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At least 469 records · Page 26

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NASA NTRS1989

Geometrical optics design of a compact range Gregorian subreflector system by the principle of the central ray

In recent years, the compact range has become very popular for measuring Radar Cross Section (RCS) and antenna patterns. The compact range, in fact, offers several advantages due to reduced size, a controlled environment, and privacy. On the other hand, it has some problems of its own, which must be solved properly in order to achieve high quality measurement results. For example, diffraction from the edges of the main reflector corrupts the plane wave in the target zone and creates spurious scattering centers in RCS measurements. While diffraction can be minimized by using rolled edges, the field of an offset single reflector compact range is corrupted by three other errors: the taper of the reflected field, the cross polarization introduced by the tilt of the feed and the aperture blockage introduced by the feed itself. These three errors can be eliminated by the use of a subreflector system. A properly designed subreflector system offers very little aperture blockage, no cross-polarization introduced and a minimization of the taper of the reflected field. A Gregorian configuration has been adopted in order to enclose the feed and the ellipsoidal subreflector in a lower chamber, which is isolated by absorbers from the upper chamber, where the main parabolic reflector and the target zone are enclosed. The coupling between the two rooms is performed through a coupling aperture. The first cut design for such a subreflector system is performed through Geometrical Optics ray tracing techniques (GO), and is greatly simplified by the use of the concept of the central ray introduced by Dragone. The purpose of the GO design is to establish the basic dimensions of the main reflector and subreflector, the size of the primary and secondary illuminating surfaces, the tilt angles of the subreflector and feed, and estimate the feed beamwidth. At the same time, the shape of the coupling aperture is initially determined.

Clerici, Giancarlo↗

DOE OSTI2024

High-Temperature Wireless Sensor Platform Powered by Energy Scavenging

This paper reports on the development of key components required for a self-powered oscillator unit designed to wirelessly transmit its signal under full insertion in high-temperature (HT) harsh-environments (HE), such as those present in power plants and industrial settings (metallurgic, oil extraction, molding, and aerospace). The oscillator employed a silicon carbide (SiC) power transistor and HT passive components on a screen-printed alumina circuit board capable of operation beyond 300 °C. The HT oscillator circuit was powered solely by in-situ energy scavenging thermoelectric generator (TEG) modules using passive cooling, eliminating the need for an external power supply or active cooling. In addition, a silicon-based external booster circuit was used to achieve the required TEG voltage regulation to test the TEG-powered HT oscillator circuit. The TEG-powered oscillator circuit was tested inside a non-metallic furnace from room temperature to over 300 °C for transmission of a wireless signal, which was detected outside the furnace at 11 ft (3.4 m). Such a wireless transmitting system powered only by in-situ TEGs, with no requirement for external power or active cooling, is very attractive for flexible, mobile stand-alone control and sensor units targeted for operation in HT HE conditions found in power plants and industrial settings.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2019

Dynamical properties of a room temperature ionic liquid: Using molecular dynamics simulations to implement a dynamic ion cage model [plus supplemental information]

The transport behavior of ionic liquids (ILs) is pivotal for a variety of applications, especially when ILs are used as electrolytes. Many aspects of the transport dynamics of ILs remain to be understood. Here, a common ionic liquid, 1-butyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide (BmimNTf 2 ), was studied with molecular dynamics simulations. The results show that BmimNTf 2 displays typical structural relaxation, subdiffusive behavior, and a breakdown of the Stokes-Einstein diffusion relation as in glass-forming liquids. In addition, the simulations show that the translational dynamics, reorientation dynamics, and structural relaxation dynamics are well described by the Vogel-Fulcher-Tammann equation like fragile glass forming liquids. Building on previous work that employed ion cage models, it was found that the diffusion dynamics of the cations and anions were well described by a hopping process random walk where the step time is the ion cage lifetime obtained from the cage correlation function. Detailed analysis of the ion cage structures indicated that the electrostatic potential energy of the ion cage dominates the diffusion dynamics of the caged ion. The ion orientational relaxation dynamics showed that ion reorientation is a necessary step for ion cage restructuring. The dynamic ion cage model description of ion diffusion presented here may have implications for designing ILs to control their transport behavior.

