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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 469 records · Page 26
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Synthesis Methods for Nanoparticle Morphology Control in Energy Applications

Lightweight nano-composite materials, nano-coatings, nanocatalysts, nano-structured materials have demonstrated an ability to reduce emissions and maximize clean energy production. Nanoparticles play an important role in engineering and decarbonization for energy applications, and a wide range of nanoparticle synthesis methods have been developed to include those that enable control over particle morphology. The ability to control nanoparticle morphology allows the tailoring and improvement of material properties that will accelerate efforts towards lowering carbon emissions by developing advanced catalysts for carbon sequestration and will enhance energy efficient processes and technologies. Synthesis methods aimed towards shape control of nanoparticles have demonstrated an ability to form spheres, rods, flower-like shapes, cubes, plates, shells, and chiral geometries. Processing methods used to form these morphologies include microwave assisted synthesis, solvothermal, hydrothermal, and a wide range of capping agents. A discussion of a few of these methods is given along with results and applications.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Process Development of the Vaporizing Foil Actuator Welding Technique

The industrial focus on continuous improvement for products is leading design engineers to consider multi-material design concepts more frequently. The design concepts use the advantages of each material while simultaneously minimizing the drawbacks. It also allows for the overall weight of the products to be reduced. Some traditional joining methods, though, struggle to join dissimilar material combinations. A technique known as vaporizing foil actuator welding, which was developed around ten years ago, is a solid-state joining method that has the potential to overcome the barriers to dissimilar material joining. The biggest drawbacks of vaporizing foil actuator welding are that it is still exclusively used in laboratory settings and early in the technology development process. As such, there is not enough confidence in the process for it to be transitioned to manufacturing environments yet. This work begins by analyzing the current state of the technology and identifying a roadmap to achieve a transition to manufacturing. The analysis found that increased confidence in the technology requires sample to sample repeatability to be improved. Beyond that, the process also needs to be fully automated before it can be considered as a viable technique for mass production. In order to further develop the technique, a fully automated work cell was constructed. By removing the human element from the process, this cell helped identify iii the aspects which contribute to process variability. The positioning of the vaporizing foil actuator was identified as the most important factor in process stability. A small set of samples were made in the automated cell with the addition of one component epoxy adhesive around the perimeter of the weld. These samples showed improved process repeatability compared with the samples made without adhesive. This indicates that small amounts of adhesive may be critical in using the process in industrial settings. Additionally, work was performed with manual positioning and adhesive dispensing. This work found that a hybrid joint behaves like traditional weld bonding, where the addition of adhesive makes the joint stronger than if either of the two joining methods were used on their own. To realize this performance with vaporizing foil actuator welding, though, the adhesive needs to be protected from burning during the rapid compression of air during the impact process.

36 MATERIALS SCIENCE↗
NASA NTRS1986

Thermal stability of lightweight graphite glass sandwich reflectors for far infrared astronomy

Graphite fiber-reinforced glass matrix composites are being developed for a variety of structural applications requiring excellent thermomechanical stability. These materials are ideally suited for lightweight, high strength, thermally stable infrared mirrors because of their low density, low thermal expansion, high strength and stiffness, and their ability to be machined, replicated and figured using standard polishing techniques. These properties are particularly promising for applications such as a 3-meter balloon-borne far-infrared and submillimeter telescope mirror which must be both very lightweight and able to retain its figure accuracy when cycled between room temperature and its operating temperature of -50 C. This paper presents the results of a set of low temperature optical tests conducted to determine the figure stability of a 30-cm diameter, frit-bonded graphite/glass mirror in the +20 to -60 C temperature range using a 10.6 micron laser interferometer. The results indicate that the residual change in figure was less than 0.3 microns, rms.

