there are two controls accessible by the computer. The first is the mirror position and the second is a zoom factor which modifies the amplitude of the position of the parameter. Another advantage of the LRID is the use of a visible low power laser. Some of the commercial systems use a higher intensity invisible laser which causes safety concerns. By using a low power visible laser, not only can one see the beam and avoid direct eye contact, but also the lower intensity reduces the risk of damage to the eye, and no protective eyeware is required.

Defigueiredo, Rui J. P.↗

Safe Autonomous Flight Environment (SAFE50) for the Notional Last 50 ft of Operation of 55 lb Class of UAS

The most difficult phase of small Unmanned Aerial System (sUAS) deployment is autonomous operations below the notional 50 ft in urban landscapes. Understanding the feasibility of safely flying sUAS autonomously below 50 ft is a game changer for many civilian applications. This paper outlines three areas of research currently underway which address key challenges for flight in the urban landscape. These are: (1) Off-line and On-board wind estimation and accommodation; (2) Real-time trajectory planning via characterization of obstacles using a LIDAR; (3) On-board information fusion for real-time decision-making and safe trajectory generation.

Autonomy↗

All-sky Retrieval of Atmospheric Temperature, Water Vapor, Clouds, Trace Gases, and Surface Properties from Operational Hyperspectral IR Sounders

Operational IR sounders such AIRS, CrIS, and IASI provide high quality hyperspectral measurements for weather and climate applications. We will describe a new all-sky Single Field-of-view Sounder Atmospheric Product (SiFSAP). The uniqueness of this product is that it uses all available channels from hyperspectral sounders and the optimal estimation retrieval is done at a single FOV spatial resolution. The SiFSAP includes atmospheric temperature, water vapor, clouds, trace gases, surface skin, and surface emissivity and will be produced operationally at NASA GES DISC. We will describe the core component of the SiFSAP algorithm, which is the Principal Component-based Radiative Transfer Model (PCRTM), and will show example applications of the SiFSAP product for various atmospheric weather and dynamics studies. We also describe a new Climate Fingerprinting Sounder Product (ClimFiSP), which is derived from spatiotemporally averaged level-1 hyperspectral radiances directly. The ClimFiSP algorithm uses consistent radiative kernels and a robust spectral fingerprinting method. It provides fast and accurate data fusion products from multiple satellite sensors. We have applied this method to both AIRS and CrIS (on SNPP and on NOAA 20) data and generated two decades climate data records for atmospheric temperature, water vapor, cloud, trace gases, and surface skin temperature. The ClimFiSP are being transitioned to NASA data centers for routine generations level-3 products.

pcrtm↗

Modeling the Height of Young Forests Regenerating from Recent Disturbances in Mississippi using Landsat and ICESat data

Many forestry and earth science applications require spatially detailed forest height data sets. Among the various remote sensing technologies, lidar offers the most potential for obtaining reliable height measurement. However, existing and planned spaceborne lidar systems do not have the capability to produce spatially contiguous, fine resolution forest height maps over large areas. This paper describes a Landsat-lidar fusion approach for modeling the height of young forests by integrating historical Landsat observations with lidar data acquired by the Geoscience Laser Altimeter System (GLAS) instrument onboard the Ice, Cloud, and land Elevation (ICESat) satellite. In this approach, "young" forests refer to forests reestablished following recent disturbances mapped using Landsat time-series stacks (LTSS) and a vegetation change tracker (VCT) algorithm. The GLAS lidar data is used to retrieve forest height at sample locations represented by the footprints of the lidar data. These samples are used to establish relationships between lidar-based forest height measurements and LTSS-VCT disturbance products. The height of "young" forest is then mapped based on the derived relationships and the LTSS-VCT disturbance products. This approach was developed and tested over the state of Mississippi. Of the various models evaluated, a regression tree model predicting forest height from age since disturbance and three cumulative indices produced by the LTSS-VCT method yielded the lowest cross validation error. The R(exp 2) and root mean square difference (RMSD) between predicted and GLAS-based height measurements were 0.91 and 1.97 m, respectively. Predictions of this model had much higher errors than indicated by cross validation analysis when evaluated using field plot data collected through the Forest Inventory and Analysis Program of USDA Forest Service. Much of these errors were due to a lack of separation between stand clearing and non-stand clearing disturbances in current LTSS-VCT products and difficulty in deriving reliable forest height measurements using GLAS samples when terrain relief was present within their footprints. In addition, a systematic underestimation of about 5 m by the developed model was also observed, half of which could be explained by forest growth that occurred between field measurement year and model target year. The remaining difference suggests that tree height measurements derived using waveform lidar data could be significantly underestimated, especially for young pine forests. Options for improving the height modeling approach developed in this study were discussed.