36 MATERIALS SCIENCE↗

NASA NTRSDate not supplied

Use of Mechanical Heat Switch to Speed up TVAC Transitions on Flight Hardware Below 200K

Spaceflight hardware that operates at temperatures well below room temperature usually require being well isolated from their warmer environment in order to manage thermal parasitics adequately. This is especially true for spaceflight systems that rely on passive cooling such as a radiator. During ground testing, this design configuration can be problematic for TVAC cycling between operational temperature extremes, since the hardware temperatures may move extremely slowly and lengthen the duration of an already expensive and heavily staffed system-level TVAC campaign. One of the challenges of using an external means of speeding up temperature transitions is that a TVAC campaign usually also requires the simulation of flight-like environments to validate the design, and introducing a test feature to speed up transitions can disrupt the system such that flight-like environments are not achievable. Such an approach was used for the L’Ralph instrument level TVAC test. L’Ralph is a passively cooled instrument on the Lucy mission with planned flyby’s of the Trojan asteroids around 5.5 AU. The optics and visible detector are cooled below 190K, and the IR detector is cooled below 110K. During instrument TVAC qualification testing, a mechanical motor-controlled heat switch uses clamping pressure via a vise-grip mechanism to achieve faster temperature transitions by increasing the conduction to a cold sink. The heat switch system then disengages and employs zero-Q controls to achieve flight-like thermal environments for thermal balance plateaus. Results from stand-alone testing of the heat switch are discussed, including correlated on/off ratios and the expected conductance across its operational temperature range. Test data from an instrument level TVAC that successfully utilized the heat switch are also shown.

Daniel G Bae↗

NASA NTRSDate not supplied

Lessons Learned From the Construction of a Portable Cleanroom for NASA OSIRIS-REx Mission Deintegration

NASA Johnson Space Center (JSC) Infrastructure and Astromaterials Acquisition & Curation Office completed construction and commissioning of the OSIRIS-REx (OREx) Deintegration portable cleanroom at the Utah Test and Training Range (UTTR). The new portable cleanroom was designed to receive the OREx sample return capsule from the landing point on the range to an ISO7 environment. Scientists used the portable clean-room to deintegrate the sample canister from the sample return capsule. Once separated, the sample canister was put in a container under nitrogen purge for transportation to B31 at the Johnson Space Center for astromaterial sample extraction, preliminary analysis, and long-term curation. The portable cleanroom was built by a subcontractor at their facility and then deconstructed to be transported to the remote location at UTTR. Since construction was completed in a remote location all tools and materials had to be transported from contractor site in Dallas, TX. The cleanroom was constructed within an existing facility, which provided conditioned air, electric power, and protection from the elements. Careful coordination was required between the host facility, cleanroom contractor, mission scientists, and JSC facilities and curation personnel. An existing anteroom at JSC was transported to UTTR and added to the portable cleanroom after there was concern about contamination without one for personnel entry/exit. The scientific study of organics is critical for the mission, so a stringent contamination control plan was implemented for low organics. Given these mission requirements the cleanroom construction materials were carefully selected to not hinder the scientific search for amino acids and the study of organics in the samples. The same cleanroom contractor that built the long-term astromaterial curation cleanroom back at JSC Houston, TX was selected to build the portable cleanroom and instructed to use the same materials. The cleanroom had double doors to open and allow the sample return capsule to fit into the cleanroom on its stand and be transferred to a clean stand already in the cleanroom. The portable cleanroom successfully completed its mission and the sample canister was safely deintegrated and transported to JSC under nitrogen purge.

