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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS1973

Trajectory description

The Mariner 9 spacecraft was launched by an Atlas/Centaur launch vehicle (AC-23) on a direct-ascent trajectory from the Air Force Eastern Test Range (AFETR) launch complex 36B on May 30, 1971. Liftoff occurred at 22 h 23 min 04.5 s GMT, slightly more than 6 min after the opening of a 60-min launch window. The vehicle rose vertically for approximately 15 s, during which time, a programmed roll to a launch azimuth of 92.74 deg was performed. After the initial vertical rise, the vehicle, guided by the open-loop Atlas autopilot, began to pitch over into a zero-lift trajectory. The first of three main powered phases was terminated by booster engine cutoff (BECO) at 22 h 25 min 35.5 s. After the Atlas booster engine package was jettisoned 3 s later, the flight continued under the power of the Atlas sustainer engine and guided by the Centaur guidance system operating in a closed-loop mode.

Webb, W. A.↗
NASA NTRS2003

Use of Soft Computing Technologies For Rocket Engine Control

The problem to be addressed in this paper is to explore how the use of Soft Computing Technologies (SCT) could be employed to further improve overall engine system reliability and performance. Specifically, this will be presented by enhancing rocket engine control and engine health management (EHM) using SCT coupled with conventional control technologies, and sound software engineering practices used in Marshall s Flight Software Group. The principle goals are to improve software management, software development time and maintenance, processor execution, fault tolerance and mitigation, and nonlinear control in power level transitions. The intent is not to discuss any shortcomings of existing engine control and EHM methodologies, but to provide alternative design choices for control, EHM, implementation, performance, and sustaining engineering. The approaches outlined in this paper will require knowledge in the fields of rocket engine propulsion, software engineering for embedded systems, and soft computing technologies (i.e., neural networks, fuzzy logic, and Bayesian belief networks), much of which is presented in this paper. The first targeted demonstration rocket engine platform is the MC-1 (formerly FASTRAC Engine) which is simulated with hardware and software in the Marshall Avionics & Software Testbed laboratory that

Trevino, Luis C.↗
NASA NTRS2016

Marshall Space Flight Center Ground Systems Development and Integration

Ground Systems Development and Integration performs a variety of tasks in support of the Mission Operations Laboratory (MOL) and other Center and Agency projects. These tasks include various systems engineering processes such as performing system requirements development, system architecture design, integration, verification and validation, software development, and sustaining engineering of mission operations systems that has evolved the Huntsville Operations Support Center (HOSC) into a leader in remote operations for current and future NASA space projects. The group is also responsible for developing and managing telemetry and command configuration and calibration databases. Personnel are responsible for maintaining and enhancing their disciplinary skills in the areas of project management, software engineering, software development, software process improvement, telecommunications, networking, and systems management. Domain expertise in the ground systems area is also maintained and includes detailed proficiency in the areas of real-time telemetry systems, command systems, voice, video, data networks, and mission planning systems.

Wade, Gina↗
NASA NTRS2006

Integrating International Engineering Organizations For Successful ISS Operations

The International Space Station (ISS) is a multinational orbiting space laboratory that is built in cooperation with 16 nations. The design and sustaining engineering expertise is spread worldwide. As the number of Partners with orbiting elements on the ISS grows, the challenge NASA is facing as the ISS integrator is to ensure that engineering expertise and data are accessible in a timely fashion to ensure ongoing operations and mission success. Integrating international engineering teams requires definition and agreement on common processes and responsibilities, joint training and the emergence of a unique engineering team culture. ISS engineers face daunting logistical and political challenges regarding data sharing requirements. To assure systematic information sharing and anomaly resolution of integrated anomalies, the ISS Partners are developing multi-lateral engineering interface procedures. Data sharing and individual responsibility are key aspects of this plan. This paper describes several examples of successful multilateral anomaly resolution. These successes were used to form the framework of the Partner to Partner engineering interface procedures, and this paper describes those currently documented multilateral engineering processes. Furthermore, it addresses the challenges experienced to date, and the forward work expected in establishing a successful working relationship with Partners as their hardware is launched.

