Study of tooling concepts for manufacturing operations in space Final report
Mechanical linkage device for manufacturing operations with orbital workshops
Boyd, R. E.↗
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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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Nickel-Graphite Composite Compliant Interface and/or Hot Shoe Material
Next-generation high-temperature thermoelectric-power-generating devices will employ segmented architectures and will have to reliably withstand thermally induced mechanical stresses produced during component fabrication, device assembly, and operation. Thermoelectric materials have typically poor mechanical strength, exhibit brittle behavior, and possess a wide range of coefficient of thermal expansion (CTE) values. As a result, the direct bonding at elevated temperatures of these materials to each other to produce segmented leg components is difficult, and often results in localized microcracking at interfaces and mec hanical failure due to the stresses that arise from the CTE mismatch between the various materials. Even in the absence of full mechanical failure, degraded interfaces can lead to increased electrical and thermal resistances, which adversely impact conversion efficiency and power output. The proposed solution is the insertion of a mechanically compliant layer, with high electrical and thermal conductivity, between the low- and high-temperature segments to relieve thermomechanical stresses during device fabrication and operation. This composite material can be used as a stress-relieving layer between the thermoelectric segments and/or between a thermoelectric segment and a hot- or cold-side interconnect material. The material also can be used as a compliant hot shoe. Nickel-coated graphite powders were hot-pressed to form a nickel-graphite composite material. A freestanding thermoelectric segmented leg was fabricated by brazing the compliant pad layer between the high-temperature p- Zintl and low-temperature p-SKD TE segments using Cu-Ag braze foils. The segmented leg stack was heated in vacuum under a compressive load to achieve bonding. The novelty of the innovation is the use of composite material that re duces the thermomechanical stresses en - countered in the construction of high-efficiency, high-temperature therm - o-electric devices. The compliant pad enables the bonding of dissimilar thermoelectric materials while maintaining the desired electrical and thermal properties essential for efficient device operation. The modulus, CTE, electrical, and thermal conductances of the composite can be controlled by varying the ratio of nickel to graphite.
Firdosy, Samad A.↗
Mechanical energy storage device for hip disarticulation
An artificial leg including a trunk socket, a thigh section hingedly coupled to the trunk socket, a leg section hingedly coupled to the thigh section and a foot section hingedly coupled to the leg section is outlined. A mechanical energy storage device is operatively associated with the artificial leg for storage and release of energy during the normal walking stride of the user. Energy is stored in the mechanical energy storage device during a weight-bearing phase of the walking stride when the user's weight is on the artificial leg. Energy is released during a phase of the normal walking stride, when the user's weight is removed from the artificial leg. The stored energy is released from the energy storage device to pivot the thigh section forwardly about the hinged coupling to the trunk socket.
Vallotton, W. C.↗
Program for the exploitation of unused NASA patents
The program to exploit unused NASA patents through the use of a multidisciplinary approach involving faculty students, and research staff is reported. NASA patents were screened for their applicability outside the space program, specific applications were identified, and the technical and commercial feasibility of these applications was established. Also application of this technology by governmental agencies outside the space program was sought. The program was specifically interested in energy absorbing devices such as those developed for lunar soft landings. These energy absorbing devices absorb large amounts of mechanical energy but are, in general, not reusable. Some of these devices can also operate as structural elements until their structural load capacity is exceeded and they become activated as energy absorbers. The capability of these devices to operate as structural elements and as energy absorbing devices makes them candidates for many applications in the fields of transportation and materials handling safety where accidents take a large toll in human injury and property damage.
Fay, R. J.↗
Impulse Measurements of Electric Solid Propellant in an Electrothermal Ablation-Fed Pulsed Plasma Thruster
Electric solid propellants are advanced solid chemical rocket propellants that can be controlled (ignited, throttled and extinguished) through the application and removal of an electric current. These propellants are also being considered for use in the ablative pulsed plasma thruster. In this paper, the performance of an electric solid propellant operating in an electrothermal ablation-fed pulsed plasma thruster was investigated using an inverted pendulum micro-Newton thrust stand. The impulse bit and specific impulse of the device using the electric solid propellant were measured for short-duration test runs of 100 pulses and longer-duration runs to end-of-life, at energy levels of 5, 10, 15 and 20 J. Also, the device was operated using the current state-of-the-art ablation-fed pulsed plasma thruster propellant, polytetrafluoroethylene or PTFE. Impulse bit measurements for PTFE indicate 100±20 μN-s at an initial energy level of 5 J, which increases linearly by ~30 μN-s/J with increased initial energy. Measurements of the impulse bit for the electric solid propellant are on average lower than PTFE by 10% or less. Specific impulse for when operating on PTFE is calculated to be about 450 s compared to 225 s for the electric solid propellant. The 50% reduction in specific impulse is due to increased mass ablated during operation with the electric solid propellant relative to PTFE.