astromaterials curation↗

NASA NTRSDate not supplied

Portable Cleanroom for NASA OSIRIS-REx Mission Deintegration

astromaterials curation↗

DOE OSTI2020

Phase Transformations among TiO2 Polymorphs

Polymorphs widely exist in nature and synthetic systems and are well known to determine material properties. Understanding phase transformation mechanisms among polymorphs enables the design of structures and tuning of phases to tailor material properties. However, current understanding is limited due to the lack of direct observations that track the processes and the structural evolution is not known at atomic scale. Here, integrating (semi) in situ transmission electron microscopy and density functional theory, we report atomic structural evolutions of phase transformation from anatase (A) to rutile (R), brookite (B), R-phase, and TiO. Besides the consistent paths with previous reports, we discover several unreported paths, including a [001] direction and (020) plane of anatase to [100]A and (011)R of rutile, respectively, ( , ) and , . Density functional theory analysis elucidates atomic structural evolution during the processes and over 16% of Ti-O bonds break and reform during the processes with energy barriers of ~0.7-1.0 eV per TiO2 formula unit. Under electron-beam irradiation, anatase particles transform into TiO2-R phase or TiO at high or room temperature, respectively. We also reveal the anisotropic nature of electron-beam effect, which is seldom discussed: dependence of crystallographic orientation with respect to electron-beam irradiation direction. Understanding the atomic structural evolution sheds light on interpreting and controlling TiO2 polymorphs and interface structures for various applications. The revealed electron-beam effects in our work provide guidance for in situ transmission electron microscopy studies.

Song, Miao↗

NASA NTRS2012

NASA's Lunar Polar Ice Prospector, RESOLVE: Mission Rehearsal in Apollo Valley

After the completion of the Apollo Program, space agencies didn't visit the moon for many years. But then in the 90's, the Clementine and Lunar Prospector missions returned and showed evidence of water ice at the poles. Then in 2009 the Lunar Crater Observation and Sensing Satellite indisputably showed that the Cabeus crater contained water ice and other useful volatiles. Furthermore, instruments aboard the Lunar Reconnaissance Orbiter (LRO) show evidence that the water ice may also be present in areas that receive several days of continuous sunlight each month. However, before we can factor this resource into our mission designs, we must understand the distribution and quantity of ice or other volatiles at the poles and whether it can be reasonably harvested for use as propellant or mission consumables. NASA, in partnership with the Canadian Space Agency (CSA), has been developing a payload to answer these questions. The payload is named RESOLVE. RESOLVE is on a development path that will deliver a tested flight design by the end of 2014. The team has developed a Design Reference Mission using LRO data that has RESOLVE landing near Cabeus Crater in May of2016. One of the toughest obstacles for RESOLVE's solar powered mission is its tight timeline. RESOLVE must be able to complete its objectives in the 5-7 days of available sunlight. The RESOLVE team must be able to work around obstacles to the mission timeline in real time. They can't afford to take a day off to replan as other planetary missions have done. To insure that this mission can be executed as planned, a prototype version of RESOLVE was developed this year and tested at a lunar analog site on Hawaii, known as Apollo Valley, which was once used to train the Apollo astronauts. The RESOLVE team planned the mission with the same type of orbital imagery that would be available from LRO. The simulation team prepositioned a Lander in Apollo Valley with RESOLVE on top mounted on its CSA rover. Then the mission simulation began as the operations team's consoles came alive with data and images. They executed the mission just like the real mission with lunar communications delays and limited bandwidth and a realistic remote mission control room. This paper will describe the RESOLVE payload in detail and describe the results of the mission simulation in Hawaii.