Blome, Elizabeth↗
NASA NTRS1991

NASA software documentation standard software engineering program

The NASA Software Documentation Standard (hereinafter referred to as Standard) can be applied to the documentation of all NASA software. This Standard is limited to documentation format and content requirements. It does not mandate specific management, engineering, or assurance standards or techniques. This Standard defines the format and content of documentation for software acquisition, development, and sustaining engineering. Format requirements address where information shall be recorded and content requirements address what information shall be recorded. This Standard provides a framework to allow consistency of documentation across NASA and visibility into the completeness of project documentation. This basic framework consists of four major sections (or volumes). The Management Plan contains all planning and business aspects of a software project, including engineering and assurance planning. The Product Specification contains all technical engineering information, including software requirements and design. The Assurance and Test Procedures contains all technical assurance information, including Test, Quality Assurance (QA), and Verification and Validation (V&V). The Management, Engineering, and Assurance Reports is the library and/or listing of all project reports.

Source record↗
NASA NTRS1991

NASA Software Documentation Standard

The NASA Software Documentation Standard (hereinafter referred to as "Standard") is designed to support the documentation of all software developed for NASA; its goal is to provide a framework and model for recording the essential information needed throughout the development life cycle and maintenance of a software system. The NASA Software Documentation Standard can be applied to the documentation of all NASA software. The Standard is limited to documentation format and content requirements. It does not mandate specific management, engineering, or assurance standards or techniques. This Standard defines the format and content of documentation for software acquisition, development, and sustaining engineering. Format requirements address where information shall be recorded and content requirements address what information shall be recorded. This Standard provides a framework to allow consistency of documentation across NASA and visibility into the completeness of project documentation. The basic framework consists of four major sections (or volumes). The Management Plan contains all planning and business aspects of a software project, including engineering and assurance planning. The Product Specification contains all technical engineering information, including software requirements and design. The Assurance and Test Procedures contains all technical assurance information, including Test, Quality Assurance (QA), and Verification and Validation (V&V). The Management, Engineering, and Assurance Reports is the library and/or listing of all project reports.

Source record↗
NASA NTRS2012

Nuclear Thermal Propulsion (NTP): A Proven Growth Technology for Human NEO/Mars Exploration Missions

The nuclear thermal rocket (NTR) represents the next "evolutionary step" in high performance rocket propulsion. Unlike conventional chemical rockets that produce their energy through combustion, the NTR derives its energy from fission of Uranium-235 atoms contained within fuel elements that comprise the engine s reactor core. Using an "expander" cycle for turbopump drive power, hydrogen propellant is raised to a high pressure and pumped through coolant channels in the fuel elements where it is superheated then expanded out a supersonic nozzle to generate high thrust. By using hydrogen for both the reactor coolant and propellant, the NTR can achieve specific impulse (Isp) values of ~900 seconds (s) or more - twice that of today s best chemical rockets. From 1955 - 1972, twenty rocket reactors were designed, built and ground tested in the Rover and NERVA (Nuclear Engine for Rocket Vehicle Applications) programs. These programs demonstrated: (1) high temperature carbide-based nuclear fuels; (2) a wide range of thrust levels; (3) sustained engine operation; (4) accumulated lifetime at full power; and (5) restart capability - all the requirements needed for a human Mars mission. Ceramic metal "cermet" fuel was pursued as well, as a backup option. The NTR also has significant "evolution and growth" capability. Configured as a "bimodal" system, it can generate its own electrical power to support spacecraft operational needs. Adding an oxygen "afterburner" nozzle introduces a variable thrust and Isp capability and allows bipropellant operation. In NASA s recent Mars Design Reference Architecture (DRA) 5.0 study, the NTR was selected as the preferred propulsion option because of its proven technology, higher performance, lower launch mass, versatile vehicle design, simple assembly, and growth potential. In contrast to other advanced propulsion options, no large technology scale-ups are required for NTP either. In fact, the smallest engine tested during the Rover program - the 25,000 lbf (25 klbf) "Pewee" engine is sufficient when used in a clustered engine arrangement. The "Copernicus" crewed spacecraft design developed in DRA 5.0 has significant capability and a human exploration strategy is outlined here that uses Copernicus and its key components for precursor near Earth object (NEO) and Mars orbital missions prior to a Mars landing mission. The paper also discusses NASA s current activities and future plans for NTP development that include system-level Technology Demonstrations - specifically ground testing a small, scalable NTR by 2020, with a flight test shortly thereafter.

