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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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A mirror or mirror assembly fabricated by molding, pressing, assembling, or depositing one or more bulk metal glass (BMG), bulk metal glass composite (BMGMC), or amorphous metal (AM) parts and where the optical surface and backing of the mirror can be fabricated without machining or polishing by utilizing the unique molding capabilities of this class of materials.
We describe the design, fabrication, and validation of a cryogenically compatible quasioptical thermal source for characterization of detector arrays. The source is constructed using a graphite-loaded epoxy mixture that is molded into a tiled pyramidal structure. The mold is fabricated using a hardened steel template produced via a wire electron discharge machining process. The absorptive mixture is bonded to a copper backplate enabling thermalization of the entire structure and measurement of the source temperature. Measurements indicate that the reflectance of the source is less than 0.001 across a spectral band extending from 75 to 330 gigahertz.
This Summer I participated in two projects at Kennedy Space Center in Cape Canaveral, Florida. The projects focus on the NASA's Deep Space Gateway applications for future Mars travel. All of these projects use recycling technology to use resources found on Earth and on other planets for fuel and other environmental applications. The first project I took the lead on is “Plasma Arc Gasification.†Plasma is a high temperature and very efficient way to process waste to create usable byproducts. The plasma chamber in temperature is comparable to that of the sun and this energy will help create an environment in which the waste can be recycled properly for not only plant support, but also for possible fuel application as well. I preformed the tests in a quartz tube, which is used to hold the waste (cotton, plastics, nylon, paper and a human waste simulant) and the waste is then combusted using O2 (present in air) into gases such as H2, H2O, CH4 and CO2. I determined which gases are present using a Fourier-transform infrared spectroscopy (FTIR) machine, which analyzes the peaks of the gases using liquid nitrogen. Problems arose in the beginning from the reactor emitting electromagnetic waves (EMI) that interfered with the technology of the experiment, specifically the thermocouples. This was solved through multiple tests with the positioning of the thermocouple power supply further away from the plasma reactor. I worked with another intern, Daniel Santander, who developed a space plant chamber which uses CO2 and H2O (harvested from the plasma reactor) to grow plants in space. The chamber possess a CO2 monitor, which controls the amount of gas that enters the chamber, along with a water integration system to supply the amount of water needed for proper plan growth. This technology will then be used for plant growth in space for the Astronauts on future space flights and possibly on the International Space Station (ISS). The second project I worked on is the “Orbital Syngas / Commodity Augmentation Reactor (OSCAR)†which focuses on the issues experienced in long-duration space flight regarding waste disposal. In previous space flight missions, waste was stored on board and returned to Earth for disposal. This technique is not applicable to long space flight missions to Mars due to the rocket being months away from Earth. OSCAR is using microgravity waste disposal techniques to produce fuels from the recycled waste. The waste is converted to syngas through a thermal degradation process. This process helps create an environmentally friendly way to dispose and reuse trash on board the space craft. Currently waste is being tested in the form of cotton and plastics. OSCAR is designed as a microgravity reactor that is currently being tested in a drop tower rig at Glenn Research Center. I helped design the 3D model for the insulation that will line the reactor. The first few trials, I dissolved the plastic of the mold in acetone. This method worked, but was very costly. I then received a silicone material to construct the mold from Swamp Works here at Kennedy. Through multiple trials with the silicone, this method worked best for developing the end pieces of the insulation for the chamber.
The goal of this work is to utilize topology optimization methods to obtain low-speed flexible wind tunnel models with simple jig outer mold lines, but highly-tuned aeroelastic flutter behavior. The wing is conceptually constructed with commonly-available 3D printed materials, of which the optimizer may select one of two at every location in the wing; a stiffer material meant to bear the loads, and a softer rubber-like material for space filling, and to form the outer mold line, where needed. Results are shown for three topological parameterizations: 2D topologies with a fixed nondesignable plate through the camber line, 2D parameterizations without the plate, and 3D parameterizations where the topology can vary though the depth of the wing, at a given planform location.