Larson, William E.↗

DOE OSTI2021

Development of Integrated Mechanical Pods

This presentation highlights early wins, updated progress, and upcoming developments on ‘national-scale shared development platform’ for rapid prototyping, testing and validation of various integrated Mechanical Pod solutions and form factors. Such pod solutions consist of a set of all-electric heat pump mechanical equipment that have integrated functionalities through built-in controls, with heating, cooling, hot water, ventilation (including energy recovery), electrical management, and battery storage within a single package. The presentation draws inspiration from the success of bathroom pods in the US modular construction industry, UK’s efforts with unitizing mechanical systems as ‘utility cupboards’, and VEIC’s early wins in design-build of all-electric Mechanical Pod solutions in Vermont. The presentation includes researchers and partners involved with NREL in Design for Manufacturing and Assembly (DfMA), Virtual Design and Construction (VDC), and digital twin based process optimization modeling of integrated Mechanical Pod solutions. The presentation aims to highlight early wins from such a platform and how various physical and virtual tools are currently being employed as part of NREL’s ongoing multi-year project funded by US DOE. Streamlined procurement, coordination, installation, and O&M of Mechanical Pods such that the majority of work is delegated to the off-site modular factory implies monetary savings. Such a seemingly basic shift in location of the construction process leads to great reduction in complexity, first cost, lead time, and waste, and greater opportunities for innovative compartmentalization and integration of mechanical systems appropriately sized for each apartment or hotel guest room. However, past studies on unitized combination systems show that high installation costs, maintenance issues, challenges with system integration, limitations in existing electrical infrastructure, and lack of architecturally appealing solutions are key barriers. NREL and partners aim to address key barriers through DfMA approach, rapid prototyping and testing, and digital twin process optimization modeling. The presentation is also a call for interested entities to partner with NREL as part of the national-scale development platform, help drive both product and process innovation, and encourage open source sharing of learnings. Learning objectives include (1) learn about the vision of national-scale shared development platform for process-product innovation on integrated mechanical pod solutions and how to get involved, (2) gain an understanding of the components of an all-electric, high performance home, design characteristics and equipment included in an all-electric mechanical pod, integration of mechanical systems within a modular factories’ assembly line, and the system’s commissioning, operation and maintenance. The pre-planning and coordination with the factory and sub-contractors are also highlighted, (3) gain an understanding of using process modeling tools to quantify resource-constrained performance of operations (such as integration of energy efficiency strategies) to manufacture modules of varying design, (4) gain insights on virtual design, rapid prototyping, and emulated testing of various form factors across different climatic conditions. The need for such preliminary testing with open source sharing of learnings will also be highlighted.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2020

Experimental demonstration and performance evaluation of a complex fenestration system for daylighting and thermal harvesting

Two significant design strategies for mitigating building energy consumption are daylight redirection and solar energy harvesting. Effective daylighting implementation enhances the amount of useful natural light within a space and offsets the need for electric lighting. Solar energy harvesting systems can mitigate energy costs from mechanical systems by managing incoming thermal loads or capturing solar energy that can be used to supplement thermal systems in the building. While there are many available façade-based technologies that can perform daylighting or solar thermal energy harvesting, there remains a limitation in available systems that can perform both of them simultaneously. This paper, describes the design and experimental demonstration of a Liquid Filled Prismatic Louver (LFPL) system, which combines both energy-saving strategies. The LFPL system was installed in a south-facing room in New York City and evaluated for indoor daylight penetration and potential for thermal energy harvesting. Daylight redirection is achieved through the prismatic louver geometry and proper orientation, whereas thermal energy harvesting is achieved through IR absorption from the liquid (e.g., water) within the prisms. Daylighting performance was evaluated by illuminance measurements at key locations within the space, whereas thermal harvesting performance was evaluated through temperature measurements and thermal imaging analysis. We show that the LFPL system, with all prismatic elements oriented at the same angle, achieve a 2-fold and 8-fold enhancement in daylight redirection to the ceiling, for prism orientations of 10° and 20°, respectively. We also demonstrate the system’s capability to adjust to specific lighting needs, within the space, through the dynamic individual orientation of prismatic elements; thus, achieving a concentrated ceiling illuminance enhancement of ~100 times and ~200 times at 2.5 and 4.3 m away from the window sill, providing workplane illuminance enhancement of 6 and 2 times more than in the case of the control room with regular windows. Furthermore, we illustrate a reduction of potential heating loads at locations close to the window from the combination of infrared absorption in the water volume and the redirection of the incoming solar radiation, leading to a reduction of the workplane temperature by an average of 7–10 °C.