Borowski, Stanley K.↗
NASA NTRS2003

Pulse Detonation Rocket Magnetohydrodynamic Power Experiment

The production of onboard electrical power by pulse detonation engines is problematic in that they generate no shaft power; however, pulse detonation driven magnetohydrodynamic (MHD) power generation represents one intriguing possibility for attaining self-sustained engine operation and generating large quantities of burst power for onboard electrical systems. To examine this possibility further, a simple heat-sink apparatus was developed for experimentally investigating pulse detonation driven MHD generator concepts. The hydrogen oxygen fired driver was a 90 cm long stainless steel tube having a 4.5 cm square internal cross section and a short Schelkin spiral near the head end to promote rapid formation of a detonation wave. The tube was intermittently filled to atmospheric pressure and seeded with a CsOH/methanol prior to ignition by electrical spark. The driver exhausted through an aluminum nozzle having an area contraction ratio of A*/A(sub zeta) = 1/10 and an area expansion ratio of A(sub zeta)/A* = 3.2 (as limited by available magnet bore size). The nozzle exhausted through a 24-electrode segmented Faraday channel (30.5 cm active length), which was inserted into a 0.6 T permanent magnet assembly. Initial experiments verified proper drive operation with and without the nozzle attachment, and head end pressure and time resolved thrust measurements were acquired. The exhaust jet from the nozzle was interrogated using a polychromatic microwave interferometer yielding an electron number density on the order of 10(exp 12)/cm at the generator entrance. In this case, MHD power generation experiments suffered from severe near-electrode voltage drops and low MHD interaction; i.e., low flow velocity, due to an inherent physical constraint on expansion with the available magnet. Increased scaling, improved seeding techniques, higher magnetic fields, and higher expansion ratios are expected to greatly improve performance.

Litchford, R. J.↗
NASA NTRS2005

NESTA: NASA Engineering Shuttle Telemetry Agent

The Spaceport Processing Systems Branch at NASA Kennedy Space Center has developed and deployed an agent based tool to monitor the Space Shuttle's ground processing telemetry stream. The application, the NASA Engineering Shuttle Telemetry Agent, increases situational awareness for system and hardware engineers during ground processing of the Shuttle's subsystems. The agent provides autonomous monitoring of the telemetry stream and automatically alerts system engineers when predefined criteria have been met. Efficiency and safety are improved through increased automation. Sandia National Labs' Java Expert System Shell is employed as the rule engine. The shell's predicate logic lends itself well to capturing the heuristics and specifying the engineering rules of this spaceport domain. The declarative paradigm of the rule-based agent yields a highly modular and scalable design spanning multiple subsystems of the Shuttle. Several hundred monitoring rules have been written thus far with corresponding notifications sent to Shuttle engineers. This paper discusses the rule-based telemetry agent used for Space Shuttle ground processing and explains the problem domain, development of the agent software, benefits of AT technology, and deployment and sustaining engineering of the product.

Semmel, Glenn S.↗
NASA NTRS2012

Modular Growth NTR Space Transportation System for Future NASA Human Lunar, NEA and Mars Exploration Missions

The nuclear thermal rocket (NTR) is a proven, high thrust propulsion technology that has twice the specific impulse (I(sub sp) approx.900 s) of today's best chemical rockets. During the Rover and NERVA (Nuclear Engine for Rocket Vehicle Applications) programs, twenty rocket reactors were designed, built and ground tested. These tests demonstrated: (1) a wide range of thrust; (2) high temperature carbide-based nuclear fuel; (3) sustained engine operation; (4) accumulated lifetime; and (5) restart capability - everything required for affordable human missions beyond LEO. In NASA's recent Mars Design Reference Architecture (DRA) 5.0 study, the NTR was selected as the preferred propulsion option because of its proven technology, higher performance, lower IMLEO, versatile vehicle design, and growth potential. Furthermore, the NTR requires no large technology scale-ups since the smallest engine tested during the Rover program - the 25 klb(sub f) "Pewee" engine is sufficient for human Mars missions when used in a clustered engine configuration. The "Copernicus" crewed Mars transfer vehicle developed for DRA 5.0 was an expendable design sized for fast-conjunction, long surface stay Mars missions. It therefore has significant propellant capacity allowing a reusable "1-year" round trip human mission to a large, high energy near Earth asteroid (NEA) like Apophis in 2028. Using a "split mission" approach, Copernicus and its two key elements - a common propulsion stage and integrated "saddle truss" and LH2 drop tank assembly - configured as an Earth Return Vehicle / propellant tanker, can also support a short round trip (approx.18 month) / short orbital stay (60 days) Mars reconnaissance mission in the early 2030's before a landing is attempted. The same short stay orbital mission can be performed with an "all-up" vehicle by adding an "in-line" LH2 tank to Copernicus to supply the extra propellant needed for this higher energy, opposition-class mission. To transition to a reusable Mars architecture, Copernicus' saddle truss / drop tank assembly is replaced by an in-line tank and "star truss" assembly with paired modular drop tanks to further increase the vehicle's propellant capacity. Shorter "1-way" transit time fast-conjunction Mars missions are another possibility using this vehicle configuration but, as with reusability, increased launch mass is required. "Scaled down" versions of Copernicus (sized to a SLS lift capability of approx.70 t - 100 t) can be developed initially allowing reusable lunar cargo delivery and crewed landing missions, easy NEA missions (e.g., 2000 SG344 also in 2028) or an expendable mission to Apophis. Mission scenario descriptions, key vehicle features and operational characteristics are provided along with a brief discussion of NASA's current activities and its "pre-decisional" plans for future NTR development.