The Advanced Telescope for High ENergy Astrophysics (ATHENA) mission requires high quantum efficiency (QE) x-ray absorption, >90.6% at 7 keV and low specific heat capacity, 0.731 pJ/K. The designed ATHENA x-ray absorbers are cantilevered square tiles (pitch of 317 microns) of 1.05 μm thick Au and 5.51 μm thick Bi electroplated films supported by stems that connect the absorber to the detector below. We discuss some of the methods used to produce x-ray absorbers meeting these specifications for ATHENA. To tune the thermal conductance of the device and the effect on the normal-to superconducting transition shape, the stems need to be small diameter and can have a weak bottle-neck connection to the substrate. A funnel shape of the stem using a proximity exposed photoresist mold has been developed to improve the strength of the connections. Further requirements on the absorbers include low levels of fine particulate remaining on the substrate after production and zero shorts between absorbers due to incomplete ion milling or trapped fine particular between absorbers. To optimize for post patterning substrate cleanliness and absorber yield, we have examined several methods of absorber fabrication. Three such methods are 1) an ion mill/wet etch combination, 2) a photoresist mold for electroplating followed by wet or dry etch to remove the seed layer, and 3) an electroplating process with leveling to smooth the surface followed by ion mill to separate the absorbers. The different combinations of wet and dry etches lead to different yields and surface appearance of the absorber sidewalls. We present results on the achieved pixel yields and the energy resolution of pixels made with the various fabrication methods. We discuss the impact of absorber patterning method on performance, uniformity, and yield.
Summary: Achieving Uranus in-situ science objectives through deploying probes in the atmosphere requires thermal protection systems capable of withstanding extreme entry environments. NASA’s 3-D Woven based thermal protection systems (TPS), developed specifically to meet this challenge, are mature, efficient, and capable of withstanding such entry. These science-enabling capabilities need to be sustained, otherwise mission implementation risk may increase to the point that the mission is untenable. The heatshield technology has been developed in concert with industry, and manufacturing processes have been technology transferred. Current technology readiness does not guarantee future availability. Sustainment requires maintaining expertise within NASA as well as ensuring that proven industrial expertise and capabilities will be readily available in the future. A constant awareness and risk assessment followed by risk mitigation are required. The scientific community needs to be aware of these challenges. It needs to engage NASA to ensure these capabilities will be available when needed. As was the case with the atrophy of heritage carbon phenolic that led to developing the 3-D Woven capabilities, our vigilance is again needed to sustain these enabling TPS capabilities for Uranus and for other missions. Background: NASA invested in and developed Heatshield for Extreme Entry Environment Technology (HEEET) TPS that was matured to TRL 6 in 2019 as a tiled system with seams and gap-fillers. Manufacturing readiness included development of specialized looms, molding, and infusion processes using commercial partners. In support of the Mars Sample Return mission, a single-layer, seamless, single-piece variant referred to as 3MDCP (3-D woven Mid-Density Carbon-Phenolic) was developed and is limited to a 1.3m maximum diameter scale due to weaving width limitations of 80”. Molding techniques developed to transform a flat, 2”-thick 3-D woven preform into a sphere-cone shape prior to phenolic resin infusion has been demonstrated. A team at NASA Ames is currently working with industry to demonstrate infusion at full-scale. By 2026, 3MDCP will be at a high level of maturity in technical, manufacturing, and integration readiness as well as material characterization. HEEET and 3MDCP for Uranus Entry: Several system studies have evaluated and baselined 3-D Woven TPS for Uranus entry, both HEEET as well as 3MDCP. If the aeroshell carrying the descent probe is 1.3m or less, then 3MDCP is a very capable and the most mass-efficient choice. If the aeroshell is bigger than 1.3m diameter, then HEEET can meet the mission need as it allows for an aeroshell of any diameter. HEEET and 3MDCP are capable of Saturn in-situ science missions prioritized in the New Frontiers-5 draft Announcement of Opportunity (AO) and if Saturn is the mission of choice, there is a pathway for sustaining the capability. Capability Sustainment: Given NASA’s current budgetary constraints, the postponement of the next New Frontiers AO to no earlier than 2026 and the unknown delay in starting the UOP flagship effort point to potential gap years for the HEEET and 3MDCP capabilities. The first step in capability sustainment is to understand the risks as they emerge, assess those risks, and develop plans to mitigate them. Keeping the science community, who are interested in UOP as well as the larger Giant Planet missions, informed of the emerging challenges requires continuous risk assessment/mitigation. Without these steps, atrophy is more likely within the industrial partners with which NASA has partnered. This presentation will provide more details as well as steps NASA can take to minimize the impact to the UOP mission.