Glascock, Matthew S.↗
200 h of discharge cycling with an all-aqueous copper thermally regenerative ammonia battery
Thermally regenerative ammonia batteries (TRABs) offer an approach to energy storage and electricity generation by harnessing low-grade heat (T < 150 °C). A TRAB discharge resembles that of a flow battery, where electrochemical reactions produce electrical power from energy stored within aqueous electrolytes. While there are many types of TRABs, the all-aqueous copper TRAB (Cu aq -TRAB) has produced the largest power and energy storage densities. Despite many improvements to TRAB performance, most tests have only lasted a few hours, which are not representative of operation times expected of these devices. Herein, we operated a Cu aq -TRAB for 200 h of constant current discharging to assess battery performance and component stability. After 200 h of testing, the average power density increased slightly to 7.2 mW cm -2 , which was within 0.01 % of starting conditions. Likewise, the average energy density for the final cycle was only 0.03 % lower than the initial cycle. The overall insensitivity of the power cell to cycling represents a major milestone in the advancement of TRAB systems. In conclusion, energy dispersive X-ray spectroscopy provides evidence to suggest that these small changes in power and energy density are likely to the membrane acclimating to TRAB electrolytes.
25 ENERGY STORAGE↗
Plasma confinement state classification via FPP relevant microwave diagnostics
We present a parsimonious and robust machine learning approach for identifying plasma confinement states in fusion power plants (FPPs) where reliable identification of the low-confinement and high-confinement regimes is critical for safe and efficient operation. Unlike research-oriented devices, FPPs must operate with a severely constrained set of diagnostics. To address this challenge, we demonstrate that a minimalist model, using only electron cyclotron emission (ECE) signals, can achieve accurate and reliable state classification. ECE provides electron temperature profiles without the engineering or survivability issues of in-vessel probes, making it a primary candidate for FPP-relevant diagnostics. Our framework employs ECE as input, extracts features using radial basis functions, and applies a gradient boosting classifier, achieving a test accuracy of 96% (correct predictions). Robustness analysis and feature importance analyzes confirm the approach’s reliability. These results demonstrate that state-of-the-art performance is attainable from a restricted diagnostic set, paving the way for minimalist yet resilient plasma control architectures for FPPs.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
SPARC 3D Field Physics and Support of the Non-Axisymmetric Coil Assessment
Commonwealth Fusion Systems (CFS) is deploying SPARC, a net-energy tokamak, by 2025. A notable challenge facing all tokamak approaches to fusion energy production is maintaining a stable plasma and thereby steady energy production. “Disruptions” to plasma operation are often encountered in devices when they operate at high normalized pressure, high normalized density, or high normalized current. SPARC is unique in that it is expected to demonstrate Q>=2 in a plasma with low normalized pressure and density, but with a more modest current limit buffer sufficient to avoid disruptions. Due to both the high normalized current and high magnetic field of the SPARC design, it is expected to decrease its relative resilience to instabilities driven by non-axisymmetry in the externally applied magnetic field, termed ‘error fields’. To prevent error field driven instabilities, a primary line of defense is strict engineering tolerances in magnet fabrication and installation. A secondary line of defense is a purpose-built set of magnetic coils to correct these errors, termed error field correction coils (EFCCs). The overarching goals of this INFUSE project were to evaluate the effectiveness of the EFCCs in the SPARC design and provide guidance as to how to improve this effectiveness.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
Reconfiguration of Analog Electronics for Extreme Environments: Problem or Solution?
