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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 397 records · Page 22

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NASA NTRS1992

Extraterrestrial applications of solar optics for interior illumination

Solar optics is a terrestrial technology that has potential extraterrestrial applications. Active solar optics (ASO) and passive solar optics (PSO) are two approaches to the transmission of sunlight to remote interior spaces. Active solar optics is most appropriate for task illumination, while PSO is most appropriate for general illumination. Research into solar optics, motivated by energy conservation, has produced lightweight and low-cost materials, products that have applications to NASA's Controlled Ecological Life Support System (CELSS) program and its lunar base studies. Specifically, prism light guides have great potential in these contexts. Several applications of solar optics to lunar base concepts are illustrated.

Eijadi, David A.↗

NASA NTRS2001

Manufacturing Challenges Implementing Material Changes for the Super Light Weight External Tank: A Welding Process Perspective

A viewgraph presentation gives an overview of the manufacturing challenges in implementing welding material changes for the super lightweight external tank. Details are given on the external tank configuration, the weld purging equipment used, planning the selection of weld filler wire alloy, the initial weld microstructure, the wide panel tensile testing, and the dome cap welding.

Lawless, K.↗

NASA NTRS2003

Integrated Propulsion/Vehicle System Structurally Optimized

Ongoing research and testing are essential in the development of air-breathing hypersonic propulsion technology, and this year some positive advancement was made at the NASA Glenn Research Center. Recent work performed for GTX, a rocket-based combined-cycle, single-stage-to-orbit concept, included structural assessments of both the engine and flight vehicle. In the development of air-breathing engine technology, it is impractical to design and optimize components apart from the fully integrated system because tradeoffs must be made between performance and structural capability. Efforts were made to control the flight trajectory, for example, to minimize the aerodynamic heating effects. Structural optimization was applied to evaluate concept feasibility and was instrumental in the determination of the gross liftoff weight of the integrated system. Achieving low Earth orbit with even a small payload requires an aggressive approach to weight minimization through the use of lightweight, oxidation-resistant composite materials. Assessing the integrated system involved investigating the flight trajectory to determine where the critical load events occur in flight and then generating the corresponding environment at each of these events. Structural evaluation requires the mapping of the critical flight loads to finite element models, including the combined effects of aerodynamic, inertial, combustion, and other loads. NASA s APAS code was used to generate aerodynamic pressure and temperature profiles at each critical event. The radiation equilibrium surface temperatures from APAS were used to predict temperatures through the thickness. Heat transfer solutions using NASA's MINIVER code and the SINDA code (Cullimore & Ring Technologies, Littleton, CO) were calculated at selective points external to the integrated vehicle system and then extrapolated over the entire exposed surface. FORTRAN codes were written to expedite the finite element mapping of the aerodynamic heating effects for the internal structure.

Hunter, James E.↗

NASA NTRS2006

Flexible Fabrics with High Thermal Conductivity for Advanced Spacesuits

This paper describes the effort and accomplishments for developing flexible fabrics with high thermal conductivity (FFHTC) for spacesuits to improve thermal performance, lower weight and reduce complexity. Commercial and additional space exploration applications that require substantial performance enhancements in removal and transport of heat away from equipment as well as from the human body can benefit from this technology. Improvements in thermal conductivity were achieved through the use of modified polymers containing thermally conductive additives. The objective of the FFHTC effort is to significantly improve the thermal conductivity of the liquid cooled ventilation garment by improving the thermal conductivity of the subcomponents (i.e., fabric and plastic tubes). This paper presents the initial system modeling studies, including a detailed liquid cooling garment model incorporated into the Wissler human thermal regulatory model, to quantify the necessary improvements in thermal conductivity and garment geometries needed to affect system performance. In addition, preliminary results of thermal conductivity improvements of the polymer components of the liquid cooled ventilation garment are presented. By improving thermal garment performance, major technology drivers will be addressed for lightweight, high thermal conductivity, flexible materials for spacesuits that are strategic technical challenges of the Exploration