Borowski, Stanley K.↗
NASA NTRS2012

Near Earth Asteroid Human Mission Possibilities Using Nuclear Thermal Rocket (NTR) Propulsion

The NTR is a proven technology that generates high thrust and has a specific impulse (Isp (is) approximately 900 s) twice that of today's best chemical rockets. During the Rover and NERVA (Nuclear Engine for Rocket Vehicle Applications) programs, twenty rocket reactors were designed, built and ground tested. These tests demonstrated: (1) a wide range of thrust; (2) high temperature carbide-based nuclear fuel; (3) sustained engine operation; (4) accumulated lifetime; and (5) restart capability - all the requirements needed for a human mission to Mars. Ceramic metal fuel was also evaluated as a backup option. In NASA's recent Mars Design reference Architecture (DRA) 5.0 study, the NTR was selected as the preferred propulsion option because of its proven technology, higher performance, lower launch mass, versatile vehicle design, simple assembly, and growth potential. In contrast to other advanced propulsion options, NTP requires no large technology scale-ups. In fact, the smallest engine tested during the Rover program - the 25 klbf 'Pewee' engine is sufficient for a human Mars mission when used in a clustered engine configuration. The 'Copernicus crewed NTR Mars transfer vehicle design developed for DRA 5.0 has significant capability that can enable reusable '1-year' round trip human missions to candidate near Earth asteroids (NEAs) like 1991 JW in 2027, or 2000 SG344 and Apophis in 2028. A robotic precursor mission to 2000 SG344 in late 2023 could provide an attractive Flight Technology Demonstration of a small NTR engine that is scalable to the 25 klbf-class engine used for human missions 5 years later. In addition to the detailed scientific data gathered from on-site inspection, human NEA missions would also provide a valuable 'check out' function for key elements of the NTR transfer vehicle (its propulsion module, TransHab and life support systems, etc.) in a 'deep space' environment prior to undertaking the longer duration Mars orbital and landing missions that would follow. The initial mass in low Earth orbit required for a mission to Apophis is approximately 323 t consisting of the NTR propulsion module ((is) approximately 138 t), the integrated saddle truss and LH2 drop tank assembly ((is) approximately 123 t), and the 6-crew payload element ((is) approximately 62 t). The later includes a multi-mission Space Excursion Vehicle (MMSEV) used for close-up examination and sample gathering. The total burn time and required restarts on the three 25 klbf 'Pewee-class' engines operating at Isp (is) approximately 906 s, are approximately 76.2 minutes and 4, respectively, well below the 2 hours and 27 restarts demonstrated on the NERVA eXperimental Engine, the NRX-XE. The paper examines the benefits, requirements and characteristics of using NTP for the above NEA missions. The impacts on vehicle design of HLV payload volume and lift capability, crew size, and reusability are also quantified.

Borowski, Stanley↗
NASA NTRS2012

Nuclear Thermal Rocket (Ntr) Propulsion: A Proven Game-Changing Technology for Future Human Exploration Missions