Bluege, J. H.↗
NASA NTRS1992

Photovoltaic Array Space Power flight experiment plus diagnostics (PASP+) modules

The Photovoltaic Array Space Power Plus Diagnostics flight experiment (PASP+) subsumes twelve solar array modules which represent the state of the art in the space photovoltaic array industry. Each of the twelve modules individually feature specific photovoltaic technologies such as advanced semiconductor materials, multi-bandgap structures, lightweight array designs, advanced interconnect technologies, or concentrator array designs. This paper will describe each module in detail including the configuration, components, materials, anticipated on orbit performance, and some of the aspects of each array technology. The layout of each module and the photovoltaic cells or array cross section will be presented graphically. A discussion on the environmental constraints and materials selection will be included as well as a delineation of the differences between the modules and the baseline array configuration in its intended application.

Cooley, William T.↗
NASA NTRS1980

Echo's Legacy

The Echo 1 Satellite is simply a very large balloon, the diameter of a 10 story building. Metallized Products, Inc. developed a special material for NASA used for the balloons's skin. For "bouncing signals," material had to be reflective, lightweight, and thin enough to be folded into a beach ball size canister for delivery into orbit, where it would automatically inflate. Material selected was mylar polyester, with a reflective layer of tiny aluminum particles so fine that Echo's skin had a thickness half that of cellophane on a cigarette package.

Source record↗
NASA NTRSDate not supplied

MEDLI2: Ablator Models for Flight

During the entry of Mars Science Laboratory (MSL) the heatshield was equipped with the instrumentation suite Mars Entry, Descent, and Landing Instruments (MEDLI). In-depth thermocouple (TC) data was used to reconstruct the surface heating[1,2]. Discrepancies between MEDLI’s flight heating data and predicted thermal response and recession[3] led to a campaign to characterize and test Mars2020 and MEDLI2 (Mars Entry, Descent, and Landing Instrument 2)[4] flight-lot thermal protection materials (TPS) at relevant ground test conditions. This paper covers the development and validation of flight-lot material response models for the heatshield material Phenolic Impregnated Carbon Ablator (PICA) and the backshell material SLA-561V (Super Lightweight Ablator). Virgin and char properties such as thermal conductivity and emissivity were updated as a function of temperature and pressure in the MEDLI2 specific material response models. Other material properties were characterized and determined to be similar to prior TPS material measurements used for the heritage models. MEDLI2 also investigated the impact of the protective coating that was applied to MSL and Mars2020’s PICA heatshield to reduce the particulate matter shedding. Evidence from arc jet experiments on coated PICA showed that although there were no adverse effects on the performance of the TPS, there were differences in the in-depth temperatures and reduced recession compared to material response predictions of uncoated PICA.[5,6]. Fully Implicit Ablation and Thermal response (FIAT)[7] material response simulations were conducted with the heritage and MEDLI2 flight-lot material models. FIAT-predicted in-depth temperature responses and recession predictions were compared to flight-lot certification ground-test arc jet test data and MEDLI2 thermocouple data.

Materials Response↗
DOE OSTI2020

A macromolecular assembly directed ceramic aerogel monolith material

Ceramic aerogels exhibit remarkable thermal insulation for energy efficient building applications, while it is indispensable to understand their nanoporous structure evolution to control their thermal regulation performance. In this study, we design and synthesize a lightweight porous silica aerogel monolithic material, and demonstrate its thermal insulation performance regulated by the morphology of porous nanostructures controlled by surfactant induced self-assembly. The micelle networks and in situ gas bubble formation guide the formation of uniform pores in the as-synthesized monolith, which shows superior thermal and acoustic insulation and robust mechanical stability with a thermal conductivity of 0.032 W m –1 K –1 , a soundproof performance improvement by 17% at a frequency of 800 Hz, and a 1.3 MPa compressive strength with a Young's modulus of 15 MPa. Lastly, these findings provide a new route to manufacture low-cost aerogel monolithic insulation materials for energy efficient building applications.

36 MATERIALS SCIENCE↗
NASA NTRS2016

Materials for Space: It's Challenging!