This paper argues in favor of adaptive reconfiguration as a technique to expand the operational envelope of analog electronics for extreme environments (EE). In addition to hardening-by-process and hardening-by-design, "hardening-by-reconfiguration", when applicable, could be used to mitigate drifts, degradation, or damage on electronic devices (chips) in EE, by using re-configurable devices and an adaptive self-reconfiguration of their circuit topology. Conventional circuit design exploits device characteristics within a certain temperature/radiation range; when that is exceeded, the circuit function degrades. On a reconfigurable device, although component parameters change in EE, as long as devices still operate, albeit degraded, a new circuit design, suitable for new parameter values, may be mapped into the reconfigurable structure to recover the initial circuit function. Partly degraded resources are still used, while completely damaged resources are bypassed. Designs suitable for various environmental conditions can be determined prior to operation or can be determined in-situ, by adaptive reconfiguration algorithms running on built-in digital controllers. Laboratory demonstrations of this technique were performed by JPL in several independent experiments in which bulk CMOS reconfigurable devices were exposed to, and degraded by, low temperatures (approx. 196 C), high temperatures (approx.300 C) or radiation (300kRad TID), and then recovered by adaptive reconfiguration using evolutionary search algorithms. Taking this technology from Technology Readiness Level (TRL) 3 to TRL 5 is the target of a current NASA project.
Field Programmable Transistor Array (FPTA)↗
Applications to aircraft propulsion systems
Estimates of the prospects for quiet airplanes in the future are summarized. The SST using afterburning turbojets and no sound suppression is estimated to produce 129 EPNdb on the sideline. Suppression devices and operating techniques can reduce this noise markedly. The present fleet of 707's and DC-8's produces noises nearly as high as 120 decibels on approach. Combinations of sound absorbing devices and engine modifications are expected to give a noise near 100 decibels. The new advanced technology transports (ATT) are being studied with two noise goals in mind: one is 10 decibels and the other is 20 decibels below the FAR level of 106 on takeoff. New trijets using new quiet engines are expected to meet 90 EPNdb. Future advances in technology are expected to yield another 5 decibels to give noise levels of 80 EPNdb. The STOL airplane has a noise goal of 95 EPNdb along a sideline 500 feet from the runway.
Sanders, N. D.↗
Orbital refill of propulsion vehicle tankage
Techniques for orbital refueling of space based vehicles were developed and experimental programs to verify these techniques were identified. Orbital refueling operations were developed for two cryogenic orbital transfer vehicles (OTV's) and an Earth storable low thrust liquid propellant vehicle. Refueling operations were performed assuming an orbiter tanker for near term missions and an orbital depot. Analyses were conducted using liquid hydrogen and N2O4. The influence of a pressurization system and acquisition device on operations was also considered. Analyses showed that vehicle refill operations will be more difficult with a cryogen than with an earth storable. The major elements of a successful refill with cryogens include tank prechill and fill. Propellant quantities expended for tank prechill appear to to insignificant. Techniques were identified to avoid loss of liquid or excessive tank pressures during refill. It was determined that refill operations will be similar whether or not an orbiter tanker or orbital depot is available. Modeling analyses were performed for prechill and fill tests to be conducted assuming the Spacelab as a test bed, and a 1/10 scale model OTV (with LN2 as a test fluid) as an experimental package.
Merino, F.↗
A g-load display for remotely piloted vehicles and other aircraft that are subject to maneuvering constraints
The absence of kinesthetic cues deprives RPV pilots of essential feedback, particularly during high speed maneuvers. A display was designed to facilitate pilot control of g loads and to permit an immediate indication of g-load constraint violations. The display embodies all the motion vector components that contribute to maneuvering accelerations. In one mode of operation, the device displays the components of angular velocity as variable length pointers emanating from the center of a circle whose radius is determined by the linear velocity of the vehicle. An alternative mode of operation permits the pilot to select a display in which g loads are presented directly as variable length pointers emanating from the center of a circle whose radius is again determined by the linear velocity of the vehicle. Each circle defines a safe region of operation, and penetration of the circumference of the appropriate circle by a pointer implies that the structural design load was exceeded.
Howard, J. C.↗
Portable device for detection of petit mal epilepsy
A portable device that analyzes the electroencephalogram to determine if petit mal epilepsy waveforms are present is developed and tested. Clinicians should find it useful in diagnosing seizure activity of their patients. The micropower, battery-operated, portable device indicates a seizure has occurred if three criteria are satisfied: (1) frequencies of 2.5-7 Hz, (2) large-amplitude waves, and (3) minimum number of waves per second. Levels and counts are adjustable, thus insuring high reliability against noise artifacts and permitting each subject to be individually fitted. The device has shown promise in giving the patient a possible mechanism of seizure control or suppression.