Li, Ainong↗

Parametrized equation of state for electron liquids in the Singwi-Tosi-Land-Sjolander aproximation

Results are reported of a theoretical study of an equation of state for electron liquids (one-component plasmas of electrons embedded in a uniform neutralizing background of positive charges), where there is an interplay between the strong Coulomb-coupling effect and the degrees of Fermi degeneracy. Calculations are based on the Singwi-Tosi-Land-Sjolander approximation (1968). The calculated results are parametrized in the form of analytic formulas for the interaction and excess free energies, which are applicable over a wide range of parameters as long as the electrons are in a paramagnetic fluid state. Unlike the present study, earlier studies concentrated on plasmas where the Fermi degeneracy parameter tended either to zero or to infinity, thus excluding many actual plasmas (stellar interiors, heavy planets such as Jupiter, plasmas in projected inertial confinement fusion experiments, and the liquid metals).

Tanaka, S.↗

Thermal and range fusion for a planetary rover

This paper describes how fusion between thermal and range imaging allows us to discriminate different types of materials in outdoor scenes. First, we analyze how pure vision segmentation algorithms applied to thermal images allow discriminating materials such as rock and sand. Second, we show how combining thermal and range information allows us to better discriminate rocks from sand. Third, as an application, we examine how an autonomous legged robot can use these techniques to explore other planets.

Caillas, Claude↗

Advanced Space Propulsion

This presentation describes a number of advanced space propulsion technologies with the potential for meeting the need for dramatic reductions in the cost of access to space, and the need for new propulsion capabilities to enable bold new space exploration (and, ultimately, space exploitation) missions of the 21st century. For example, current Earth-to-orbit (e.g., low Earth orbit, LEO) launch costs are extremely high (ca. $10,000/kg); a factor 25 reduction (to ca. $400/kg) will be needed to produce the dramatic increases in space activities in both the civilian and government sectors identified in the Commercial Space Transportation Study (CSTS). Similarly, in the area of space exploration, all of the relatively 'easy' missions (e.g., robotic flybys, inner solar system orbiters and landers; and piloted short-duration Lunar missions) have been done. Ambitious missions of the next century (e.g., robotic outer-planet orbiters/probes, landers, rovers, sample returns; and piloted long-duration Lunar and Mars missions) will require major improvements in propulsion capability. In some cases, advanced propulsion can enable a mission by making it faster or more affordable, and in some cases, by directly enabling the mission (e.g., interstellar missions). As a general rule, advanced propulsion systems are attractive because of their low operating costs (e.g., higher specific impulse, ISD) and typically show the most benefit for relatively 'big' missions (i.e., missions with large payloads or AV, or a large overall mission model). In part, this is due to the intrinsic size of the advanced systems as compared to state-of-the-art (SOTA) chemical propulsion systems. Also, advanced systems often have a large 'infrastructure' cost, either in the form of initial R&D costs or in facilities hardware costs (e.g., laser or microwave transmission ground stations for beamed energy propulsion). These costs must then be amortized over a large mission to be cost-competitive with a SOTA system with a low initial development and infrastructure cost and a high operating cost. Note however that this has resulted in a 'Catch 22' standoff between the need for large initial investment that is amortized over many launches to reduce costs, and the limited number of launches possible at today's launch costs. Some examples of missions enabled (either in cost or capability) by advanced propulsion include long-life station-keeping or micro-spacecraft applications using electric propulsion or BMDO-derived micro-thrusters, low-cost orbit raising (LEO to GEO or Lunar orbit) using electric propulsion, robotic planetary missions using aerobraking or electric propulsion, piloted Mars missions using aerobraking and/or propellant production from Martian resources, very fast (100-day round-trip) piloted Mars missions using fission or fusion propulsion, and, finally, interstellar missions using fusion, antimatter, or beamed energy. The NASA Advanced Propulsion Technology program at the Jet Propulsion Laboratory (JPL) is aimed at assessing the feasibility of a range of near-term to far term advanced propulsion technologies that have the potential to reduce costs and/or enable future space activities. The program includes cooperative modeling and research activities between JPL and various universities and industry; and directly supported independent research at universities and industry. The cooperative program consists of mission studies, research and development of ion engine technology using C60 (Buckminsterfullerene) propellant, and research and development of lithium-propellant Lorentz-force accelerator (LFA) engine technology. The university/industry-supported research includes modeling and proof-of-concept experiments in advanced, high-lsp, long-life electric propulsion, and in fusion propulsion.

