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All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Advancement of Metal Additive Manufacturing Processes and Alloys for Rocket Propulsion Applications

NASA has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the 2000’s. Several efforts have focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into development and flight applications. While many common aerospace alloys have been and continue to be a focus of ongoing development, the need for custom-alloy developments for high performance applications enabled by various AM processes has been realized. The applications being targeted are liquid rocket engines with high heat fluxes, high pressure, and that utilize propellants such as hydrogen, which can degrade the alloy. NASA has recently focused on the development and advancement of novel alloy advancement using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, and JBK-75. These alloys have been evaluated using powder bed fusion (PBF), directed energy deposition (DED), and solid-state AM processes. The results from these processes have demonstrated that AM can enable rapid development of new alloy systems that can yield higher performances across various metal AM processes. These alloys have undergone the fundamental metallurgical evaluations, heat treatment study, and microstructure characterization and mechanical testing campaign. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL). This presentation will provide a background and overview of various AM-enabled novel alloys, a comparison across the AM processes, and development including metallurgical and mechanical property studies. It will also cover the latest advancement in the parallel component development and testing and future developments. The goal of these alloy development and use of various AM processes is to allow for technology infusion into NASA and commercial spaceflight missions as well as to establish and sustain the needed commercial AM supply chain.

Additive Manufacturing↗
NASA NTRSDate not supplied

Metal Additive Manufacturing Developments for Propulsion Applications

NASA has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the 2000’s. Several efforts have focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into development and flight applications. While many common aerospace alloys have been and continue to be a focus of ongoing development, the need for custom-alloy developments for high performance applications enabled by various AM processes has been realized. The applications being targeted are liquid rocket engines with high heat fluxes, high pressure, and that utilize propellants such as hydrogen, which can degrade the alloy. NASA has recently focused on the development and advancement of novel alloy advancement using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, and JBK-75. These alloys have been evaluated using powder bed fusion (PBF), directed energy deposition (DED), and solid-state AM processes. The results from these processes have demonstrated that AM can enable rapid development of new alloy systems that can yield higher performances across various metal AM processes. These alloys have undergone the fundamental metallurgical evaluations, heat treatment study, and microstructure characterization and mechanical testing campaign. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL). This presentation will provide a background and overview of various AM-enabled novel alloys, a comparison across the AM processes, and development including metallurgical and mechanical property studies. It will also cover the latest advancement in the parallel component development and testing and future developments. The goal of these alloy development and use of various AM processes is to allow for technology infusion into NASA and commercial spaceflight missions as well as to establish and sustain the needed commercial AM supply chain.

Additive Manufacturing↗
NASA NTRS2015

Space-to-Space Power Beaming Enabling High Performance Rapid Geocentric Orbit Transfer

The use of electric propulsion is more prevalent than ever, with industry pursuing all electric orbit transfers. Electric propulsion provides high mass utilization through efficient propellant transfer. However, the transfer times become detrimental as the delta V transitions from near-impulsive to low-thrust. Increasing power and therefore thrust has diminishing returns as the increasing mass of the power system limits the potential acceleration of the spacecraft. By using space-to-space power beaming, the power system can be decoupled from the spacecraft and allow significantly higher spacecraft alpha (W/kg) and therefore enable significantly higher accelerations while maintaining high performance. This project assesses the efficacy of space-to-space power beaming to enable rapid orbit transfer while maintaining high mass utilization. Concept assessment requires integrated techniques for low-thrust orbit transfer steering laws, efficient large-scale rectenna systems, and satellite constellation configuration optimization. This project includes the development of an integrated tool with implementation of IPOPT, Q-Law, and power-beaming models. The results highlight the viability of the concept, limits and paths to infusion, and comparison to state-of-the-art capabilities. The results indicate the viability of power beaming for what may be the only approach for achieving the desired transit times with high specific impulse.