14 SOLAR ENERGY↗

DOE OSTI2026

Analysis of strategies to meet ASHRAE S241 infectious aerosol control targets by space type and region using EnergyPlus™ simulations

Professional organizations, such as ASHRAE, have recently proposed new voluntary standards for controlling infectious aerosols. Specifically, ASHRAE Standard 241 (S241) defines equivalent clean air targets for a range of space types that can be met through combinations of mitigation measures. This paper seeks to inform the selection of measures by space type and climate zone through building simulations that quantify the impacts of increased outdoor air ventilation; increasing filtration and/or adding germicidal ultraviolet (GUV) in the central heating, ventilation, and air-conditioning (HVAC) systems; or using portable air cleaners (PACs), upper room GUV, or whole room GUV approaches to increase equivalent clean air delivery. The measures are assessed individually and in practical combinations for their ability to meet S241 in four space types (offices, classrooms, dining areas, and healthcare waiting rooms) using prototype buildings modeled using EnergyPlus. The mitigation measures are compared holistically against baseline building operations using metrics for equivalent clean air, energy, and comfort. The results in this study show that single measures can meet S241 for offices with minimal impacts on energy and comfort, while either upper room GUV systems or combinations of measures such as MERV 13 HVAC filtration with PACs are needed to meet S241 for classrooms. The dining area and healthcare waiting room targets cannot be met in this study when assuming design occupancy and MS2 as the challenge agent, even when combining multiple measures together. This paper provides valuable considerations when designing measures to meet S241 for a range of spaces and scenarios.

GUV↗

DOE OSTI2021

A review of thermal physics and management inside lithium-ion batteries for high energy density and fast charging

Traditionally it has been assumed that battery thermal management systems should be designed to maintain the battery temperature around room temperature. That is not always true as lithium-ion battery (LIB) R&D is pivoting towards the development of high energy density and fast charging batteries. Therefore, it is necessary to have a comprehensive review of thermal considerations for LIBs targeted for high energy density and fast charging, i.e., the optimal thermal condition, thermal physics (heat transport and generation) inside the battery, and thermal management strategies. As the energy density and charge rate increases, the optimal battery temperature can shift to be higher than room temperature. In the first part of the review various sources of heat generation inside LIBs and various approaches to minimizing battery heat generation are summarized. The importance of heat of mixing due to ion diffusion during fast charging is also highlighted. To improve the temperature uniformity and avoid excessive internal temperature rise, heat transfer inside the battery needs to be enhanced, and reducing the thermal contact resistance between the electrodes and separator can significantly increase the effective thermal conductivity of batteries. In the second part of the review various challenges and latest developments related to thermal transport and properties of LIBs are discussed. Finally, a summary of latest advancement on smart control of internal temperature of LIBs is discussed as depending on the ambient temperature and the optimal temperature; the battery heat needs to be retained or dissipated to elevate or avoid temperature rise.

25 ENERGY STORAGE↗

NASA NTRS1996

Nutrient management effects on sweetpotato genotypes under controlled environment

Sweetpotato is one of several crops recommended by National Aeronautics and Space Administration (NASA) for bioregenerative life support studies. One of the objectives of the Tuskegee University NASA Center is to optimize growth conditions for adaptability of sweetpotatoes for closed bioregenerative systems. The role of nutrient solution management as it impacts yield has been one of the major thrusts in these studies. Nutrient solution management protocol currently used consists of a modified half Hoagland solution that is changed at 14-day intervals. Reservoirs are refilled with deionized water if the volume of the nutrient solution was reduced to 8 liters or less before the time of solution change. There is the need to recycle and replenish nutrient solution during crop growth, rather than discard at 14 day intervals as previously done, in order to reduce waste. Experiments were conducted in an environmental growth room to examine the effects of container size on the growth of several sweetpotato genotypes grown under a nutrient replenishment protocol. Plants were grown from vine cuttings of 15cm length and were planted in 0.15 x 0.15 x 1.2m growth channels using a closed nutrient film technique system. Nutrient was supplied in a modified half strength Hoagland's solution with a 1:2.4 N:K ratio. Nutrient replenishment protocol consisted of daily water replenishment to a constant volume of 30.4 liters in the small containers and 273.6 liters in the large container. Nutrients were replenished as needed when the EC of the nutrient solution fell below 1200 mhos/cm. The experimental design used was a split-plot with the main plot being container size and genotypes as the subplot. Nine sweetpotato genotypes were evaluated. Results showed no effect of nutrient solution container size on storage root yield, foliage fresh and dry mass, leaf area or vine length. However, plants grown using the large nutrient solution container accumulated more storage root dry mass than those with the small containers. Although plants grown with the smaller containers showed greater water uptake, plant nutrient uptake was lower than with the larger container. All genotypes evaluated showed variation in their responses to all parameters measured.

