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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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
NASA NTRS1990

The effect of laser pulse tailored welding of Inconel 718

Pulse tailored laser welding has been applied to wrought, wrought grain grown, and cast Inconel 718 using a CO2 laser. Prior to welding, the material was characterized metallographically and the solid state transformation regions were identified using Differential Scanning Calorimetry and high temperature x-ray diffraction. Bead on plate welds (restrained and unrestrained) were then produced using a matrix of pulse duty cycles and pulsed average power. Subsequent characterization included heat affected zone width, penetration and underbead width, the presence of cracks, microfissures and porosity, fusion zone curvature, and precipitation and liquated region width. Pedigree welding on three selected processing conditions was shown by microstructural and dye penetrant analysis to produce no microfissures, a result which strongly indicates the viability of pulse tailored welding for microfissure free IN 718.

Mccay, T. Dwayne↗
NASA NTRS1990

Welding And Cutting A Nickel Alloy By Laser

Technique effective and energy-efficient. Report describes evaluation of laser welding and cutting of Inconel(R) 718. Notes that electron-beam welding processes developed for In-718, but difficult to use on large or complex structures. Cutting of In-718 by laser fast and produces only narrow kerf. Cut edge requires dressing, to endure fatigue.

Banas, C. M.↗
NASA NTRS2002

Investigation of Friction Stir Welding and Laser Engineered Net Shaping of Metal Matrix Composite Materials

The improvement in weld quality by the friction stir welding (FSW) process invented by TWI of Cambridge, England, patented in 1991, has prompted investigation of this process for advanced structural materials including Al metal matrix composite (Al-MMC) materials. Such materials can have high specific stiffness and other potential beneficial properties for the extreme environments in space. Developments of discontinuous reinforced Al-MMCs have found potential space applications and the future for such applications is quite promising. The space industry has recognized advantages of the FSW process over conventional welding processes such as the absence of a melt zone, reduced distortion, elimination of the need for shielding gases, and ease of automation. The process has been well proven for aluminum alloys, and work is being carried out for ferrous materials, magnesium alloys and copper alloys. Development work in the FSW welding process for joining of Al-MMCs is relatively recent and some of this and related work can be found in referenced research publications. NASA engineers have undertaken to spear head this research development work for FSW process investigation of Al-MMCs. Some of the reported related work has pointed out the difficulty in fusion welding of particulate reinforced MMCs where liquid Al will react with SiC to precipitate aluminum carbide (Al4C3). Advantages of no such reaction and no need for joint preparation for the FSW process is anticipated in the welding of Al-MMCs. The FSW process has been best described as a combination of extrusion and forging of metals. This is carried out as the pin tool rotates and is slowly plunged into the bond line of the joint as the pin tool's shoulder is in intimate contact with the work piece. The material is friction-stirred into a quality weld.

Ravinder M. Diwan↗
NASA NTRS2026

Thermal Cycle and Capacitance Testing of Mezzo Industries Phase Changer Material Heat Capacitor

Effective Thermal management is essential for the safety and performance of human spacecraft, especially during long-duration missions with fluctuating heat loads. Phase Change Material (PCM) heat exchangers offer a compact, efficient solution by storing and releasing thermal energy through latent heat during phase transitions. This allows PCM systems to buffer transient thermal loads without immediate heat rejection, reducing the need for oversized radiators – particularly critical during ascent and re-entry when radiators are stowed. By maintaining stable temperatures in crew cabins and equipment bays, PCM technology enhances crew comfort, protects sensitive systems, and supports long-term mission sustainability with minimal mass and volume impact. A phase change material heat capacitor prototype, designed and built under a NASA Small Business Innovation Research grant by Mezzo Technologies, utilizes a laser welding microtube manufacturing process that promises increased reliability and performance over current manufacturing methods like brazing. This heat exchanger was tested through coolant thermal cycling within the expected flow rates and temperature range of the Orion spacecraft, the crewed spacecraft taking NASA astronauts to the moon under the Artemis Program. The useful heat storage capacitance was measured and compared to Orion spacecraft requirements.

Active Thermal Control Systems↗
NASA NTRS2009

Laser Peening Effects on Friction Stir Welding

The laser peening process can result in considerable improvement to crack initiation, propagation, and mechanical properties in FSW which equates to longer hardware service life Processed hardware safety is improved by producing higher failure tolerant hardware, and reducing risk. Lowering hardware maintenance cost produces longer hardware service life, and lower hardware down time. Application of this proposed technology will result in substantial benefits and savings throughout the life of the treated components

Hatameleh, Omar↗
NASA NTRS1985

Improved turbopump dynamics

A study was initiated to investigate the practicality of increasing rotor critical speeds by changes in manufacturing method. The technique would be to build a pump with an all laser welded shaft and case; such unit to be opened by laser cutting and rebuilt by rewelding the same surface. Use of a split casing, common in industry, would permit assembly of the rotor outside the case. A team was formed to perform the study; however, the work of the team was severely restricted by conflict with higher priority tasks. No manpower was available to evaluate alternate configurations. Thus, much of the synergetic effects of cohesive design modification was lost. Although very limited results were achieved, nothing was found to indicate that the method is not worth further investigation.