Dankanich, John W.↗
NASA NTRSDate not supplied

Growing the success of Small Satellite missions through community learning

The successful utilization of small satellites for scientific missions relies on continual infusion of technology innovations, creative approaches, and new capabilities, all of which advance at a very rapid pace. Achieving these advancements requires open and efficient exchange of results, experiences, and ideas. Community learning is particularly challenging in this fast-growing community involving an increasingly diverse set of players from all sectors: industry, academia, government, and the public at large. Building and cultivating a community of practices around small satellite technology development and mission implementation are key objectives for NASA’s Small Spacecraft Systems Virtual Institute (S3VI). The institute has developed and provides access to a large collection of products, tools, and activities to advance clear communications and coordination regarding small spacecraft undertakings across NASA, to provide mission enabling information to the smallsat research community, to engage with stakeholders in industry, government, academia and the general public, and to support the overall small spacecraft community. New and updated offerings by the S3VI include: The2021 NASA State of the Art Report of Small Spacecraft Technology, the Small Spacecraft Reliability Initiative Knowledge Base, and the “MISSION ACCOMPLISHED”webinar series. These and other institute products will help scientists and engineers planning future missions answer pertinent questions, such as: What is the state of the art of small spacecraft technology that can be used?What are some best practices that other experts and teams can recommend? What did previous missions accomplish? What lessons could be learned from previous missions? What flight-proven parts are available? What emerging technologies could be taken advantage of? A status will be presented on S3VI activities facilitating community learning within the small satellite science community through the collection, sharing, and exchange of experiences with small satellite mission development and execution across all NASA mission areas.

Moretto Jorgensen, T↗
NASA NTRSDate not supplied

Growing the Success of Small Satellite Missions Through Community Learning

The successful utilization of small satellites for scientific missions relies on continual infusion of technology innovations, creative approaches, and new capabilities, all of which advance at a very rapid pace. Achieving these advancements requires open and efficient exchange of results, experiences, and ideas. Community learning is particularly challenging in this fast-growing community involving an increasingly diverse set of players from all sectors: industry, academia, government, and the public at large. Building and cultivating a community of practices around small satellite technology development and mission implementation are key objectives for NASA’s Small Spacecraft Systems Virtual Institute (S3VI). The institute has developed and provides access to a large collection of products, tools, and activities to advance clear communications and coordination regarding small spacecraft undertakings across NASA, to provide mission enabling information to the smallsat research community, to engage with stakeholders in industry, government, academia and the general public, and to support the overall small spacecraft community. New and updated offerings by the S3VI include: The2021 NASA State of the Art Report of Small Spacecraft Technology, the Small Spacecraft Reliability Initiative Knowledge Base, and the “MISSION ACCOMPLISHED” webinar series. These and other institute products will help scientists and engineers planning future missions answer pertinent questions, such as: What is the state of the art of small spacecraft technology that can be used? What are some best practices that other experts and teams can recommend? What did previous missions accomplish? What lessons could be learned from previous missions? What flight-proven parts are available? What emerging technologies could be taken advantage of? A status will be presented on S3VI activities facilitating community learning within the small satellite science community through the collection, sharing, and exchange of experiences with small satellite mission development and execution across all NASA mission areas.

Small Satellite↗
NASA NTRS2003

Fiber Reinforcement Architectures of PMCs on the Hygrothermal-Mechanical Performance for Aeropropulsion Applications

A rigid lightweight sandwich support structure, for the combustor chamber of a new generation liquid propellant rocket engine, was designed and fabricated using Polymer Matric Composite (PMC) facesheet on a Ti honeycomb or Carbon foam core. The facesheet consisted of high stiffness carbon fiber, M40JB, and high temperature Polyimides, such as PMR-11-50 and HFPE-II. Six different fiber architectures; 4HS woven fabric, uni-fabric, woven-uni hybrid, stitched woven fabric, stitched uni-fabric and tri-axial braided structures have been investigated for optimum stiffness-thickness-weight-performance design criteria for the hygrothermal-mechanical propulsion service exposure conditions including rapid heating up to 200 F/sec, maximum operating temperature of 600 F, internal pressure up to 100 psi. An extensive property and performance database including dry-wet mechanical properties at both 25 F and 600 F in various loading modes, thermal and physical properties including blistering onset condition was developed for fiber architecture down-selection and design guidelines. Various optimized process methods including vacuum bag compression molding, solvent assistant RTM (SaRTM), resin film infusion (RFI) were utilized for PMC panel fabrication depending on the architecture type. In the case of stitched woven fabric architecture, the optimal stitch pattern was chosen in terms of stitch density and yarn size, based on both in-plane mechanical properties and blistering performance. Potential reduction of the in-plane properties transverse to the line of stitching was also evaluated. Attempt to correlate the experimental results with theoretical micro-mechanics predictions will be presented.