To meet the projected demand for single-aisle composite aircraft in 2040, the production rate of these aircraft will need to increase by four to six times what is currently achievable. A composite manufacturing process with the potential to enable the targeted rates is isothermal resin infusion where infusion and cure occur at the same temperature. However, presently there is not an accepted aerospace-grade resin that can support this isothermal infusion process and maintain acceptable resin properties. Therefore, resin development initiatives have designed anionic catalyzed epoxy systems capable of isothermal infusion and rapid cure at a temperature below 100 ˚C in one hour. High-performance aerospace properties are achieved after undergoing a freestanding post-cure. The resins facilitate faster, energy efficient production cycles by reducing the time and temperature required for cure and eliminating temperature ramps typically required of materials used in the aerospace industry. This work discusses several of the developed resin systems and the impact of varying composition on rheological, thermal, and mechanical properties. Carbon fiber composites were fabricated for one composition by resin transfer molding to demonstrate the potential of these isothermal, rapid cure systems for meeting industry needs.
Plastic spin forged female master mold for production of 9.5-foot diameter paraboloidal male master and mirror for solar collection
Cell wall synthesis, and enzyme activity control in cellular slime mold development
The Open VSP model represents the geometry of PEGASUS as is currently modeled. PEGASUS is a concept vehicle that will not be physically produced. As such, the baseline model is subject to change without notice or requirement that updates are provided external to NASA. The current baseline is derived from the outer mold line (OML) of the ATR 42-500. As such, planform areas for the wing, fuselage, vertical tail, and horizontal tail mimic those published in public ATR 42 literature. NASA Aeronautics Systems Analysis Branch (ASAB) does not contain any proprietary data on the ATR 42, thus the PEGASUS model does not contain any proprietary or sensitive information. Further, model details that are required for an actual aircraft such as airfoils, twist distributions and propeller geometries are unknown at this time, and generic stand-ins are used within the OpenVSP model. The intent is to provide this model to Georgia Tech ASDL to allow the ASDL team to model the impact of the propulsion system at the wingtip’s impact on structural characteristics. The ASDL will be using the model to generate estimated aerodynamic load and structural members for analysis.
Vacuum forming of a sheet of thermoplastic material around a mandrel conforming to the shape of the finished object provides a pattern for an investment mold. The thickness of the metal part is determined by the thickness of the plastic pattern.
Elastic, pressure-sensitive orifice is used to automatically regulate the rate of gas flow into bearings under varying loads. Formed of a molded elastomer, theses orifices increase the stability of gas bearings.
Motor brushes of proper quantities of molybdenum disulfide and copper or silver are manufactured by sintering techniques. Graphite molds are used. These brushes operate satisfactorily for long periods in normal atmosphere or in a high-vacuum environment.
Particulate, fused amorphous silica is formed into complex shapes by casting in plaster molds. High temperature firing is not required. This ceramic is resistant to thermal shock and exhibits good strength properties.
Plastic material combined with stainless-steel fibers and molded under heat and pressure into a desired configuration is both soft enough to deform under a load and resilient enough to return to its original shape when the load is removed.
Molded insulating spacer with one or more cavities is used as an insulated holder for mounting metal-case transistors in a chassis containing densely packed electronic components. The transistors are mechanically supported on their bases and electrically isolated from each other by the holder.
Spray-on process constructs molds used in forming sections of thermal insulation blankets. The process simplifies the fabrication of blankets by eliminating much of the equipment formerly required and decreasing the time involved.
Interchangeable molded fiberglass shells are locked together to form storage units of various depths. These units can hold components weighing 1500 pounds, are easily transportable, and protect contents from contamination.