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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 NTRSDate not supplied

Maturation of Additive Manufactured Aerospace Alloys and Development of Mechanical and Thermophysical Properties for Space Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts have focused on the understanding of AM processes through design optimization, component fabrication, material characterization, testing, standards development, and infusion into propulsion development for flight applications. NASA and partners have matured commonly used aerospace alloys from various alloy families (Nickel, Steel, Iron, Aluminum, and Titanium) and AM processes. An extensive effort has been ongoing between NASA, industry partners, and academia to complete detailed AM process and heat treatment characterization, in addition to generating temperature-dependent mechanical and thermophysical properties. This presentation highlights the characterization and property results using laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes among various alloys. In addition to commonly used alloys, there is a need for ongoing AM optimized alloys using integrated computational materials engineering (ICME) and process development for high performance applications. The applications targeted are launch vehicles, liquid rocket engines, advanced propulsion systems, advanced power systems, and in-space propulsion with high heat fluxes, high pressure, and that utilize propellants such as hydrogen, which can degrade alloys. This presentation will also discuss some of the ongoing novel alloy development and maturation using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, and C-103. The results from these processes have demonstrated that AM can enable rapid development and new AM optimized alloys can yield higher performance. These alloys have undergone modeling, fundamental metallurgical evaluations, heat treatment studies, and microstructure characterization and mechanical testing campaigns. This, combined with direct application-specific component fabrication and hot-fire testing, can enable the increase of the Technology Readiness Level (TRL) through high duty-cycle testing. This presentation provides a background and overview of these various common and AM-enabled alloys and processing developments including the initial effort related to metallurgical, mechanical, and thermophysical property studies. It also covers the latest advancement in the parallel component development, hot-fire testing, and future developments for these alloys.

Additive Manufacturing↗
NASA NTRSDate not supplied

Novel Test and Analysis Methodology for the Assessment of Joint under Re-entry Environment

Spacecraft thermal protection systems require unique approaches for design verification due to the extreme environments seen during space travel and atmospheric re-entry. In this work, unique considerations for design, analysis, and verification of a tiled heatshield design with material nonlinearity, material property temperature-dependency, material property rate-dependency, and geometric stress concentrations are presented. Such designs require a thorough application of the building block approach to derive appropriate material property datasets, and a novel application of analysis models to aid in the structural verification with testing. The custom application of material rate-dependency in finite element analysis software is presented as a means of leveraging the rate-dependent test data for the material property dataset. Because bonded tile heatshields contain so many design considerations and nonlinearities which often preclude the ability to easily achieve the requisite test factors in qualification testing, a novel sub-element test was developed that amplifies the stress singularity beyond flight conditions. The test achieves an over-test over flight stress conditions. The approach for sub-element coupon design can be extended to other bonded joint designs and can be used in aiding a qualification program.

Pavel Babuska↗
NASA NTRS2023

Temperature Effect on Silicate Melt-Sulfide-Metal Trace Element Partitioning in the Presence of Sulfur Under Reduced Conditions

The reduced nature of Mercury, enstatite chondrites, and the aubrite parent bodies (APB) have raised many questions regarding the geochemical behavior of typically lithophile, heat-producing, and rare-earth elements (REE) in magmas at low oxygen fugacity (fO2). Due to decreasing O availability at these low fO2, and an abundance of S(sup 2(-)), sulfur (S) acts as an important anion that changes the partitioning behavior of many elements and modifies the physical properties of silicate melts. Preliminary observations suggest that major and minor elements exhibit different geochemical affinities in highly reduced, S-rich systems compared to terrestrial rocks. The speciation and bonding environment of S, dictated by P/T/fO2 conditions, may strongly influence the degree to which S affects partitioning behavior. Here we investigate the partitioning behavior of major, minor, and trace elements between silicate melt, sulfide melt, and metal as well as the coordination chemistry of S in highly reduced silicate melts. Our work is focused on investigating solely the entropy-dependent temperature effect on partitioning of elements for which we currently have MESSENGER data (K, Na, Th, U, Si, Mg, Fe, Ti, Ca, Al, Cr, Mn, S, Cl) as well as a host of geochemically relevant trace elements such as REEs (P, Co, Ni, Mo, Ce, Nd, Sm, Eu, Gd, Dy, Yb). Previous studies in which temperature, pressure, and fO2 were co-varied found that as fO2 decreases, heat-producing elements U and Th become more chalcophile, while K becomes less chalcophile. Concurrently, nominally lithophile elements Mg and Ca become more chalcophile and were observed as minor elements in exsolved sulfides and bonded with S species in silicate melt. These studies, however, could not disentangle entropic effects from changes in the fO2. New temperature-dependent partitioning data from our work will be used to determine which elements are most likely to retain their lithophile character and hence be incorporated into silicates, and which elements are likely contained within the sulfide (chalcophile) and metal core (siderophile), setting the stage for the thermal and magmatic evolution of reduced planetary bodies.