Shin, Eugene↗
NASA NTRS2016

Design for Survivability: An Approach to Assured Autonomy

Rapidly expanding unmanned air traffic includes and will continue to include non-cooperative participants. Non-cooperative behavior may be due to technical failure, a lack of appropriate equipment, a careless or malicious operator. Regardless of the cause, the outcome remains: growing density of non-cooperative traffic will increase the risk of collision between unmanned vehicles and aircraft carrying humans. As a result, the degraded safety of airspace may limit access to airspace, with adverse consequences for the traveling public and the economy. Because encounters with small non-cooperative objects, such as birds or wayward drones, can happen too rapidly for an external control system to mitigate them, it is imperative that the aircraft that carry humans survive encounters with non-cooperative vehicles. To-date, design for survivability has been practiced explicitly in the military domain. Survivability against collisions in civil aviation has been limited to tolerances against bird strikes; and these tolerances have proved inadequate on occasion. The growing risk of collision with unmanned vehicles now requires the development of survivability discipline for civilian transport aircraft. The new discipline must be infused into multidisciplinary design methods, on par with traditional disciplines. In this paper, we report on a preliminary study of survivability considerations for the civil aviation domain.

Alexandrov, Natalia M.↗
NASA NTRS2023

The Assembly, Test, and Integration of LOFTID (Low-Earth Orbit Flight Test of an Inflatable Decelera-tor)

R.J. Bodkin Biography Mr. Bodkin worked in industry for a rapid prototype company focusing on UAVs and manned experimental aircraft. Later he served as the Inflation System Lead on IRVE-II and 3 and the Re-Entry Vehicle Lead for LOFTID at NASA Langley Research Center. Introduction: The Low-Earth Orbit Flight Test of an Inflatable Decelerator (LOFTID), developed in partnership with United Launch Alliance (ULA) and flown in conjunction with the National Oceanic and Atmospheric Administration (NOAA) Joint Polar Satellite System-2 (JPSS-2) satellite, demonstrated Hypersonic Inflatable Aerodynamic Decelerator (HIAD) technology has progressed and is ready for mission infusion. LOFTID’s success demonstrates that aeroshells are not limited to the internal diame-ter of the launch vehicle payload fairing, allowing larger payloads to be deployed to the surfaces of planetary bodies with atmospheres. The challenges of assembling, integrating, and testing this revolutionary spacecraft will be dis-cussed as well as issues associated with doing this with a fixed launch date the project did not control. Assembly: Because LOFTID flew as a rideshare partner with JPSS-2, it was constrained with addi-tional schedule, milestone, and technical require-ments that were beyond the project’s control. As-sembly of the LOFTID hardware was challenged with the normal mechanical fit issues while also having to navigate the SARS-COVID-II pandemic. Challenges ranged from availability of team per-sonnel required on-site for vehicle assembly to dif-ficulties associated with team collaboration while working remotely and increased costs and lead times of components due to supply chain con-straints. Numerous additional challenges cascaded from the additional time required. Integration: LOFTID flew as a secondary pay-load to JPSS-2 in a mission-unique configuration, directly under JPSS-2 primary payload, inside the Payload Adapter that integrated JPSS-2 to the Atlas V launch vehicle. A mission unique Payload Adapt-er Separation System (PASS) was required to sepa-rate the Payload Adapter from the Launch Vehicle prior to the start of the LOFTID flight demonstra-tion. Development of this system was challenging due to a shortened development schedule resulting from the iterative nature of Payload Adapter devel-opment with the partners at ULA. Preparations to integrate the main segments of the LOFTID vehicle posed unique challenges of having to accommodate issues with a fixed launch date that led to some cre-ative solutions to the integration. The partnership agreement with ULA and JPSS-2 resulted in a mass simulator designed to be installed late in the inte-gration in the event the LOFTID vehicle was not ready in time.. Test: LOFTID testing was carried out in several phases. Some components were tested at the com-ponent level, others at the sub-system levels and then finally the integrated vehicle level. This culmi-nated with the Complete Systems Test (CST) per-formed in a vacuum chamber as one of the final checkouts prior to disassembly for re-packing of the aeroshell. CST challenges will be discussed as well as obstacles encountered post-CST. After CST, the vehicle was disassembled so the HIAD could be repacked, and the vehicle was reassembled for ac-ceptance vibration testing. Testing concluded with the fully assembled vehicle being shipped to the launch site for final testing and integrations with the Payload Adapter to JPSS-2 for launch and opera-tions. Conclusion: The challenges posed by the AI&T for LOFTID could inform the planetary community of some of the opportunities and challenges of de-veloping technologies on a rideshare with a rela-tively small budget.