Space environments place tremendous demands on materials that must perform with exceptional reliability to realize the goals of human or robotic space exploration missions. Materials are subjected to extremes of temperature, pressure, radiation and mechanical loads during all phases of use, including takeoff and ascent, exposure to space or entry into an atmosphere, and operation in a planetary atmosphere. Space materials must be robust and enable the formation of lightweight structures or components that perform the required functions; materials that perform multiple functions are of particular interest. This talk will review the unique challenges for materials in space and some of the specific material capabilities that will be needed for future exploration missions. A description of needs and trends in thermal protection materials and systems will complete the talk.

ablators↗
NASA NTRS2007

Optical Property Measurements on the Stardust Sample Return Capsule

The Advanced Materials for Exploration (AME) task Materials Analysis of Returned Hardware from Stardust received funding to perform non-destructive analyses of the non-primary science hardware components of the Stardust sample return capsule. These components were (a) the blunt body reentry heatshield, encased in Phenolic Impregnated Carbon Ablator (PICA); (b) the backshell of Super Lightweight Ablator 561 (SLA-561) material handpacked into phenolic Flexcore and coated with CV-1100 silicone; (c) the rope seal used in between the heatshield and backshell; (d) the internal multi-layer insulation (MLI) blankets; and (e) parts of the Kevlar straps left attached to the backshell. These components were analyzed to determine the materials' durability in the space environment. The goals of the task were (a) to determine how the various materials from which the components were built weathered the extreme temperatures and harsh space environment during the capsule's nearly 7-year voyage to and from its rendezvous with Comet Wild 2 and (b) to provide lessons-learned data for designers of future missions.

Finckenor, Miria↗
NASA NTRS2003

Material Properties Analysis of Structural Members in Pumpkin Balloons

The efficient design, service-life qualification, and reliability predictions for lightweight aerospace structures require careful mechanical properties analysis of candidate structural materials. The demand for high-quality laboratory data is particularly acute when the candidate material or the structural design has little history. The pumpkin-shaped super-pressure balloon presents both challenges. Its design utilizes load members (tendons) extending from apex to base around the gas envelope to achieve a lightweight structure. The candidate tendon material is highly weight-efficient braided HM cord. Previous mechanical properties studies of Zylon have focused on fiber and yarn, and industrial use of the material in tensile applications is limited. For high-performance polymers, a carefully plamed and executed properties analysis scheme is required to ensure the data are relevant to the desired application. Because no directly-applicable testing standard was available, a protocol was developed based on guidelines fiom professional and industry organizations. Due to the liquid-crystalline nature of the polymer, the cord is very stiff, creeps very little, and does not yield. Therefore, the key material property for this application is the breaking strength. The pretension load and gauge length were found to have negligible effect on the measured breaking strength over the ranges investigated. Strain rate was found to have no effect on breaking strength, within the range of rates suggested by the standards organizations. However, at the lower rate more similar to ULDB operations, the strength was reduced. The breaking strength increased when the experiment temperature was decreased from ambient to 183K which is the lowest temperature ULDB is expected to experience. The measured strength under all test conditions was well below that resulting from direct scale-up of fiber strength based on the manufacturers data. This expected result is due to the effects of the braiding process and material ageing.

