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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
NASA NTRS1979

The promise of space processing

The long exposure to a virtually zero-gravity environment is a truly unique situation that cannot be duplicated or even approximated for any length of time on earth. The topics discussed are: (1) low gravity; (2) atmospheric effects; (3) potential advantages of materials processing in space; (4) the absence of buoyancy-driven convection; (5) the absence of hydrostatic pressure; (6) the absence of sedimentation and buoyancy; (7) containerless processing; and (8) ultrahigh vacuum processing.

Source record↗
NASA NTRS2003

Sodium Heat Pipe Module Processing For the SAFE-100 Reactor Concept

To support development and hardware-based testing of various space reactor concepts, the Early Flight Fission-Test Facility (EFF-TF) team established a specialized glove box unit with ancillary systems to handle/process alkali metals. Recently, these systems have been commissioned with sodium supporting the fill of stainless steel heat pipe modules for use with a 100 kW thermal heat pipe reactor design. As part of this effort, procedures were developed and refined to govern each segment of the process covering: fill, leak check, vacuum processing, weld closeout, and final "wet in". A series of 316 stainless steel modules, used as precursors to the actual 321 stainless steel modules, were filled with 35 +/- 1 grams of sodium using a known volume canister to control the dispensed mass. Each module was leak checked to less than10(exp -10) std cc/sec helium and vacuum conditioned at 250 C to assist in the removal of trapped gases. A welding procedure was developed to close out the fill stem preventing external gases from entering the evacuated module. Finally the completed modules were vacuum fired at 750 C allowing the sodium to fully wet the internal surface and wick structure of the heat pipe module.

Martin, James↗
NASA NTRS1980

Materials processing in space, 1980 science planning document

The scientific aspects of the Materials Processing in Space program are described with emphasis on the major categories of interest: (1) crystal growth; (2) solidification of metals, alloys, and composites; (3) fluids and chemical processes; (4) containerless processing, glasses, and refractories; (5) ultrahigh vacuum processes; and (6) bioprocessing. An index is provided for each of these areas. The possible contributions that materials science experiments in space can make to the various disciplines are summarized, and the necessity for performing experiments in space is justified. What has been learned from previous experiments relating to space processing, current investigations, and remaining issues that require resolution are discussed. Recommendations for the future direction of the program are included.

Naumann, R. J.↗
NASA NTRS1988

Commercial aspects of epitaxial thin film growth in outer space

A new concept for materials processing in space exploits the ultra vacuum component of space for thin film epitaxial growth. The unique low earth orbit space environment is expected to yield 10 to the -14th torr or better pressures, semiinfinite pumping speeds and large ultra vacuum volume (about 100 cu m) without walls. These space ultra vacuum properties promise major improvement in the quality, unique nature, and the throughput of epitaxially grown materials especially in the area of semiconductors for microelectronics use. For such thin film materials there is expected a very large value added from space ultra vacuum processing, and as a result the application of the epitaxial thin film growth technology to space could lead to major commercial efforts in space.

Ignatiev, Alex↗
NASA NTRS2023

Dry Preform Stitching Using Temporary Vacuum Consolidation

Stitched composites (composite parts stitched in a dry preform state that are infused with resin and cured to a final shape) offer a variety of benefits for modern aircraft structures. In this document one means of stitching dry fabric preforms in a state of temporary vacuum consolidation is discussed. This vacuum consolidation allows for the completion of stitching procedures while the dry preform thickness is temporarily reduced to a thickness reflective of its final cured thickness. Here, a temporary vacuum consolidation process enabling stitching of preforms of unconsolidated nominal thickness greater than the maximum allowable stitching thickness for the Integrated Structural Assembly of Advanced Composite (ISAAC) system is explored as a use case for such processes. Temporary vacuum consolidation processes may lead to simplified manufacturing processes or desirable composite material properties in the future.