R.J. Bodkin↗
DOE OSTI2020

Linking Internal Dosimetries of the Propyl Metabolic Series in Rats and Humans Using Physiologically Based Pharmacokinetic (PBPK) Modeling

The metabolic series approach has successfully linked internal dosimetries of metabolically related compounds reducing cost and time for chemical risk assessments. Here, we developed a physiologically based pharmacokinetic (PBPK) model in rats and humans for the propyl metabolic series including propyl acetate, 1-propanol, propionaldehyde, and propionic acid. Manufacturers use these compounds as organic solvents and intermediates during chemical synthesis. Public exposures can occur through using consumer products containing propyl compounds like cosmetics, aerosol sprays, or foods. To develop the PBPK model, we measured in vitro metabolism of propyl acetate in blood and liver S9 fractions. We measured concentrations of propyl compounds in blood following intravenous (iv) infusion of 13C-propanol or 13C-propionic acid and closed chamber inhalation exposures to propyl acetate or propanol in rats. Using these studies and other published data, we modified an existing PBPK model for the butyl metabolic series to simulate time course concentrations of propyl compounds in rats and humans. Consistent with measured in vitro and in vivo data, the optimized propyl series model predicts rapid clearance of propyl acetate, higher concentrations of propanol in blood from propyl acetate inhalation compared to propanol inhalation, and low concentrations of propionic acid in blood from exposures to propyl acetate or propanol. Regulators can use this model as a tool for propyl compound risk assessment by linking internal dosimetries under various exposure scenarios.

Smith, Jordan N.↗
NASA NTRSDate not supplied

TPSAS-NF1676L-25778-DND

Testing required to design and certify aircraft structures has increased dramatically with the growth in use of composite materials, and the development time and cost have become an issue as industry looks towards the next generation of aircraft. To help address this challenge, NASA has formed an industry-spanning consortium with the goal of cutting by 30% today's 10-year timeline for developing and certifying composite aircraft structures. This goal is to be achieved by infusing leading edge, physics-based tools to improve the prediction of the response and failure of composite aerospace structures. The plan for the public-private partnership of NASA, the FAA, airframe manufacturers, aircraft engine manufacturers, and several universities is to conduct joint research under the five-year Advanced Composites Program (ACP). The emphasis of the ACP project is the development of damage prediction and non-destructive inspection methods capabilities that are sufficiently reliable to enable a reduction in the element and subcomponent testing necessary for design and certification. ACP also is expected to create rapid design tools to speed preliminary design and improve safety and performance. A critical element of this research concerns the residual strength of postbuckled stiffened panels with impact damage. This presentation will discuss different aspects of ongoing research on the prediction of structural collapse due to skin/stiffener separation. In particular, the presentation will examine issues that must be addressed in the analysis, such as R-curve toughening, delamination migration, bridging, as well as some unexpected effects of ply orientation.

Carlos G Davila↗
DOE OSTI2025

Advancing molecular machine learning representations with stereoelectronics-infused molecular graphs

Molecular representation is a critical element in our understanding of the physical world and the foundation for modern molecular machine learning. Previous molecular machine learning models have used strings, fingerprints, global features and simple molecular graphs that are inherently information-sparse representations. However, as the complexity of prediction tasks increases, the molecular representation needs to encode higher fidelity information. This work introduces a new approach to infusing quantum-chemical-rich information into molecular graphs via stereoelectronic effects, enhancing expressivity and interpretability. Learning to predict the stereoelectronics-infused representation with a tailored double graph neural network workflow enables its application to any downstream molecular machine learning task without expensive quantum-chemical calculations. We show that the explicit addition of stereoelectronic information substantially improves the performance of message-passing two-dimensional machine learning models for molecular property prediction. We show that the learned representations trained on small molecules can accurately extrapolate to much larger molecular structures, yielding chemical insight into orbital interactions for previously intractable systems, such as entire proteins, opening new avenues of molecular design. Finally, we have developed a web application (simg.cheme.cmu.edu) where users can rapidly explore stereoelectronic information for their own molecular systems.