Sterling, W. J.↗
NASA NTRS2020

Breakthrough Materials for Space Applications Workshop

In the course of its 60 year history, the National Aeronautics and Space Administration (NASA) has blazed trails in the development and advancement of aerospace materials and the transition of these advancements to industry. The Agency has overseen the infusion of new high-performance materials into a diverse array of mission applications, including aeronautics, planetary science, and human spaceflight. The next generation of demanding exploration missions, including a return to the lunar surface with humans in the 2020s, will present new and unprecedented material challenges. Selecting or developing materials to survive the environments of launch and the high temperatures present in propulsion systems, operate in a microgravity and/or a vacuum environment (which includes exposure to radiation), and/or survive years on a planetary surface is an immense challenge. In addition to functioning in their intended use environment, materials for space must also possess extremely high-performance characteristics. The anecdotal Von Braun quote “space is weightlifting” reminds us of the need to minimize the mass of a space system while still meeting safety margins. The cost of launching a kg to orbit is estimated currently at $10,000; barring a drastic reduction in launch costs, lightweight and high-strength materials will remain the most sought-after spaceflight materials for the foreseeable future. Other primary considerations for materials in spaceflight applications include affordability, compatibility with other systems and materials, and manufacturability. The emergence of new advanced manufacturing processes such as friction stir welding and additive manufacturing have revolutionized the aerospace industry in recent years. Additive manufacturing in particular allows for rapid fabrication of components and greater design freedom. With the advent of these new processes, however, comes the need to develop new specifications, process control approaches (including material modeling), testing, and nondestructive evaluation techniques to ensure that parts meet the stringent functional requirements for spaceflight.

Prater, T.↗
NASA NTRS1999

Technology Demonstrator for Direct Polishing of a 50cm C/SiC Ultra Light Mirror

The NRSU portion of the contract was completed on schedule and within acceptable limits of the estimated cost. The lapping of the substrate started on schedule, and completed ahead of schedule. The polishing of the substrate was begun ahead of schedule, and was completed approximately one month ahead of schedule. It is our opinion that the substrate meets the requirements of "diffraction limited performance at 2 microns" over the measured 16 in. area. The final photos suggest that there may be edge roll-off beyond the 16 in. diameter. However, we cannot quantify this. It is our opinion that this material is suitable for use in lightweight optics as long as cladding of some type is used (Silicon, SiC, Sol-Gel, etc), as the bare material itself is too "porous" to obtain a high quality finish. We feel that this part was at the low limit of structural integrity required to mechanically polish to this level of figure requirement. Any lesser structural integrity would require some form of "non contact" figuring.

Scribner, Ken↗
NASA NTRS1987

On Motion Planning and Control of Multi-Link Lightweight Robotic Manipulators

A general gross and fine motion planning and control strategy is needed for lightweight robotic manipulator applications such as painting, welding, material handling, surface finishing, and spacecraft servicing. The control problem of lightweight manipulators is to perform fast, accurate, and robust motions despite the payload variations, structural flexibility, and other environmental disturbances. Performance of the rigid manipulator model based computed torque and decoupled joint control methods are determined and simulated for the counterpart flexible manipulators. A counterpart flexible manipulator is defined as a manipulator which has structural flexibility, in addition to having the same inertial, geometric, and actuation properties of a given rigid manipulator. An adaptive model following control (AMFC) algorithm is developed to improve the performance in speed, accuracy, and robustness. It is found that the AMFC improves the speed performance by a factor of two over the conventional non-adaptive control methods for given accuracy requirements while proving to be more robust with respect to payload variations. Yet there are clear limitations on the performance of AMFC alone as well, which are imposed by the arm flexibility. In the search to further improve speed performance while providing a desired accuracy and robustness, a combined control strategy is developed. Furthermore, the problem of switching from one control structure to another during the motion and implementation aspects of combined control are discussed.

Cetinkunt, Sabri↗
NASA NTRS2007

Triboluminescent Materials for Smart Optical Damage Sensors for Space Applications

Triboluminescence is light that is produced by pressure, friction or mechanical shock. New composite materials are constantly being reengi neered in an effort to make lightweight spacecrafts for various NASA missions. For these materials there is interest in monitoring the con dition of the composite in real time to detect any delamination or cr acking due to damage, fatigue or external forces. Methods of periodic inspection of composite structures for mechanical damage such as ult rasonic testing are rather mature. However, there is a need to develop a new technique of damage detection for composites, which could dete ct cracking or delamination from any desired location within a materi al structure in real time. This could provide a valuable tool in the confident use of composite materials for various space applications. Recently, triboluminnescent materials have been proposed as smart sen sors of structural damage. To sense the damage, these materials can b e epoxy bonded or coated in a polymer matrix or embedded in a composi te host structure. When the damage or fracture takes place in the hos t structure, it will lead to the fracture of triboluminescent crystal s resulting in a light emission. This will warn, in real time, that a structural damage has occurred. The triboluminescent emission of the candidate phosphor has to be sufficiently bright, so that the light signal reaching from the point of fracture to the detector through a fiber optic cable is sufficiently strong to be detected. There are a large number of triboluminescent materials, but few satisfy the above criterion. Authors have synthesized a Eu based organic material know n as Europium tetrakis (dibenzoylmethide) triethylammonium .(EuD(sub 4)TEA), one of the bright triboluminescent materials, which is a pote ntial candidate for application as a damage sensor and could be made into a wireless sensor with the addition of microchip, antenna and el ectronics. Preliminary results on the synthesis and characterization of this material shall be presented.