The NTR represents the next evolutionary step in high performance rocket propulsion. It generates high thrust and has a specific impulse (Isp) of approx.900 seconds (s) or more V twice that of today s best chemical rockets. The technology is also proven. During the previous Rover and NERVA (Nuclear Engine for Rocket Vehicle Applications) nuclear rocket programs, 20 rocket reactors were designed, built and ground tested. These tests demonstrated: (1) a wide range of thrust; (2) high temperature carbide-based nuclear fuel; (3) sustained engine operation; (4) accumulated lifetime; and (5) restart capability V all the requirements needed for a human mission to Mars. Ceramic metal cermet fuel was also pursued, as a backup option. The NTR also has significant growth and evolution potential. Configured as a bimodal system, it can generate electrical power for the spacecraft. Adding an oxygen afterburner nozzle introduces a variable thrust and Isp capability and allows bipropellant operation. In NASA s recent Mars Design Reference Architecture (DRA) 5.0 study, the NTR was selected as the preferred propulsion option because of its proven technology, higher performance, lower launch mass, simple assembly and mission operations. In contrast to other advanced propulsion options, NTP requires no large technology scale-ups. In fact, the smallest engine tested during the Rover program V the 25,000 lbf (25 klbf) Pewee engine is sufficient for human Mars missions when used in a clustered engine arrangement. The Copernicus crewed spacecraft design developed in DRA 5.0 has significant capability and a human exploration strategy is outlined here that uses Copernicus and its key components for precursor near Earth asteroid (NEA) and Mars orbital missions prior to a Mars landing mission. Initially, the basic Copernicus vehicle can enable reusable 1-year round trip human missions to candidate NEAs like 1991 JW and Apophis in the late 2020 s to check out vehicle systems. Afterwards, the Copernicus spacecraft and its 2 key components, now configured as an Earth Return Vehicle / propellant tanker, would be used for a short round trip (approx.18 - 20 months)/short orbital stay (60 days) Mars / Phobos survey mission in 2033 using a split mission approach. The paper also discusses NASA s current Foundational Technology Development activities and its pre-decisional plans for future system-level Technology Demonstrations that include ground testing a small (approx.7.5 klbf) scalable NTR before the decade is out with a flight test shortly thereafter.

Borowski, Stanley K.↗
NASA NTRS2000

One year old and growing: a status report of the International Space Station and its partners

The International Space Station (ISS), as the largest international science and engineering program in history, features unprecedented technical, cost, scheduling, managerial, and international complexity. A number of major milestones have been accomplished to date, including the construction of major elements of flight hardware, the development of operations and sustaining engineering centers, astronaut training, and eight Space Shuttle/Mir docking missions. International partner contributions and levels of participation have been baselined, and negotiations and discussions are nearing completion regarding bartering arrangements for services and new hardware. As ISS is successfully executed, it can pave the way for more inspiring cooperative achievements in the future. Published by Elsevier Science Ltd.

Spacecraft↗
NASA NTRS2002

Mission Engineering of a Rapid Cycle Spacecraft Logistics Fleet

The requirement for logistics re-supply of the International Space Station has provided a unique opportunity for engineering the implementation of NASA's first dedicated pressurized logistics carrier fleet. The NASA fleet is comprised of three Multi-Purpose Logistics Modules (MPLM) provided to NASA by the Italian Space Agency in return for operations time aboard the International Space Station. Marshall Space Flight Center was responsible for oversight of the hardware development from preliminary design through acceptance of the third flight unit, and currently manages the flight hardware sustaining engineering and mission engineering activities. The actual MPLM Mission began prior to NASA acceptance of the first flight unit in 1999 and will continue until the de-commission of the International Space Station that is planned for 20xx. Mission engineering of the MPLM program requires a broad focus on three distinct yet inter-related operations processes: pre-flight, flight operations, and post-flight turn-around. Within each primary area exist several complex subsets of distinct and inter-related activities. Pre-flight processing includes the evaluation of carrier hardware readiness for space flight. This includes integration of payload into the carrier, integration of the carrier into the launch vehicle, and integration of the carrier onto the orbital platform. Flight operations include the actual carrier operations during flight and any required real-time ground support. Post-flight processing includes de-integration of the carrier hardware from the launch vehicle, de-integration of the payload, and preparation for returning the carrier to pre-flight staging. Typical space operations are engineered around the requirements and objectives of a dedicated mission on a dedicated operational platform (i.e. Launch or Orbiting Vehicle). The MPLM, however, has expanded this envelope by requiring operations with both vehicles during flight as well as pre-launch and post-landing operations. These unique requirements combined with a success-oriented schedule of four flights within a ten-month period have provided numerous opportunities for understanding and improving operations processes. Furthermore, it has increased the knowledge base of future Payload Carrier and Launch Vehicle hardware and requirement developments. Discussion of the process flows and target areas for process improvement are provided in the subject paper. Special emphasis is also placed on supplying guidelines for hardware development. The combination of process knowledge and hardware development knowledge will provide a comprehensive overview for future vehicle developments as related to integration and transportation of payloads.