Trevino, Luis A.↗

NASA NTRS2011

Development of Passive Fuel Cell Thermal Management Technology

The NASA Glenn Research Center is developing advanced passive thermal management technology to reduce the mass and improve the reliability of space fuel cell systems for the NASA exploration program. The passive thermal management system relies on heat conduction within the cooling plate to move the heat from the central portion of the cell stack out to the edges of the fuel cell stack rather than using a pumped loop cooling system to convectively remove the heat. Using the passive approach eliminates the need for a coolant pump and other cooling loop components which reduces fuel cell system mass and improves overall system reliability. Previous analysis had identified that low density, ultra-high thermal conductivity materials would be needed for the cooling plates in order to achieve the desired reductions in mass and the highly uniform thermal heat sink for each cell within a fuel cell stack. A pyrolytic graphite material was identified and fabricated into a thin plate using different methods. Also a development project with Thermacore, Inc. resulted in a planar heat pipe. Thermal conductivity tests were done using these materials. The results indicated that lightweight passive fuel cell cooling is feasible.

Burke, Kenneth A.↗

NASA NTRS2014

PRSEUS Structural Concept Development

A lighter, more robust airframe is one of the key technological advancements necessary for the successful launch of any large next-generation transport aircraft. Such a premise dictates that considerable improvements beyond current state-of-the-art aluminum structures is needed, and that improvements of this magnitude will require an extensive use of composite materials that are not only lightweight, but also economical to produce. To address this challenge, researchers at NASA and The Boeing Company are developing a novel structural concept called the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) under the Environmentally Responsible Aviation (ERA) Project. It is an integrally stiffened panel concept that is stitched together and designed to maintain residual load-carrying capabilities under a variety of damage scenarios. In addition to improved structural performance, an important facet of this unique arrangement of stitched carbon fibers is its innovative manufacturing method that has the potential to lower fabrication costs by eliminating fasteners and autoclave cures. The rationale and development status for this new approach forms the basis of the work described in this paper. The test specimens described herein were fabricated, or are currently being fabricated, by The Boeing Company, while the structural analyses and testing tasks are being performed by NASA and Boeing personnel.

Velicki, Alex↗

NASA NTRS2015

Method for Producing Launch/Landing Pads and Structures Project

Current plans for deep space exploration include building landing-launch pads capable of withstanding the rocket blast of much larger spacecraft that that of the Apollo days. The proposed concept will develop lightweight launch and landing pad materials from in-situ materials, utilizing regolith to produce controllable porous cast metallic foam brickstiles shapes. These shapes can be utilized to lay a landing launch platform, as a construction material or as more complex parts of mechanical assemblies.

Technology Portfolio System↗

NASA NTRS2017

Hybrid Gear Performance Under Loss-of-Lubrication Conditions

Hybrid composite gear technology is being investigated to increase power density in rotorcraft drive systems. These gears differ from conventional steel gears in that the structural web material is replaced with a lightweight carbon fiber composite. Past studies have focused on performance of this technology under normal operating conditions, however, for this technology to be viable it must also withstand adverse conditions. The study presented here evaluates the performance of hybrid gears under loss-of-lubrication conditions in NASA Glenn Research Centers Contact Fatigue Test Facility. Two experiments are presented using small-scale 3.5 inch (8.9 cm) pitch diameter hybrid gears and compared to a baseline steel gear pair. Results of these tests show that there are limitations to the use of a hexagonal interlock pattern between the steel and composite. There is also evidence that the presence of polymer in the gear during an oil out event has a potential to increase time to failure. Further studies are planned to expand on these initial findings.

Gearbox↗

NASA NTRS2017

Hybrid Gear Performance Under Loss-of-Lubrication Conditions

Gearbox↗

NASA NTRS2019

High-Resolution, Lightweight, and Low-cost X-Ray Optics for the Lynx Observatory

We describe an approach to build an x-ray mirror assembly that can meet Lynx’s requirements of high-angular resolution, large effective area, light weight, short production schedule, and low-production cost. Adopting a modular hierarchy, the assembly is composed of 37,492 mirror segments, each of which measures ∼100 mm × 100 mm × 0.5 mm. These segments are integrated into 611 modules, which are individually tested and qualified to meet both science performance and spaceflight environment requirements before they in turn are integrated into 12 metashells. The 12 metashells are then integrated to form the mirror assembly. This approach combines the latest precision polishing technology and the monocrystalline silicon material to fabricate the thin and lightweight mirror segments. Because of the use of commercially available equipment and material and because of its highly modular and hierarchical building-up process, this approach is highly amenable to automation and mass production to maximize production throughput and to minimize production schedule and cost. As of fall 2018, the basic elements of this approach, including substrate fabrication, coating, alignment, and bonding, have been validated by the successful building and testing of single-pair mirror modules. In the next few years, the many steps of the approach will be refined and perfected by repeatedly building and testing mirror modules containing progressively more mirror segments to fully meet science performance, spaceflight environments, as well as programmatic requirements of the Lynx mission and other proposed missions, such as AXIS.