Stitched Composites↗
NASA NTRS2002

Thermophysical Property Measurements in the MSFC ESL

Electrostatic Levitation (ESL) is an advanced technique for containerless processing of metals, ceramics, and semiconductors. Because no container is required, there is no contamination from reaction with a crucible, allowing processing of high temperature, highly reactive melts. The high vacuum processing environment further reduces possible contamination of the samples. Finally, there is no container to provide heterogeneous nucleation sites, so the undercooled range is also accessible for many materials. For these reasons, ESL provides a unique environment for measuring thermophysical properties of liquid materials. The properties that can be measured in ESL include density, surface tension, viscosity, electrical and thermal conductivity, specific heat, phase diagram, TTT- and CCT- curves, and other thermodynamic properties. In this paper, we present data on surface tension and viscosity, measured by the oscillating drop technique, and density, measured by an automated photographic technique, measured in the ESL at NASA Marshall Space Flight Center.

Hyers, R. W.↗
NASA NTRSDate not supplied

Anti-Fog Coatings For Spacesuit Helmets

A permanent and robust anti-fog coating was developed that is applied to the interior of polycarbonate spacesuit helmets. The coating is a mechanically resilient and permanent superhydrophilic (SHPL) layer produced by a two-step process consisting of a plasma processing pre-etch followed by the deposition of an optically transparent Diamond Like Carbon (DLC) coating to achieve an anti-fog, SHPL-DLC layer with Water Contact Angle (WCA) < 10°. The all-dry vacuum process consists of an oxygen plasma etching to engineer the surface of the polycarbonate, creating a well-controlled nanotextured morphology, which is key to the superhydrophilic properties, followed by vacuum deposited Plasma Enhanced Chemical Vapor Deposition (PECVD) DLC coating with high surface energy. The process is carried out at low temperatures compatible with polycarbonate materials and the two steps are performed back-to-back without breaking vacuum between steps. The process is readily scalable and compatible with large scale production volumes. The SHPL-DLC coating was tested for > 200 hours exposure using a breath simulator with no detrimental effect on the coating performance. The coating was also tested for exposure to cleaning fluids, IPA chemical exposure, adhesion testing per ASTM D3359, and abrasion resistance per MIL-E-12397 with no detrimental effects.

Spacesuit↗
NASA NTRS1983

Investigation of test methods, material properties and processes for solar cell encapsulants

The goal of the program is to identify, test, evaluate and recommend encapsulation materials and processes for the fabrication of cost-effective and long life solar modules. Of the $18 (1948 $) per square meter allocated for the encapsulation components approximately 50% of the cost ($9/sq m) may be taken by the load bearing component. Due to the proportionally high cost of this element, lower costing materials were investigated. Wood based products were found to be the lowest costing structural materials for module construction, however, they require protection from rainwater and humidity in order to acquire dimensional stability. The cost of a wood product based substrate must, therefore, include raw material costs plus the cost of additional processing to impart hygroscopic inertness. This protection is provided by a two step, or split process in which a flexible laminate containing the cell string is prepared, first in a vacuum process and then adhesively attached with a back cover film to the hardboard in a subsequent step.

Willis, P. B.↗
NASA NTRS1973

Evaluation of load-life relation with ball bearings at 500 F

A survey of the literature suggests that a stress-life exponent of approximately 12 is typical of vacuum-processed steels for ball bearings rather than the exponent of 9 which has been generally accepted by the bearing industry and bearing users. Tests run with vacuum-degassed AISI 52100 balls in the five-ball fatigue tester at four maximum Hertz stress levels in the range from 650,000 to 875,000 psi showed good agreement with the literature. However, tests run with consumable-electrode vacuum melted AISI M-50 steel angular-contact ball bearings at 500 F at three thrust loads did not show significant deviation from the accepted ninth power stress-life relation.

Parker, R. J.↗
NASA NTRS1973

Evaluation of load-life relation with ball bearings at 500 deg F

A survey of the literature suggests that a stress-life exponent of approximately 12 is typical of vacuum-processed steels for ball bearings rather than the exponent of 9 which has been generally accepted by the bearing industry and bearing users. Tests run with vacuum-degassed AISI 52100 balls in the five-ball fatigue tester at four maximum Hertz stress levels in the range from 650000 to 875000 psi showed good agreement with the literature. However, tests run with consumable-electrode vacuum melted AISI M-50 steel angular-contact ball bearings at 500 deg F at three thrust loads did not show significant deviation from the accepted ninth power stress-life relation.