Holladay, Jon↗
NASA NTRS1999

Towards Integrated Pulse Detonation Propulsion and MHD Power

The interest in pulse detonation engines (PDE) arises primarily from the advantages that accrue from the significant combustion pressure rise that is developed in the detonation process. Conventional rocket engines, for example, must obtain all of their compression from the turbopumps, while the PDE provides additional compression in the combustor. Thus PDE's are expected to achieve higher I(sub sp) than conventional rocket engines and to require smaller turbopumps. The increase in I(sub sp) and the decrease in turbopump capacity must be traded off against each other. Additional advantages include the ability to vary thrust level by adjusting the firing rate rather than throttling the flow through injector elements. The common conclusion derived from these aggregated performance attributes is that PDEs should result in engines which are smaller, lower in cost, and lighter in weight than conventional engines. Unfortunately, the analysis of PDEs is highly complex due to their unsteady operation and non-ideal processes. Although the feasibility of the basic PDE concept has been proven in several experimental and theoretical efforts, the implied performance improvements have yet to be convincingly demonstrated. Also, there are certain developmental issues affecting the practical application of pulse detonation propulsion systems which are yet to be fully resolved. Practical detonation combustion engines, for example, require a repetitive cycle of charge induction, mixing, initiation/propagation of the detonation wave, and expulsion/scavenging of the combustion product gases. Clearly, the performance and power density of such a device depends upon the maximum rate at which this cycle can be successfully implemented. In addition, the electrical energy required for direct detonation initiation can be significant, and a means for direct electrical power production is needed to achieve self-sustained engine operation. This work addresses the technological issues associated with PDEs for integrated aerospace propulsion and MHD power. An effort is made to estimate the energy requirements for direct detonation initiation of potential fuel/oxidizer mixtures and to determine the electrical power requirements. This requirement is evaluated in terms of the possibility for MHD power generation using the combustion detonation wave. Small scale laboratory experiments were conducted using stoichiometric mixtures of acetylene and oxygen with an atomized spray of cesium hydroxide dissolved in alcohol as an ionization seed in the active MHD region. Time resolved thrust and MHD power generation measurements were performed. These results show that PDEs yield higher I(sub sp) levels than a comparable rocket engine and that MHD power generation is viable candidate for achieving self-excited engine operation.

Litchford, Ron J.↗
NASA NTRSDate not supplied

Recent Activities of the Marshall Space Flight Center Natural Environments Branch Terrestrial & Planetary Environments Team

- The Natural Environments (NE) Branch is within the MSFC Engineering Directorate’s Spacecraft and Vehicle System (S&VS) Department - S&VS plans, performs and directs the technical Design, Analysis, Test, Evaluation, Verification, Integration, and Applied Research and Development of future Spacecraft and Launch Vehicle Systems - Current programs we support - Space Launch System, Human Landing System, Mars Ascent Vehicle, Orion, Gateway - NE maintains expertise in terrestrial, space, and planetary natural environments definition, characterization, and analysis - Responsibility to disseminate this expertise to Agency programs and projects in support of environment definition, requirements development, vehicle development, operations, and sustaining engineering through program’s life cycle - Branch has two teams; Terrestrial and Planetary Environments (T&PE) and Space Environments (SE) - T&PE has extensive expertise characterizing terrestrial surface and atmospheric (aloft) environments - Winds, temperature, humidity, pressure, lightning, density, precipitation, radiant energy, aerosols, sea state, sea surface temperature - Maintains climatological databases for engineering analyses

Ryan K. Decker↗
DOE OSTI2024

Enhanced joining strength in additive-manufactured polylactic-acid structures fused by embedded heated metallic meshes

Additively manufactured thermoplastic polymers, such as polylactic acid (PLA), hold significant promise for sustainable engineering structures, including wind turbine blades. Upscaling these structures beyond the limitations of 3D printer build volumes is a challenge; fusion joining presents a potential solution. This paper introduces a displacement-controlled resistance welding process for PLA, as an alternative to the typical force-controlled methods. Here, we investigated the bonding quality of resistance-welded and adhesive-bonded PLA beams through three-point bending and measured the surface deformations using digital image correlation. Different metal meshes (30%/0.11 mm Ni—Cu, 34%/0.07 mm Ni—Cu, and 36%/0.25 mm Co—Ni) served as heating elements. The process parameters were varied for the 34%/0.07 mm Ni—Cu mesh to identify an optimum set of parameters. Results showed that this optimized displacement-controlled welding achieved 94% of the original strength of monolithic samples. This indicates that the new welding process not only ensures high-quality bonding and fine surface finishing but also promotes sustainability, recyclability, and economic efficiency in various polymer and composite structural applications.

Additive manufacturing↗