Solanaceae/genetics/growth & development↗

NASA NTRS2010

Electrical Switching of Perovskite Thin-Film Resistors

Electronic devices that exploit electrical switching of physical properties of thin films of perovskite materials (especially colossal magnetoresistive materials) have been invented. Unlike some related prior devices, these devices function at room temperature and do not depend on externally applied magnetic fields. Devices of this type can be designed to function as sensors (exhibiting varying electrical resistance in response to varying temperature, magnetic field, electric field, and/or mechanical pressure) and as elements of electronic memories. The underlying principle is that the application of one or more short electrical pulse(s) can induce a reversible, irreversible, or partly reversible change in the electrical, thermal, mechanical, and magnetic properties of a thin perovskite film. The energy in the pulse must be large enough to induce the desired change but not so large as to destroy the film. Depending on the requirements of a specific application, the pulse(s) can have any of a large variety of waveforms (e.g., square, triangular, or sine) and be of positive, negative, or alternating polarity. In some applications, it could be necessary to use multiple pulses to induce successive incremental physical changes. In one class of applications, electrical pulses of suitable shapes, sizes, and polarities are applied to vary the detection sensitivities of sensors. Another class of applications arises in electronic circuits in which certain resistance values are required to be variable: Incorporating the affected resistors into devices of the present type makes it possible to control their resistances electrically over wide ranges, and the lifetimes of electrically variable resistors exceed those of conventional mechanically variable resistors. Another and potentially the most important class of applications is that of resistance-based nonvolatile-memory devices, such as a resistance random access memory (RRAM) described in the immediately following article, Electrically Variable Resistive Memory Devices (MFS-32511-1).

Liu, Shangqing↗

DOE OSTI2024

Mechanisms of Hysteresis and Reversibility across the Voltage-Driven Perovskite–Brownmillerite Transformation in Electrolyte-Gated Ultrathin La 0.5 Sr 0.5 CoO 3−δ

Perovskite cobaltites have emerged as archetypes for electrochemical control of materials properties in electrolyte-gate devices. Voltage-driven redox cycling can be performed between fully oxygenated perovskite and oxygen-vacancy-ordered brownmillerite phases, enabling exceptional modulation of the crystal structure, electronic transport, thermal transport, magnetism, and optical properties. The vast majority of studies, however, have focused heavily on the perovskite and brownmillerite end points. In contrast, here we focus on hysteresis and reversibility across the entire perovskite ↔ brownmillerite topotactic transformation, combining gate-voltage hysteresis loops, minor hysteresis loops, quantitative operando synchrotron X-ray diffraction, and temperature-dependent (magneto)transport, on ion-gel-gated ultrathin (10-unit-cell) epitaxial La 0.5 Sr 0.5 CoO 3-δ films. Further, gate-voltage hysteresis loops combined with operando diffraction reveal a wealth of new mechanistic findings, including asymmetric redox kinetics due to differing oxygen diffusivities in the two phases, nonmonotonic transformation rates due to the first-order nature of the transformation, and limits on reversibility due to first-cycle structural degradation. Minor loops additionally enable the first rational design of an optimal gate-voltage cycle. Combining this knowledge, we demonstrate state-of-the-art nonvolatile cycling of electronic and magnetic properties, encompassing >10 5 transport ON/OFF ratios at room temperature, and reversible metal-insulator-metal and ferromagnet-nonferromagnet-ferromagnet cycling, all at 10-unit-cell thickness with high room-temperature stability. This paves the way for future work to establish the ultimate cycling frequency and endurance of such devices.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Real Time Phasor Analytics (RTPA) and RTPA-SCR System Strength Online Tool