Boiko, Daniil A↗
NASA NTRS2004

Autonomous Multi-Sensor Coordination: The Science Goal Monitor

Many dramatic earth phenomena are dynamic and coupled. In order to fully understand them, we need to obtain timely coordinated multi-sensor observations from widely dispersed instruments. Such a dynamic observing system must include the ability to Schedule flexibly and react autonomously to sciencehser driven events; Understand higher-level goals of a sciencehser defined campaign; Coordinate various space-based and ground-based resources/sensors effectively and efficiently to achieve goals. In order to capture transient events, such a 'sensor web' system must have an automated reactive capability built into its scientific operations. To do this, we must overcome a number of challenges inherent in infusing autonomy. The Science Goal Monitor (SGM) is a prototype software tool being developed to explore the nature of automation necessary to enable dynamic observing. The tools being developed in SGM improve our ability to autonomously monitor multiple independent sensors and coordinate reactions to better observe dynamic phenomena. The SGM system enables users to specify what to look for and how to react in descriptive rather than technical terms. The system monitors streams of data to identify occurrences of the key events previously specified by the scientisther. When an event occurs, the system autonomously coordinates the execution of the users' desired reactions between different sensors. The information can be used to rapidly respond to a variety of fast temporal events. Investigators will no longer have to rely on after-the-fact data analysis to determine what happened. Our paper describes a series of prototype demonstrations that we have developed using SGM and NASA's Earth Observing-1 (EO-1) satellite and Earth Observing Systems' Aqua/Terra spacecrafts' MODIS instrument. Our demonstrations show the promise of coordinating data from different sources, analyzing the data for a relevant event, autonomously updating and rapidly obtaining a follow-on relevant image. SGM was used to investigate forest fires, floods and volcanic eruptions. We are now identifying new Earth science scenarios that will have more complex SGM reasoning. By developing and testing a prototype in an operational environment, we are also establishing and gathering metrics to gauge the success of automating science campaigns.

Koratkar, Anuradha↗
NASA NTRSDate not supplied

Additive Manufacturing (AM) for Propulsion Component and System Applications

NASA MSFC is developing several areas of additive manufacturing (AM) for propulsion component and system applications. These developments include new AM process and material development, large-scale AM pathfinder component fabrication and hot-fire testing, AM-centric design methodology, modeling and simulation, post-processing advancements, and new design applications of AM in aerospace. Some specific areas NASA has focused is the development and commercial infusion of AM supply chain for materials such as copper-alloy GRCop (Cu-Cr-Nb), Hydrogen-resistant alloys (NASA HR-1, JBK-75), refractory-based alloys (C-103, W, Mo, new formulations), and bimetallic and multi-metallic AM processes. Additional efforts have been focused on large scale AM demonstrating complex thin-wall structures up to 60” diameter using directed energy deposition. Material characterization, properties and component hot-fire testing has been completed using many of these newly developed AM alloys/processes. NASA has also focused on improvements to post-processing including powder removal, surface enhancements, and support removal to further realize cost and schedule benefits to the overall supply chain. These developments are part of the NASA Rapid Analysis and Manufacturing Propulsion Technology (RAMPT), Low Cost Upper Stage Propulsion (LCUSP) and Long Life Additive Manufacturing (LLAMA) projects, in addition to internal IRAD, and external collaborations.

Additive Manufacturing↗
NASA NTRS2020

Demonstrating Assurance of Model-Based Fault Diagnosis Systems on an Operational Mission