Zhang, William W.↗

NASA NTRS1960

VII. Some structual and materials considerations for manned military aircraft

The design of lightweight, efficient structures is one of the fundamental requirements for achievement of high performance in military aircraft. In this paper some of the structural and materials considerations that are important to the strength, weight, and integrity of aircraft structures are reviewed. A comparison of some structural materials is made on the basis of weight-strength and tear resistance. In the area of structural design, the relative weights of several types of construction that are of current interest are reviewed and the influence of different materials and the effects of the related temperatures on structural weight are indicated. Lastly, other factors that are of importance in structural design of future aircraft are discussed. These include strength under nonuniform temperatures, creep, sonic fatigue, and panel flutter.

Structural material↗

NASA NTRS1975

On development of an inexpensive, lightweight thermal micrometeroid garment for space suits

A lightweight and inexpensive coverlayer developed for space suits is described. Material selection, procurement, and testing, pattern design, and prototype fabrication are discussed. By using the minimum required cross section necessary for earth orbital mission, by utilizing the lightest weight materials possible, and by decreasing the use of weight costly taping a lightweight and economical thermal micrometeroid garment was developed. Simplification of manufacturing techniques and use of off-the-shelf materials helped to reduce costs.

Source record↗

NASA NTRS2017

Modeling the Extremely Lightweight Zerodur Mirror (ELZM) Thermal Soak Test

Exoplanet science requires extreme wavefront stability (10 pm change/10 minutes), so every source of wavefront error (WFE) must be characterized in detail. This work illustrates the testing and characterization process that will be used to determine how much surface figure error (SFE) is produced by mirror substrate materials' CTE distributions. Schott's extremely lightweight Zerodur mirror (ELZM) was polished to a sphere, mounted, and tested at Marshall Space Flight Center (MSFC) in the X-Ray and Cryogenic Test Facility (XRCF). The test transitioned the mirror's temperature from an isothermal state at 292K to isothermal states at 275K, 250K and 230K to isolate the effects of the mirror's CTE distribution. The SFE was measured interferometrically at each temperature state and finite element analysis (FEA) has been completed to assess the predictability of the change in the mirror's surface due to a change in the mirror's temperature. The coefficient of thermal expansion (CTE) distribution in the ELZM is unknown, so the analysis has been correlated to the test data. The correlation process requires finding the sensitivity of SFE to a given CTE distribution in the mirror. A novel hand calculation is proposed to use these sensitivities to estimate thermally induced SFE. The correlation process was successful and is documented in this paper. The CTE map that produces the measured SFE is in line with the measured data of typical boules of Schott's Zerodur glass.

Brooks, Thomas E.↗

NASA NTRS1983

Metal matrix composite structural panel construction

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

Mcwithey, R. R.↗

NASA NTRS2016

NIAC Phase I Study Final Report on Large Ultra-Lightweight Photonic Muscle Space Structures