Smith, R. G.↗
Sensor, fuel depletion summary report, 1 jul. 1963 - 15 mar. 1965
Control device and operational mode for fuel flow depletion in sensors - oscillator, switch drive, output switch, and wet-dry simulator
SENSOR↗
Dual-sided charge-coupled devices
Existing charge-coupled devices (CCDs) operate by detecting either the electrons or holes created in an ionization event. Here, we propose an imager, the dual-sided CCD, which collects and measures both charge carriers on opposite sides of the device via a dual-buried channel architecture. We show that this dual detection strategy provides exceptional dark-count rejection and enhanced timing capabilities. These advancements have wide-ranging implications for dark-matter searches, near-infrared/optical spectroscopy, and time-domain x-ray astrophysics.
46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
Demand Driven Energy Management for PIPO Auxiliary Power Supply Architecture
In this paper, a demand driven energy management (DDEM) technique is implemented on modular parallel input parallel output DC/DC auxiliary power supply (APS) structure. In this method, modules are brought in/out of the operation making them operate under high loading conditions, avoiding low efficiency under light load. Such a method finds its application in power conservative systems with variable load. Implementation of DDEM and the energy saved is shown using APS comprised of two 15W commercially off-the-shelf DC-DC modules, with 100–1000 VDC input and 24 V output voltage. Along with the DDEM, the lifetime of the power stage devices is controlled minimizing their junction temperature swing through control of cooling system. This control method uses digital twin as interface to virtualize the power devices loading operation/ health condition. Accordingly, no extra sensor or closed loop control required to measure the junction temperature of the devices or feedback the losses to the cooling flow.
Azadeh, Yalda↗
High-Temperature Smart Structures for Engine Noise Reduction and Performance Enhancement
One of key NASA goals is to develop and integrate noise reduction technology to enable unrestricted air transportation service to all communities. One of the technical priorities of this activity has been to account for and reduce noise via propulsion/airframe interactions, identifying advanced concepts to be integrated with the airframe to mitigate these noise-producing mechanisms. An adaptive geometry chevron using embedded smart structures technology offers the possibility of maximizing engine performance while retaining and possibly enhancing the favorable noise characteristics of current designs. New high-temperature shape memory alloy (HTSMA) materials technology enables the devices to operate in both low-temperature (fan) and high-temperature (core) exhaust flows. Chevron-equipped engines have demonstrated reduced noise in testing and operational use. It is desirable to have the noise benefits of chevrons in takeoff/landing conditions, but have them deployed into a minimum drag position for cruise flight. The central feature of the innovation was building on rapidly maturing HTSMA technology to implement a next-generation aircraft noise mitigation system centered on adaptive chevron flow control surfaces. In general, SMA-actuated devices have the potential to enhance the demonstrated noise reduction effectiveness of chevron systems while eliminating the associated performance penalty. The use of structurally integrated smart devices will minimize the mechanical and subsystem complexity of this implementation. The central innovations of the effort entail the modification of prior chevron designs to include a small cut that relaxes structural stiffness without compromising the desired flow characteristics over the surface; the reorientation of SMA actuation devices to apply forces to deflect the chevron tip, exploiting this relaxed stiffness; and the use of high-temperature SMA (HTSMA) materials to enable operation in the demanding core chevron environment. The overall conclusion of these design studies was that the cut chevron concept is a critical enabling step in bringing the variable geometry core chevron within reach. The presence of the cut may be aerodynamically undesirable in some respects, but it is present only when the chevron is not immersed in the core jet exhaust. When deployed, the gap closes as the chevron tip enters the high-speed, high-temperature core stream. Aeroacoustic testing and flow visualization support the contention that this cut is inconsequential to chevron performance.
Quackenbush, Todd R.↗
Dual charge-coupled device /CCD/, astronomical spectrometer and direct imaging camera. II - Data handling and control systems
The data collection system for the MASCOT (MIT Astronomical Spectrometer/Camera for Optical Telescopes) is described. The system relies on an RCA 1802 microprocessor-based controller, which serves to collect and format data, to present data to a scan converter, and to operate a device communication bus. A NOVA minicomputer is used to record and recall frame images and to perform refined image processing. The RCA 1802 also provides instrument mode control for the MASCOT. Commands are issued using STOIC, a FORTH-like language. Sufficient flexibility has been provided so that a variety of CCDs can be accommodated.
Dewey, D.↗