B A Anzures↗
NASA NTRSDate not supplied

Fractionation of Iron and Titanium Isotopes By Ilmenite and the Isotopic Compositions of Lunar Magma Ocean Cumulates

Basaltic volcanism on the Moon produced low- and high-Ti mare basalt suites that are also distinct with respect to their iron, titanium, and magnesium iso- topic compositions. Here, the equilibrium fractionation of Fe and Ti isotopes between ilmenite and melt was experimentally investigated in order to evaluate the role of ilmenite in generating the isotopic compositional variability among the lunar mare basalts. Ilmenite crystallization experiments were conducted using two bulk compositions: an ilmenite-saturated basaltic andesite and an ilmenite-saturated Apollo 14 black glass, and the Fe and Ti isotopic compo- sitions of the experimental ilmenites and glass (quenched melt) were analyzed using solution MC-ICPMS after hand-picking. Additionally, Nuclear Resonant Inelastic X-ray Scattering (NRIXS) measurements on synthetic ilmenite were conducted and compared to previous NRIXS measurements on synthetic lunar glasses in order to derive temperature-dependent equilibrium ilmenite-melt Fe isotopic fractionations. Experimentally determined ilmenite-melt fractionations were then incorporated into a lunar magma ocean crystallization model that tracks the major element and isotopic compositional evolution of lunar magma ocean cumulates and residual liquid. There is good agreement between the Fe equilibrium isotopic fractionation measured by NRIXS and the laboratory equili- bration experiments, and we find that the isotopic fractionation is sensitive to il- menite compositional differences (0 vs. 10% Fe3+). Further, the light Ti isotopic composition of ilmenite relative to the melt (∆49Ti ilmenite-melt = −0.09 ± 0.03h at 1100°C) is consistent with the higher coordination of Ti in ilmenite relative to melts and results of previous studies. The modeled Ti isotopic compositions for lunar magma ocean cumulates display Ti isotopic variability sufficient to explain the low- and high-Ti mare basalt sources. However, the difference in Fe isotopic composition between the low- and high-Ti mare basalts cannot be attributed solely to ilmenite fractionation. Instead, Fe isotopic fractionation by additional products of lunar magma ocean crystallization, such as clinopy- roxene, is required to generate the inferred Fe and Mg isotopic variability in the lunar mantle. Alternatively, the Fe and Mg isotopic compositions of the lunar mare basalts may indicate Fe-Mg interdiffusion has occurred in the Ti- rich component of the mare basalt source regions via reaction between ilmenite cumulates and the olivine- and pyroxene-rich lunar mantle.

Kelsey Prissel↗
NASA NTRS2024

Exploring Standing and Reflected Slow-mode Waves in Flaring Coronal Loops: A Parametric Study Using 2.5D MHD Modeling