The research goal is to develop new tools support NASA's mission of understanding of the Cosmos by developing cost effective solutions that yield a leap in performance and science data. 'Maikalani' in Hawaiian translates to, "knowledge we gain from the cosmos." Missions like Hubble have fundamentally changed humanity's view of the cosmos. Last year's Nobel prize in physics was a result of astronomical discoveries. $9B class JWST size (6.5 meter diameter) space telescopes, when launched are anticipated to rewrite our knowledge of physics. Here we report on a neoteric meta-material telescope mirror technology designed to enable a factor of 100 or more reduction in areal density, a factor of 100 reduction in telescope production and launch costs as well as other advantages; a leap to enable missions to image the cosmos in unprecedented detail, with the associated gain in knowledge. Whether terahertz, visible or X-ray, reflectors used for high quality electromagnetic imaging require shape accuracy (surface figure) to far better than 1 wavelength (lambda) of the incident photons, more typically lambda/10 or better. Imaging visible light therefore requires mirror surfaces that approximate a desired curve (e.g. a sphere or paraboloid) with smooth shape deviation of th less than approximately 1/1000 the diameter of a human hair. This requires either thick high modulus material like glass or metal, or actuators to control mirror shape. During Phase I our team studied a novel solution to this systems level design mass/shape tradespace requirement both to advance the innovative space technology concept and also to help NASA and other agencies meet current operational and future mission requirements. Extreme and revolutionary NASA imaging missions such as Terrestrial Planet Imager (TPI) require lightweight mirrors with minimum diameters of 20 to 40 meters. For reference, NASA's great achievement; the Hubble space telescope, is only 2.4 meters in diameter. What is required is a way to make large inexpensive deployable mirrors where the cost is measured in millions, not billions like current efforts. For example we seek an interim goal within 10 years of a Hubble size (2.4m) primary mirror weighing 1 pound at a cost of 10K in materials. Described here is a technology using thin ultra lightweight materials where shape can be controlled simply with a beam of light, allowing imaging with incredibly low mass yet precisely shaped mirrors. These " Photonic Muscle" substrates will eventually make precision control of giant s p a c e apertures (mirrors) possible. OCCAM substrates make precision control of giant ultra light-weight mirror apertures possible. This technology is posed to create a revolution in remote sensing by making large ultra lightweight space telescopes a fiscal and material reality over the next decade.

Cosmos↗

NASA NTRS2017

Relationship of Cure Temperature to Mechanical, Physical, and Dielectric Performance of PDMS Glass Composite for Electric Motor Insulation

Achieving NASAs aggressive fuel burn and emission reduction for N-plus-3 aircraft will require hybrid electric propulsion system in which electric motors driven by either power generated from turbine or energy storage system will power the fan for propulsion. Motors designed for hybrid electric aircraft are expected to operate at medium to high voltages over long durations in a high altitude service environment. Such conditions have driven research toward the development of wire insulation with improved mechanical strength, thermal stability and increased breakdown voltage. The silicone class of materials has been considered for electric wire insulation due to its inherent thermal stability, dielectric strength and mechanical integrity. This paper evaluates the dependence of these properties on the cure conditions of a polydimethyl-siloxane (PDMS) elastomer; where both cure temperature and base-to-catalyst ratio were varied. The PDMS elastomer was evaluated as a bulk material and an impregnation matrix within a lightweight glass veil support. The E-glass support was selected for mechanical stiffness and dielectric strength. This work has shown a correlation between cure conditions and material physical properties. Tensile strength increased with cure temperature whereas breakdown voltage tended to be independent of process variations. The results will be used to direct material formulation based on specific insulation requirements.

insulation↗

NASA NTRS1976

Lightweight orthotic appliances

Graphite-filament reinforced polymer materials are used in applications requiring high tensile strength and modulus. Superior properties of graphite composite materials permit fabrication of supports that are considerably lighter, thinner, and stiffer than conventional components.

Baucom, R. M.↗

NASA NTRS2003

Impact Resistance of Lightweight Hybrid Structures for Gas Turbine Engine Fan Containment Applications

The ballistic impact resistance of hybrid composite sandwich structures was evaluated with the ultimate goal of developing new materials or structures for potential gas turbine engine fan containment applications. The sandwich structures investigated consisted of GLARE-5 laminates as face sheets with lightweight cellular metallic materials such as honeycomb, foam, and lattice block as a core material. The impact resistance of these hybrid sandwich structures was compared to GLARE-5 laminates and 2024-T3 Al sheet, which were tested as a function of areal weight (material thickness). The GLARE-5 laminates exhibited comparable impact properties to that of 2024-T3 Al at low areal weights, even though there were significant differences in the static tensile properties of these materials. The GLARE-5, however, did have a greater ballistic limit than straight aluminum sheet at higher areal weights. Furthermore, there is up to a 25% advantage in ballistic limit for the GLARE-5/foam sandwich structures compared to straight 2024-T3 Al. But no advantage in ballistic limit was observed between any of the hybrid sandwich structures and thicker versions of GLARE-5. Recommendations for future work are provided, based on these preliminary data.

Hebsur, Mohan G.↗