Developers of robotic scientific and commercial spacecraft are trending towards use of onboard autonomous capabilities for responding quickly to dynamic environments and rapidly changing situations. These capabilities need to know the state of the spacecraft’s health. Model-based fault diagnosis (MBFD) is an approach to estimating health by continuously verifying accurate behavior and diagnosing off-nominal behavior. Proper functioning of MBFD depends on 1) the quality of the diagnostic system model that is analyzed and compared to commands and onboard measurements to estimate a system’s health state, and 2) the correct functionality of the diagnosis engine interrogating the model and comparing its analyses to observed system behavior. Our goal is to develop Verification and Validation (V&V) techniques for MBFD to provide future missions sufficient confidence in its functionality and performance to deploy it on the systems they develop. Our work has been focused on infusing the techniques we developed earlier to an operational mission. First, we are constructing diagnostic models of a spacecraft attitude control system and updating our diagnostic engine so they can be demonstrated aboard the Arcsecond Space Telescope Enabling Research in Astrophysics (ASTERIA) mission, an operational spacecraft for which experiments in autonomy are being planned and executed, using the V&V techniques we have previously developed to assure they are both correct and complete. Since it is nearing the end of its life, ASTERIA provides a unique opportunity to demonstrate MBFD since the monitored components are expected to fail. Our demonstration will give system developers additional confidence to make timely, informed MBFD deployment decisions. Second, we will be completing performance assessments of the diagnostic engine/diagnostic model ensemble both on the flight system and ground-based testbeds to gain confidence in MBFD’s ability to run successfully in a spacecraft’s resource-constrained environment without adversely affecting other on-board activities. Finally, we are capturing our experience in preparing this demonstration in a set of checklists and guidance documents. Current practice includes high-level institutional guidance documents and standards, but at a high level of abstraction that does not necessarily address specific MBFD concerns. The purpose of the new checklists is to provide future mission developers clear, unambiguous, procedure-oriented guidance on assuring MBFD. This paper describes our work in these areas. For the first area, we describe the diagnostic models and updated diagnostic engine that will be used for the on-board demonstration. We describe how the V&V techniques we developed earlier are used to assure model and engine correctness and completeness. For the second area, we identify the performance measurement and assessment techniques used to characterize the diagnostic engine and diagnostic models, and discuss the effect of measured performance on overall mission operation. Finally, we present the checklist and guidance documents and describe how they meet the goals of providing system developers with clear, unambiguous, procedure-oriented guidance on MBFD assurance. We show how the techniques we have developed map into those artifacts.

Nikora, Allen↗
DOE OSTI2022

Development of high‐performance partially biobased thermoset polyester using renewable building blocks from isosorbide, 1,3‐propanediol, and fumaric acid

Abstract Research on biobased thermoset resins has been overlooked when compared with the rapid progress on biobased thermoplastics. The objective of this work was to develop unsaturated polyester prepolymers based on building blocks derived from renewable raw materials, namely, biobased isosorbide, 1,3‐propanediol, and fumaric acid, with petroleum‐derived phthalic anhydride. The prepolymers developed herein behaved as low‐molecular weight macromolecules (oligoesters), with M n varying between 1.2 and 1.5 kDa, but achieved a high bio‐content of up to 87.1 wt%. The prepolymers were incorporated into reactive diluents comprising a blend of 2‐hydroxyethyl methacrylate and styrene, formulated to be eco‐friendlier and less toxic than typical styrene‐only incorporation approach, thus resulting in resins with viscosities between 750 and 950 cP. These resins are suitable for use in various fiber‐reinforced polymer production techniques, such as manual lamination, vacuum infusion, and pultrusion, having the benefit of presenting over 50 wt% of bio‐content in some formulations. Moreover, the crosslinked polyester resins (thermosets) exhibit comparable mechanical and thermomechanical behavior to their petrochemical‐based counterparts, with modulus of elasticity and tensile strength of up to 3.9 GPa and 62.1 MPa, respectively, and glass transition temperatures of up to 106°C, making them greener alternatives for high‐performance structural applications.

Hofmann, Mateus↗
DOE OSTI2021

Advanced strategies for the development of porous carbon as a Li host/current collector for lithium metal batteries