Abstract Recent observations of reflected propagating and standing slow-mode waves in hot flaring coronal loops have spurred our investigation into their underlying excitation and damping mechanisms. To understand these processes, we conduct 2.5D magnetohydrodynamic (MHD) simulations using an arcade active region model that includes a hot and dense loop. Our simulations allow for in-depth parametric investigations complementing and expanding our previous 3D MHD modeling results. We excite these waves using a large-amplitude, flow pulse applied at one footpoint of the loop in two distinct models as motivated by observations from the Solar Dynamics Observatory/Atmospheric Imaging Assembly (SDO/AIA). The first model (Model 1) incorporates classical compressive viscosity coefficient, while the second model (Model 2) adopts a 10-times enhanced viscosity coefficient. We obtain the following major results: (1) Our 2.5D MHD simulations reinforce previous conclusions derived from 1D and 3D MHD models that significantly enhanced viscosity is crucial for the rapid excitation of standing slow waves with damping times consistent with observations by Wang et al. (2015). (2)We uncover that nonlinearity in Model 1 delays the conversion of a reflected propagating wave into a standing wave. In contrast, Model 2 exhibits a much weak influence of nonlinearity on the excitation time of standing waves, thanks to the suppression of these effects by enhanced viscosity. (3) Our results reveal that the transverse temperature structure holds more influence on wave behavior than the density structure. In Model 1, increased loop temperature contrast significantly enhances wave trapping within the structure, mitigating the impact of temperature-dependent viscous damping. Conversely, in Model 2, the impact of temperature structure on wave behavior weakens in comparison to the effect of viscosity. (4) Model 1 displays evident nonlinear coupling to the fast and kink magnetoacoustic waves and pronounced wave leakage into the corona. Model 2 exhibits significantly weaker effects in this regard. Analyzing three observed wave events by SDO/AIA aligns with Model 2 predictions, providing further support for the substantial viscosity increase. Our 2.5D study unravels the complex interplay of wave-flow phenomena and nonlinear processes in coronal loops, extending our previous 1D modeling results to incorporate more realistic loop geometry. This provides insights into scenarios where 3D effects may be neglected, thereby enhancing our understanding of the intricate dynamics of the solar corona.

Tongjiang Wang↗
NASA NTRSDate not supplied

Thermoplastic Space Point Design (TSPD) Tall Tower Lunar Thermal Analysis

The Thermoplastics Development for Exploration Applications (TDEA) project seeks to advance NASA’s thermoplastic composites capabilities by developing structurally efficient joining solutions for large-scale space structures to support NASA’s future exploration missions. A key objective is to develop and understand advanced thermoplastic joining techniques relevant to space environments and applicable to unitized and/or reconfigurable composite structures. The TDEA project uses NASA Langley’s Tall Lunar Tower (TLT) concept as a target application for the design and development of in-space assembled thermoplastic composites. TLT is a 50-meter-tall tower constructed on the lunar surface near the south pole. The tower’s height at this location on the moon allows for extended durations of incident solar flux which can be used to generate power via photovoltaic arrays. The thermal environment present on lunar south pole represents a challenging environment for any space-based asset. This study provides an overview of the analysis techniques used to determine the temperature extremes, gradients, and timelines of a tall composite tower over a one-year duration at the Shackleton Connecting Ridge. The developed thermal model includes tower and lunar surface elements with anisotropic and temperature-dependent material properties and incorporates a solar vector orbit with time-varying solar flux. Study topics include: a comparison between the effects of simplified lunar surface topologies on thermal results, prediction of surface temperature values versus Lunar Reconnaissance Orbiter (LRO) flight data, and tower structural-thermal deformation.

Lunar↗
NASA NTRS2026

Thermoplastic Matrix Composite Design for Cryotanks Using Multiscale Modeling and Bayesian Optimization

Designing lightweight, robust cryogenic storage tanks is critical for future launch vehicles, in-space propellant storage, and hydrogen powered aircraft. This work presents a multiscale modeling and Bayesian optimization framework for the design of thermoplastic matrix composite cryotanks. Molecular dynamics simulations are first used to determine temperature-dependent constituent properties for candidate thermoplastic matrices, which are homogenized to the lamina scale using NASA’s Multiscale Analysis Tool (NASMAT). These lamina properties, in combination with laminate family generation rules, are evaluated in HyperX structural optimization software to identify stacking sequences that meet all cryogenic load requirements. A Bayesian optimization framework is applied, with HyperX in the loop (via the HyperX API) to efficiently search across material and laminate design variables, yielding an optimized cryotank configuration with significant reductions in design cycle time compared to exhaustive search approaches.

thermoplastics↗