Aggarwal, Mohan D.↗
NASA NTRSDate not supplied

Polymer Aerogels for Lunar Applications and Beyond

As the Space Community endeavors to reach new heights of exploration, materials for extreme environment are on the forefront of research. One such material would include polymer aerogels; lightweight solids with nano-scale pore size, high internal surface area, low thermal conductivity, and extremely high porosities. Due to these interesting properties, aerogels are ideal as thermal insulators but are by no means limited to this application. The high porosity and surface area also make aerogels an ideal host system for particle incorporation for applications such as catalyst supports, sensor platforms, and vibro-acoustic mitigating materials. Polymer aerogels also have the potential to combat issues found in extraterrestrial environments such as dust and radiation mitigation. Herein, current research will be discussed as it pertains to Space exploration.

Stephanie Vivod↗
DOE OSTI2022

Creep and Fatigue Characterization of High Strength Alloy Thin Sections in Advanced CO2 Heat Exchangers

The objective of this work was to characterize and model elevated temperature creep and fatigue behavior for thin sheet and foil forms of gamma-prime strengthened alloys in wrought form and as-processed folded and brazed constructions. This work was motivated by the demanding temperature and pressure service conditions of the GEN3 Concentrated Solar Power (CSP) and supercritical CO2 (sCO2) power cycle working fluid. More specifically, the possibility of leveraging the superior creep strength of gamma-prime alloys in folded-fin and brazed-plate heat exchanger constructions. Gamma-prime alloys represent a step-change in raw-material strength over solid-solution strengthened alloys. And the folded-fin and brazed-plate heat exchanger architecture is lightweight and leverages cost-effective material stock forms. The investigation contained two parallel paths. (1) The first is referred to as a fundamental investigation where Oak Ridge National Laboratory conducts uniaxial creep testing on thin sheet and foil in wrought form. This effort aimed to serve as a benchmark against a relatively sparse existing database and a baseline comparison for path number 2. (2) The second path is referred to as the practical investigation where Brayton Energy manufactures plate-fin heat exchangers and performs pressurized creep and fatigue testing. This effort aimed to de-risk heat exchanger manufacturing process for service under sCO2 CSP conditions. A total of 14 uniaxial creep tests were completed using Haynes 282 thin sheet and foil. A variety of heat treatments were specified to coincide with path number 2. Baseline metallography of test samples and creep strength performance are contained. Benchmarks relatively to existing thick-form Haynes 282 are made, as well as to other thin-form Nickel-based superalloys. Description of a wrought-form modeling approach for thin gamma-prime alloys is also discussed. A total of 11 pressurized creep and fatigue tests were completed successfully with Haynes 282 heat exchanger prototypes. Manufacturing processing details, testing details, testing results, and failure analysis are discussed. Additionally, creep modeling techniques to predict failure are discussed, and modeling to support technological-to-market. In conclusion, Haynes 282 foils were demonstrated to yield rupture two-to-three orders of magnitude higher than Haynes 230 foils under similar conditions. And the manufactured heat exchanger prototypes demonstrated strength similar to the wrought constituents. Both of which contribute to elevated performance potential or cost savings in practice. Discussion is included.

14 SOLAR ENERGY↗