Frisbee, Robert H.↗

Temperature-Staged Thermal Energy Storage Enabling Low Thermal Exergy Loss Reflux Boiling in Full Spectrum Solar Systems

Hybrid full spectrum solar systems (FSSS) designed to capture and convert the full solar wavelength spectrum use hybrid solar photovoltaic/thermodynamic cycles that require low thermal exergy loss systems capable of transferring high thermal energy rates and fluxes with very low temperature differentials and losses. One approach to achieving this capability are high-heat-flux reflux boiling systems that take advantage of high heat transfer boiling and condensation mechanisms. Advanced solar systems are also intermittent by their nature and their electrical generation is often out-of-phase with electric utility power demand, and their required power system cycling reduces efficiency, performance (dispatch ability), lifetime, and reliability. High temperature thermal energy storage (TES) at 300-600°C enables these reflux boiling systems to simultaneously store thermal energy internally to increase the energy dispatch ability of the associated solar system, as this can increase the power generation profile by several hours (up to 6-10 hours) per day. Many TES phase change materials (PCM’s) exist including KNO3, NaNO3, LiBr/KBr, MgCl2/NaCl/KCl, Zn/Mg, and CuCl/NaCl, which have various operating melting points and different latent heats of fusion. Common, cost effective TES PCM's are FeCl2/NaCl/KCl mixtures, whose phase change temperature can be varied and controlled by simple composition adjustments. This paper presents and discusses unique "temperature-staged" thermal energy storage configurations using these TES materials and analysis of such systems integrated into high-heat-flux reflux boiling systems. In this specific application, the TES materials are designed to operate at staged temperatures surrounding an operating design point near 350°C, while providing 18 kW of source heat transfer to operate a thermoacoustic power system during off-sun conditions (e.g., temporary cloud conditions, after sun-down). This work discusses relevant configurations, and critical thermal and entropy models of the TES configurations, which show the inherent minimization of thermal exergy during critical heat transfers within the configurations and systems envisioned.

Hendricks, Terry J.↗

Image Registration Workshop Proceedings

Automatic image registration has often been considered as a preliminary step for higher-level processing, such as object recognition or data fusion. But with the unprecedented amounts of data which are being and will continue to be generated by newly developed sensors, the very topic of automatic image registration has become and important research topic. This workshop presents a collection of very high quality work which has been grouped in four main areas: (1) theoretical aspects of image registration; (2) applications to satellite imagery; (3) applications to medical imagery; and (4) image registration for computer vision research.

LeMoigne, Jacqueline↗

Evaluation of Fused Synthetic and Enhanced Vision Display Concepts for Low-Visibility Approach and Landing

NASA is developing revolutionary crew-vehicle interface technologies that strive to proactively overcome aircraft safety barriers that would otherwise constrain the full realization of the next generation air transportation system. A piloted simulation experiment was conducted to evaluate the complementary use of Synthetic and Enhanced Vision technologies. Specific focus was placed on new techniques for integration and/or fusion of Enhanced and Synthetic Vision and its impact within a two-crew flight deck during low-visibility approach and landing operations. Overall, the experimental data showed that significant improvements in situation awareness, without concomitant increases in workload and display clutter, could be provided by the integration and/or fusion of synthetic and enhanced vision technologies for the pilot-flying and the pilot-not-flying. Improvements in lateral path control performance were realized when the Head-Up Display concepts included a tunnel, independent of the imagery (enhanced vision or fusion of enhanced and synthetic vision) presented with it. During non-normal operations, the ability of the crew to handle substantial navigational errors and runway incursions were neither improved nor adversely impacted by the display concepts. The addition of Enhanced Vision may not, of itself, provide an improvement in runway incursion detection without being specifically tailored for this application.

Bailey, Randall E.↗

Large Scale and Multi-Alloy Rocket Engine Component Development using Various Metal Additive Manufacturing Techniques

The NASA Marshall Space Flight Center (MSFC) has been involved with various forms of metallic additive manufacturing (AM) for use in liquid rocket engine component design, development, and testing since 2010. These AM techniques have been demonstrated to significantly reduce hardware cost, shorten fabrication schedules, increase reliability by reducing the number of joints, and improve hardware performance by allowing fabrication of designs not feasible by conventional means. The focus at the NASA MSFC for these metal additive manufacturing techniques include laser powder-bed fusion (L-PBF), blown powder directed energy deposition (DED), arc-based deposition, and Laser Wire Direct Closeout (LWDC). A variety of components have been evaluated and tested including thrust chamber injectors, injector components such as faceplates, regeneratively-cooled combustion chambers, regeneratively-cooled nozzles, gas generator and preburner hardware, and augmented spark igniters. To support these component applications in harsh environments, NASA has advanced a variety of “standard” additive manufacturing alloys such as those in the superalloy-family and also evolved new alloys including GRCop-84, GRCop-42, NASA HR-1, and JBK-75. The purpose of this presentation is to discuss the various component programs at the NASA MSFC using AM to develop, fabricate, and test combustion devices hardware and the evolution of the new additive alloys. One of these projects that will be highlighted is Rapid Analysis and Manufacturing Propulsion Technology (RAMPT), which includes new process development for large scale AM components, multi-metallic AM components, including unique component designs using additive manufacturing. Additional information will be provided on the development of other components, hot-fire testing, post-processing of AM techniques including surface enhancements (polishing) techniques, material and process characterization, future development programs, and dissemination of data to industry partners.

Additive Manufacturing↗