Kiefling, L.↗
NASA NTRSDate not supplied

Design and Applications of Tethered Spacecraft Simulators

Small, tethered spacecraft, or space tugs, are a promising space capability. They can be deployed on tethers and used for a wide variety of in-space activities; a large portion of which fall under in-space servicing, assembly, manufacturing (ISAM) functions. This includes functions such as structural mating and assembly, servicing, proximity operations, capture, docking, mating, and relocation. However, there is a great deal of work to be done to raise the Technology Readiness Level (TRL) of the capabilities needed to fully realize these capabilities. The Flat Floor Robotics Lab (FFRL) at NASA’s Marshall Spaceflight Center (MSFC) has been working on space tug development for several years. The eponymous floor is 44 by 86 feet, made from a self-leveling epoxy. This creates an extremely smooth surface that air bearings can float on with very little friction, creating a simulation of zero gravity in a two-dimensional plane. The lab has several platforms of various sizes that act as vehicle simulators for testing sensors, control algorithms, mechanisms, etc. One of these platforms is a small spacecraft simulator, which can be tethered to simulate a space tug. In the last several months, the FFRL team has been working with MSFC’s welding group to conduct a laser beam welding demonstration on air bearing platforms. This demo is utilizing a space tug simulator to fly up to a floating weld platform, where two parts are clamped together and laser welded. The space tug simulator has an air bearing to provide float, as well as several actuated air thrusters to provide propulsion and make the simulator maneuverable. Currently, flights of this simulator are completed by a human operator. An RF hand controller sends signals to both actuate and fire three sets of thrusters on the simulator. This makes any maneuvers of the space tug highly subject to human error, and operators must have dedicated practice time before being able to perform maneuvers with any sufficient reliability. For the current laser welding demonstration, human operated performance is sufficient, but future implementations of in-space welding and other ISAM efforts will require higher precision, reliability, and autonomy. MSFC has funded a project that will allow a small team in the FFRL to develop the next generation of space tug simulator, which will be automated. Closed loop control will allow a user to command a position, or set of positions, that the simulator will be able to “fly” to on its own. This Maneuverable Automated Tethered Spacecraft (MATS) simulator will have configurable design, to allow a variety of payloads and mission configurations to be demonstrated on the air bearing floor. This will be an invaluable test bed for low and mid TRL advancement for space tether mission subsystems, such as more advanced demonstrations of in-space welding. Once one MATSS is constructed and demonstrated effectively, several more can be built, enabling more advanced tether missions; Electric Sail test beds, sensor arrays, and other science-enabling missions. This paper will detail the design and test of the FFRL’s MATS simulator, including efforts to establish closed loop control and autonomous capabilities. It will also detail use cases for this technology, and how it will further develop both develop science and exploration missions.

Space Tethers↗
NASA NTRS1987

Uranium nitride fuel fabrication for SP-100 reactors

Fuel pins of uranium mononitride clad in Nb-1 percent Zr were fabricated for irradiation tests in EBR-II. Laboratory scale process parameters to synthesize UN powders and fabricate UN pellets were developed. Uranium mononitride was prepared by converting UO2 to UN. Fuel pellets were prepared by communition of UN briquettes, uniaxial pressing, and high temperature sintering. Techniques for machining, cleaning, and welding Nb-1 percent Zr cladding components were developed. End caps were electron beam welded to the tubing. Helium back-fill holes were sealed with a laser weld.

Mason, Richard E.↗
NASA NTRS1976

Laser absorption phenomena in flowing gas devices

A theoretical and experimental investigation is presented of inverse Bremsstrahlung absorption of CW CO2 laser radiation in flowing gases seeded with alkali metals. In order to motivate this development, some simple models are described of several space missions which could use laser powered rocket vehicles. Design considerations are given for a test call to be used with a welding laser, using a diamond window for admission of laser radiation at power levels in excess of 10 kW. A detailed analysis of absorption conditions in the test cell is included. The experimental apparatus and test setup are described and the results of experiments presented. Injection of alkali seedant and steady state absorption of the laser radiation were successfully demonstrated, but problems with the durability of the diamond windows at higher powers prevented operation of the test cell as an effective laser powered thruster.