Parker, R. J.↗
NASA NTRS2012

Sealing Materials for Use in Vacuum at High Temperatures

Sealing materials that can be applied and left in place in vacuum over a wide range of temperatures (especially temperatures of a few thousand degrees Celsius) have been conceived and investigated for potential utility in repairing thermal-protection tiles on the space shuttles in orbit before returning to Earth. These materials are also adaptable to numerous terrestrial applications that involve vacuum processing and/or repair of structures that must withstand high temperatures. These materials can be formulated to have mechanical handling characteristics ranging from almost freely flowing liquid-like consistency through paste-like consistency to stiff puttylike consistency, and to retain these characteristics in vacuum until heated to high curing temperatures. A sealing material of this type can be formulated to be used in any of several different ways for example, to be impregnated into a high-temperature-fabric patch, impregnated into a high-temperature-fabric gasket for sealing a patch, applied under a patch, or applied alone in the manner of putty or wallboard compound. The sealing material must be formulated to be compatible with, and adhere to, the structural material(s) to be repaired. In general, the material consists of a vacuum-compatible liquid containing one or more dissolved compound(s) and/or mixed with suspended solid particles. Depending on the intended application, the liquid can be chosen to be of a compound that can remain in place in vacuum for a time long enough to be useful, and/or to evaporate or decompose in a controlled way to leave a useful solid residue behind. The evaporation rate is determined by proper choice of vapor pressure, application of heat, and/or application of ultraviolet light or other optical radiation. The liquid chosen for the original space shuttle application is a commercial silicone vacuum-pump oil.

Pettit, Donald R.↗
NASA NTRS2012

Rolling Bearing Steels - A Technical and Historical Perspective

Starting about 1920 it becomes easier to track the growth of bearing materials technology. Until 1955, with few exceptions, comparatively little progress was made in this area. AISI 52100 and some carburizing grades (AISI 4320, AISI 9310) were adequate for most applications. The catalyst to quantum advances in high-performance rolling-element bearing steels was the advent of the aircraft gas turbine engine. With improved bearing manufacturing and steel processing together with advanced lubrication technology, the potential improvements in bearing life can be as much as 80 times that attainable in the late 1950s or as much as 400 times that attainable in 1940. This paper summarizes the chemical, metallurgical and physical aspects of bearing steels and their effect on rolling bearing life and reliability. The single most important variable that has significantly increased bearing life and reliability is vacuum processing of bearing steel. Differences between through hardened, case carburized and corrosion resistant steels are discussed. The interrelation of alloy elements and carbides and their effect on bearing life are presented. An equation relating bearing life, steel hardness and temperature is given. Life factors for various steels are suggested and discussed. A relation between compressive residual stress and bearing life is presented. The effects of retained austenite and grain size are discussed.

Zaretsky, Erwin V.↗
NASA NTRS2011

Automated Cryocooler Monitor and Control System

A system was designed to automate cryogenically cooled low-noise amplifier systems used in the NASA Deep Space Network. It automates the entire operation of the system including cool-down, warm-up, and performance monitoring. The system is based on a single-board computer with custom software and hardware to monitor and control the cryogenic operation of the system. The system provides local display and control, and can be operated remotely via a Web interface. The system controller is based on a commercial single-board computer with onboard data acquisition capability. The commercial hardware includes a microprocessor, an LCD (liquid crystal display), seven LED (light emitting diode) displays, a seven-key keypad, an Ethernet interface, 40 digital I/O (input/output) ports, 11 A/D (analog to digital) inputs, four D/A (digital to analog) outputs, and an external relay board to control the high-current devices. The temperature sensors used are commercial silicon diode devices that provide a non-linear voltage output proportional to temperature. The devices are excited with a 10-microamp bias current. The system is capable of monitoring and displaying three temperatures. The vacuum sensors are commercial thermistor devices. The output of the sensors is a non-linear voltage proportional to vacuum pressure in the 1-Torr to 1-millitorr range. Two sensors are used. One measures the vacuum pressure in the cryocooler and the other the pressure at the input to the vacuum pump. The helium pressure sensor is a commercial device that provides a linear voltage output from 1 to 5 volts, corresponding to a gas pressure from 0 to 3.5 MPa (approx. = 500 psig). Control of the vacuum process is accomplished with a commercial electrically operated solenoid valve. A commercial motor starter is used to control the input power of the compressor. The warm-up heaters are commercial power resistors sized to provide the appropriate power for the thermal mass of the particular system, and typically provide 50 watts of heat. There are four basic operating modes. "Cool " mode commands the system to cool to normal operating temperature. "Heat " mode is used to warm the device to a set temperature near room temperature. "Pump " mode is a maintenance function that allows the vacuum system to be operated alone to remove accumulated contaminants from the vacuum area. In "Off " mode, no power is applied to the system.