Lithium metal is considered a promising anode material for high-energy-density rechargeable batteries because of its high specific theoretical capacity (3860 mAh g -1 , low mass density (0.534 g cm -3 ), and low electrochemical redox potential (-3.04 V vs. the standard hydrogen electrode). However, the high reactivity of Li with the electrolyte leads to the formation of an unstable solid electrolyte interphase (SEI) and continuous side reactions. Also, the non-uniform lithium-ion flux and infinite volume expansion of Li metal cause the growth of Li dendrites. These pose significant safety challenges and cause rapid capacity fading of the lithium metal batteries (LiMBs). To resolve these issues, a low-cost, easily processed, lightweight, high-performance carbon-based porous matrix is considered promising to host Li metal deposition. The three-dimensional (3D) porous nano/microstructured carbon provides sufficient space for Li accommodation during Li plating, buffers the volume changes during Li plating/stripping, and lowers the effective current density contributing to dendrite-free Li deposition. Besides, the outstanding electrochemical and mechanical stability, flexibility and the high electronic conductivity enable the nano/microstructured carbon to serve as both Li host and current collector. The development of 3D carbon/Li composite by mechanical roll-press techniques not only eliminates the complex and risky procedure of making carbon/Li composite based on Li plating or molten Li infusion but also stabilizes the capacity at higher Li plating/stripping rates. Recently, there is an advancement in the lithiophilic decorations of 3D structure to introduce sufficient nucleation sites and the development of artificial SEI on top of the 3D matrix to suppress Li dendrite formation. Such 3D structural modifications create a uniform electric field, lower the Li nucleation overpotential, provide strong mechanical and chemical stability, and stabilize the interface thereby inhibiting the degradation of lithium and the electrolyte. Here we summarize the research progress on porous carbon/Li composites in terms of materials type, structure, fabrication technique, their electrochemical battery performance, and identify the critical challenges that need to be addressed for high-energy-density practical LiMBs.

25 ENERGY STORAGE↗
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 NTRSDate not supplied

Recent Developments of Thermal Protection Materials to Enable Lower Cost Space Missions

Introduction: Starting with the Commercial Crew Program, a new paradigm has emerged at NASA. Rather than designing rockets and spacecrafts for every mission optimized to achieve science, NASA has begun to use a service-based model and utilizing public-private partnership in developing the vehicles that can bring broader benefits as well as lower the cost for NASA missions. Commercial companies own and operate those vehicles. This allows NASA to not design missions from the bottom up, and has cost, risk, and schedule savings implications. On the other side, the constraints require meeting the requirements in terms of mass, volume, power, etc. By leveraging NASA developed technologies, commercial companies can quickly demonstrate the commercial mission concept, and, through technology transfer, adopt needed technology to address supply chain problems. A downside is that the technology has to be sufficiently mature to be transferred by NASA, which means that it requires significant investment, expertise, and time to develop. Space entities are focused on rapid development with an emphasis on manufacturing and integration innovation with reduced cost and schedule and quick entrance into the market. Thermal Protection Systems (TPS) are mission critical, but their development takes years, and involve access to arc jets or unique test facilities. Therefore, their development is both risky and investment heavy. NASA ARC developed several new TPS materials over the last decade (C-PICA, HEEET, 3MDCP, 3DMAT, ADEPT woven TPS) and brought them to high TPS maturity, making them enablers for commercials space missions from LEO, Lunar Sample Return, Mars, and Venus missions. LEO missions are relevant to future Mars missions due to the comparable entry conditions. External Partners' Missions: C-PICA is a recent improvement on NASA’s heritage PICA lightweight TPS ablator. C-PICA is now considered an enabling technology for New Frontiers and other NASA missions. C-PICA was infused into several missions from external partners. Varda Space Industries’ Winnebago-1 spacecraft successfully returned to Earth from LEO on Feb. 21st, 2024, using a C-PICA heatshield. Inversion Space’s Ray vehicle will test both ARC’s C-PICA and SIRCA TPS materials on a LEO return mission later in 2024. The Kentucky Re-Entry Probe Experiment (KREPE) is another example of a low-cost flight experiment to demonstrate the use of small entry capsules to gather data with three instrumented Kentucky Re-entry and Universal Payload System (KRUPS) capsules. NASA Arc provided C-PICA and Soft-PICA for two of the next KRUPS capsules scheduled to re-enter Earth from the ISS later in 2024. Finally, Rocket Lab’s low-cost mission to Venus, scheduled to launch in December 2024, will search for habitable conditions in Venus’ cloud layer, making use of NASA ARC provided HEEET insulation layer heat shield, and SIRCA backshell TPS materials. Future NASA Missions: NASA’s ability to help commercial missions can lead to future low-cost missions for several reasons: Competition encourages lower cost; technology maturation is now done at an integrated system level; and a common design architecture between commercial and scientific applications requires no specialized engineering design. From an engineering perspective, both of these commercial LEO capsules aforementioned are capable of a Mars entry; the commercial payload mut be replaced with as science payload. Finally, several NASA mission concepts, that could be candidates for future SIMPLEx program calls, such as VATMOS-SR and Nephele, both proposing to target the Venusian atmosphere, would make use of the HEEET insulation layer TPS for part of their heat shield.

TPS materials↗