Chapman, P. K.↗
NASA NTRS2007

Effects of Different R ratios on Fatigue Crack Growth in Laser Peened Friction Stir Welds

The influence of laser peening on the fatigue crack growth behavior of friction stir welded (FSW) Aluminum Alloy (AA) 7075-T7351 sheets was investigated. The surface modification resulting from the peening process on the fatigue crack growth of FSW was assessed for two different R ratios. The investigation indicated a significant decrease in fatigue crack growth rates resulting from using laser shock peening compared with unpeened, welded and unwelded specimens. The slower fatigue crack growth rate was attributed to the compressive residual stresses induced by the peening.

Hatamleh, Omar↗
NASA NTRS1977

Production

The manufacturing tasks and life support systems that would pertain to a space habitat located at the Lagrange equilibrium point L5 are examined. Aluminum and titanium could be obtained from the moon minerals anorthosite and ilmenite, respectively. Although hydrogen required for purifying the metals would probably have to be imported from earth, the L5 project should have abundant energy for the processing. Methods of utilizing various glasses and ceramics common in the moon are being investigated. Manufacturing processes, such as capillary brazing, ceramic melting, laser welding, and other techniques, are considered with respect to their suitability at zero gravity and in a vacuum. With regard to life support, high-intensity agriculture is discussed, with attention to the use of a mirror system to provide continuous illumination.

Hibbs, A. R.↗
NASA NTRS1994

Quantitative 3-D imaging topogrammetry for telemedicine applications

The technology to reliably transmit high-resolution visual imagery over short to medium distances in real time has led to the serious considerations of the use of telemedicine, telepresence, and telerobotics in the delivery of health care. These concepts may involve, and evolve toward: consultation from remote expert teaching centers; diagnosis; triage; real-time remote advice to the surgeon; and real-time remote surgical instrument manipulation (telerobotics with virtual reality). Further extrapolation leads to teledesign and telereplication of spare surgical parts through quantitative teleimaging of 3-D surfaces tied to CAD/CAM devices and an artificially intelligent archival data base of 'normal' shapes. The ability to generate 'topogrames' or 3-D surface numerical tables of coordinate values capable of creating computer-generated virtual holographic-like displays, machine part replication, and statistical diagnostic shape assessment is critical to the progression of telemedicine. Any virtual reality simulation will remain in 'video-game' realm until realistic dimensional and spatial relational inputs from real measurements in vivo during surgeries are added to an ever-growing statistical data archive. The challenges of managing and interpreting this 3-D data base, which would include radiographic and surface quantitative data, are considerable. As technology drives toward dynamic and continuous 3-D surface measurements, presenting millions of X, Y, Z data points per second of flexing, stretching, moving human organs, the knowledge base and interpretive capabilities of 'brilliant robots' to work as a surgeon's tireless assistants becomes imaginable. The brilliant robot would 'see' what the surgeon sees--and more, for the robot could quantify its 3-D sensing and would 'see' in a wider spectral range than humans, and could zoom its 'eyes' from the macro world to long-distance microscopy. Unerring robot hands could rapidly perform machine-aided suturing with precision micro-sewing machines, splice neural connections with laser welds, micro-bore through constricted vessels, and computer combine ultrasound, microradiography, and 3-D mini-borescopes to quickly assess and trace vascular problems in situ. The spatial relationships between organs, robotic arms, and end-effector diagnostic, manipulative, and surgical instruments would be constantly monitored by the robot 'brain' using inputs from its multiple 3-D quantitative 'eyes' remote sensing, as well as by contact and proximity force measuring devices. Methods to create accurate and quantitative 3-D topograms at continuous video data rates are described.

Altschuler, Bruce R.↗
NASA NTRS2000

Challenges of Packaging Photonic Devices

Presently used photonic packaging methods are labor intensive and often unreliable. Studies have shown laser welding to be the superior fastening technology but it must be used in combination with a compatible positioning technology. The right combination of positioning technology and fastening technology which will result in low cost, reliable photonic assemblies is yet to be developed.