This presentation showcases the Real-Time Phasor Analytics (RTPA) framework for monitoring inertia and assessing system strength in power grids. RTPA is an open-source tool designed to standardize access to data from Power Management Units (PMUs) and Phasor Data Concentrators (PDCs). It facilitates real-time connectivity to multiple PDCs in accordance with the IEEE C37.118-2 standard and supports asynchronous data stream integration. Additionally, RTPA can simulate a PDC server streaming C37.118-2 data and provides Python bindings for seamless interaction with the framework, eliminating the need for direct Rust programming.

24 POWER TRANSMISSION AND DISTRIBUTION↗

NASA NTRS2000

Rudder/Fin Seal Investigations for the X-38 Re-Entry Vehicle

NASA is currently developing the X-38 vehicle that will be used to demonstrate the technologies required for a crew return vehicle (CRV) for the International Space Station. The X-38 control surfaces require high temperature seals to limit hot gas ingestion and transfer of heat to underlying low-temperature structures to prevent over-temperature of these structures and possible loss of the vehicle. This paper presents results for thermal analyses and flow and compression tests conducted on as-received and thermally exposed seals for the rudder/fin location of the X-38. A thermal analysis of the rudder/fin dual seal assembly based on representative heating rates on the windward surface of the rudder/fin area predicted a peak seal temperature of 1900 F. The temperature-exposed seals were heated in a compressed state at 1900 F corresponding to the predicted peak temperature. Room temperature compression tests were performed to determine load versus linear compression, preload, contact area, stiffness, and resiliency characteristics for the as-received and temperature-exposed seals. Temperature exposure resulted in permanent set and loss of resiliency in these seals. Unit loads and contact pressures for the seals were below the 5 lb/in. and 10 psi limits set to limit the loads on the Shuttle thermal tiles that the seals seal against in the rudder/fin location. Measured seal flow rates for a double seal were about 4.5 times higher than the preliminary seal flow goal. The seal designs examined in this study are expected to be able to endure the high temperatures that they will be exposed to for a single-use life. Tests performed herein combined with future analyses, arc jet tests, and scrubbing tests will be used to select the final seal design for this application.

Dunlap, Patrick H., Jr.↗

NASA NTRS2000

Rudder/Fin Seal Investigations for the X-38 Re-Entry Vehicle

NASA is currently developing the X-38 vehicle that will be used to demonstrate the technologies required for a crew return vehicle (CRV) for the International Space Station. The X-38 control surfaces require high temperature seals to limit hot gas ingestion and transfer of heat to underlying low-temperature structures to prevent over-temperature of these structures and possible loss of the vehicle. This paper presents results for thermal analyses and flow and compression tests conducted on as-received and thermally exposed seals for the rudder/fin location of the X-38. A thermal analysis of the rudder/fin dual seal assembly based on representative heating rates on the windward surface of the rudder/fin area predicted a peak seal temperature of 1900 F. The temperature-exposed seals were heated in a compressed state at 1900 F corresponding to the predicted peak temperature. Room temperature compression tests were performed to determine load versus linear compression, preload, contact area, stiffness, and resiliency characteristics for the as-received and temperature-exposed seals. Temperature exposure resulted in permanent set and loss of resiliency in these seals. Unit loads and contact pressures for the seals were below the five pounds/inch and ten psi limits set to limit the loads on the Shuttle thermal tiles that the seals seal against in the rudder/fin location. Measured seal flow rates for a double seal were about 4.5 times higher than the preliminary seal flow goal. The seal designs examined in this study are expected to be able to endure the high temperatures that they will be exposed to for a single-use life. Tests performed herein combined with future analyses, arc jet tests, and scrubbing tests will be used to select the final seal design for this application.

Dunlap, Patrick H., Jr.↗