Britcliffe, Michael J.↗
NASA NTRS2006

System for Continuous Deaeration of Hydraulic Oil

A system for continuous, rapid deaeration of hydraulic oil has been built to replace a prior system that effected deaeration more slowly in a cyclic pressure/ vacuum process. Such systems are needed because (1) hydraulic oil has an affinity for air, typically containing between 10 and 15 volume percent of air and (2) in the original application for which these systems were built, there is a requirement to keep the proportion of dissolved air below 1 volume percent because a greater proportion can lead to pump cavitation and excessive softness in hydraulic-actuator force-versus-displacement characteristics. In addition to overcoming several deficiencies of the prior deaeration system, the present system removes water from the oil. The system (see figure) includes a pump that continuously circulates oil at a rate of 10 gal/min (38 L/min) between an 80-gal (303-L) airless reservoir and a tank containing a vacuum. When the circulation pump is started, oil is pumped, at a pressure of 120 psi (827 kPa), through a venturi tube below the tank with a connection to a stand-pipe in the tank. This action draws oil out of the tank via the standpipe. At the same time, oil is sprayed into the tank in a fine mist, thereby exposing a large amount of oil to the vacuum. When the oil level in the tank falls below the lower of two level switches, a vacuum pump is started, drawing a hard vacuum on the tank through a trap that collects any oil and water entrained in the airflow. When the oil level rises above higher of the two level switches or when the system is shut down, a solenoid valve between the tank and the vacuum pump is closed to prevent suction of oil into the vacuum pump. Critical requirements that the system is designed to satisfy include the following: 1) The circulation pump must have sufficient volume and pressure to operate the venturi tube and spray nozzles. 2) The venturi tube must be sized to empty the tank (except for the oil retained by the standpipe) and maintain a vacuum against the vacuum pump. 3) The tank must be strong enough to withstand atmospheric pressure against the vacuum inside and must have sufficient volume to enable exposure of a sufficiently large amount of sprayed oil to the vacuum. 4) The spray nozzles must be sized to atomize the oil and to ensure that the rate of flow of sprayed oil does not exceed the rate at which the venturi action can empty the tank. 5) The vacuum pump must produce a hard vacuum against the venturi tube and continue to work when it ingests some oil and water. 6) Fittings must be made vacuum tight (by use of O-rings) to prevent leakage of air into the system. The system is fully automatic, and can be allowed to remain in operation with very little monitoring. It is capable of reducing the air content of the oil from 11 to less than 1 volume percent in about 4 hours and to keep the water content below 100 parts per million.

Anderson, Christopher W.↗
NASA NTRS1972

Reevaluation of the stress-life relation in rolling-element bearings

Four groups of 12.7 millimeter diameter vacuum-degassed AISI 52100 balls were tested, each at a maximum Hertz stress in the range of 4.5 times 10 to 9th power to 6.0 times 10 to 9th power N/m2. Tests were run in the five-ball fatigue tester at a contact angle of 30 deg and a shaft speed of 10,000 rpm. The 10 percent fatigue lives at the four stress levels indicated that fatigue life is inversely proportional to maximum Hertz stress raised to the power of 12. This result agrees with a survey of the literature which suggests that a stress-life exponent of approximately 12 is typical of vacuum-processed bearing steels rather than the exponent of 9 which has been generally accepted by the bearing industry.

Parker, R. J.↗