Lutes, George↗
NASA NTRS2005

Development of a Thin-Film Solar Cell Interconnect for the Powersphere Concept

Dual junction amorphous silicon (a-Si) solar cells produced on polyimide substrate have been selected as the best candidate to produce a lightweight solar array for the PowerSphere program. The PowerSphere concept features a space-inflatable, geodetic solar array approximately 0.6 meters in diameter and capable of generating about 20W of electrical power. Trade studies of various wiring concepts and connection methods led to an interconnect design with a copper contact that wraps around the edge, to the back of the solar cell. Applying Plasma Vapor Deposited (PVD) copper film to both sides and the edge of the solar cell produces the wrap around contact. This procedure results in a contact pad on the back of the solar cell, which is then laser welded to a flex circuit material. The flex circuit is constructed of copper in a custom designed routing pattern, and then sandwiched in a Kapton insulation layer. The flex circuit then serves as the primary power distribution system between the solar cells and the spacecraft. Flex circuit material is the best candidate for the wiring harness because it allows for low force deployment of the solar cells by the inflatable hinges on the PowerSphere. An additional frame structure, fabricated and assembled by ILC Dover, will reinforce the wrap around contact-flex blanket connection, thus providing a mechanically robust solar cell interconnect for the PowerSphere multifunctional program. The PowerSphere team will use the wraparound contact design approach as the primary solution for solar cell integration and the flex blanket for power distribution.

Simburger, Edward J.↗
NASA NTRS2005

Multifunctional Deployment Hinges Rigidified by Ultraviolet

Multifunctional hinges have been developed for deploying and electrically connecting panels comprising planar arrays of thin-film solar photovoltaic cells. In the original intended application of these hinges, the panels would be facets of a 32-sided (and approximately spherical) polyhedral microsatellite (see figure), denoted a PowerSphere, that would be delivered to orbit in a compact folded configuration, then deployed by expansion of gas in inflation bladders. Once deployment was complete, the hinges would be rigidified to provide structural connections that would hold the panels in their assigned relative positions without backlash. Such hinges could also be used on Earth for electrically connecting and structurally supporting solar panels that are similarly shipped in compact form and deployed at their destinations. As shown in section A-A in the figure, a hinge of this type is partly integrated with an inflation bladder and partly integrated with the frame of a solar panel. During assembly of the hinge, strip extensions from a flexible circuit harness on the bladder are connected to corresponding thin-film conductors on the solar panel by use of laser welding and wrap-around contacts. The main structural component of the hinge is a layer of glass fiber impregnated with an ultraviolet-curable resin. After deployment, exposure to ultraviolet light from the Sun cures the resin, thereby rigidifying the hinge.

Kerslake, Thomas W.↗
NASA NTRS2005

High-Power Fiber Lasers Using Photonic Band Gap Materials

High-power fiber lasers (HPFLs) would be made from photonic band gap (PBG) materials, according to the proposal. Such lasers would be scalable in the sense that a large number of fiber lasers could be arranged in an array or bundle and then operated in phase-locked condition to generate a superposition and highly directed high-power laser beam. It has been estimated that an average power level as high as 1,000 W per fiber could be achieved in such an array. Examples of potential applications for the proposed single-fiber lasers include welding and laser surgery. Additionally, the bundled fibers have applications in beaming power through free space for autonomous vehicles, laser weapons, free-space communications, and inducing photochemical reactions in large-scale industrial processes. The proposal has been inspired in part by recent improvements in the capabilities of single-mode fiber amplifiers and lasers to produce continuous high-power radiation. In particular, it has been found that the average output power of a single strand of a fiber laser can be increased by suitably changing the doping profile of active ions in its gain medium to optimize the spatial overlap of the electromagnetic field with the distribution of active ions. Such optimization minimizes pump power losses and increases the gain in the fiber laser system. The proposal would expand the basic concept of this type of optimization to incorporate exploitation of the properties (including, in some cases, nonlinearities) of PBG materials to obtain power levels and efficiencies higher than are now possible. Another element of the proposal is to enable pumping by concentrated sunlight. Somewhat more specifically, the proposal calls for exploitation of the properties of PBG materials to overcome a number of stubborn adverse phenomena that have impeded prior efforts to perfect HPFLs. The most relevant of those phenomena is amplified spontaneous emission (ASE), which causes saturation of gain and power at undesirably low levels, and scattering of light from dopants. In designing a given fiber laser for reduced ASE, care must be taken to maintain a correct fiber structure for eventual scaling to an array of many such lasers such that the interactions among all the members of the array would cause them to operate in phase lock. Hence, the problems associated with improving a single-fiber laser are not entirely separate from the bundling problem, and some designs for individual fiber lasers may be better than others if the fibers are to be incorporated into bundles. Extensive calculations, expected to take about a year, must be performed in order to determine design parameters before construction of prototype individual and fiber lasers can begin. The design effort can be expected to include calculations to optimize overlaps between the electromagnetic modes and the gain media and calculations of responses of PBG materials to electromagnetic fields. Design alternatives and physical responses that may be considered include simple PBG fibers with no intensity-dependent responses, PBG fibers with intensity- dependent band-gap shifting (see figure), and broad-band pumping made possible by use of candidate broad-band pumping media in place of the air or vacuum gaps used in prior PBG fibers.

DiDomenico, Leo↗