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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS1996

Magnetic levitation systems for future aeronautics and space research and missions

The objectives, advantages, and research needs for several applications of superconducting magnetic levitation to aerodynamics research, testing, and space-launch are discussed. Applications include very large-scale magnetic balance and suspension systems for high alpha testing, support interference-free testing of slender hypersonic propulsion/airframe integrated vehicles, and hypersonic maglev. Current practice and concepts are outlined as part of a unified effort in high magnetic fields R&D within NASA. Recent advances in the design and construction of the proposed ground-based Holloman test track (rocket sled) that uses magnetic levitation are presented. It is protected that ground speeds of up to Mach 8 to 11 at sea-level are possible with such a system. This capability may enable supersonic combustor tests as well as ramjet-to-scramjet transition simulation to be performed in clean air. Finally a novel space launch concept (Maglifter) which uses magnetic levitation and propulsion for a re-usable 'first stage' and rocket or air-breathing combined-cycle propulsion for its second stage is discussed in detail. Performance of this concept is compared with conventional advanced launch systems and a preliminary concept for a subscale system demonstration is presented.

Blankson, Isaiah M.↗
NASA NTRS2008

Analysis of the Effects of Vitiates on Surface Heat Flux in Ground Tests of Hypersonic Vehicles

To achieve the high enthalpy conditions associated with hypersonic flight, many ground test facilities burn fuel in the air upstream of the test chamber. Unfortunately, the products of combustion contaminate the test gas and alter gas properties and the heat fluxes associated with aerodynamic heating. The difference in the heating rates between clean air and a vitiated test medium needs to be understood so that the thermal management system for hypersonic vehicles can be properly designed. This is particularly important for advanced hypersonic vehicle concepts powered by air-breathing propulsion systems that couple cooling requirements, fuel flow rates, and combustor performance by flowing fuel through sub-surface cooling passages to cool engine components and preheat the fuel prior to combustion. An analytical investigation was performed comparing clean air to a gas vitiated with methane/oxygen combustion products to determine if variations in gas properties contributed to changes in predicted heat flux. This investigation started with simple relationships, evolved into writing an engineering-level code, and ended with running a series of CFD cases. It was noted that it is not possible to simultaneously match all of the gas properties between clean and vitiated test gases. A study was then conducted selecting various combinations of freestream properties for a vitiated test gas that matched clean air values to determine which combination of parameters affected the computed heat transfer the least. The best combination of properties to match was the free-stream total sensible enthalpy, dynamic pressure, and either the velocity or Mach number. This combination yielded only a 2% difference in heating. Other combinations showed departures of up to 10% in the heat flux estimate.

Cuda, Vincent↗
NASA NTRS2007

Clean Assembly of Genesis Collector Canister for Flight: Lessons for Planetary Sample Return

Measurement of solar composition in the Genesis collectors requires not only high sensitivity but very low blanks; thus, very strict collector contamination minimization was required beginning with mission planning and continuing through hardware design, fabrication, assembly and testing. Genesis started with clean collectors and kept them clean inside of a canister. The mounting hardware and container for the clean collectors were designed to be cleanable, with access to all surfaces for cleaning. Major structural components were made of aluminum and cleaned with megasonically energized ultrapure water (UPW). The UPW purity was >18 M resistivity. Although aluminum is relatively difficult to clean, the Genesis protocol achieved level 25 and level 50 cleanliness on large structural parts; however, the experience suggests that surface treatments may be helpful on future missions. All cleaning was performed in an ISO Class 4 (Class 10) cleanroom immediately adjacent to an ISO Class 4 assembly room; thus, no plastic packaging was required for transport. Persons assembling the canister were totally enclosed in cleanroom suits with face shield and HEPA filter exhaust from suit. Interior canister materials, including fasteners, were installed, untouched by gloves, using tweezers and other stainless steel tools. Sealants/lubricants were not exposed inside the canister, but vented to the exterior and applied in extremely small amounts using special tools. The canister was closed in ISO Class 4, not to be opened until on station at Earth-Sun L1. Throughout the cleaning and assembly, coupons of reference materials that were cleaned at the same time as the flight hardware were archived for future reference and blanks. Likewise reference collectors were archived. Post-mission analysis of collectors has made use of these archived reference materials.

Allton, J. H.↗
DOE OSTI2020

Thin Film Characterization on Cu/SnAg Solder Interface for 3D Packaging Technologies

Copper is a commonly used interconnect metal in microelectronic interconnects due to its exceptional electrical and thermal properties. Particularly in applications of the 2.5 and 3D integration, Cu is utilized in through-silicon-vias (TSVs) and flip chip interconnects between microelectronic chips for providing miniaturization, lower power and higher performance than current 2D packaging approaches. Furthermore, SnAg capped Cu pillars are a common high-density interconnect technology for flip chip bonding. For these interconnects, specific properties of the Cu surface, such as roughness and cleanliness, are an important factor in the process to ensure quality solder bumps. During electroplating, tight processing parameters must be met so that defects are avoided, and high bump uniformity is achieved. An understanding of the interactions at the solder and Cu pillar interface is needed, based on the electroplating parameters, to determine the best method for populating solder on the wafer surface. In this study, surface treatment techniques such as oxygen plasma cleaning were performed on the Cu surfaces and the SnAg plating chemistry for depositing the solder were evaluated through hull cell testing to qualitatively determine the range of current densities to investigate. It was observed that current density while plating played a large role in solder bump deposition morphology. At the higher current densities greater than 60 mA/cm 2 , bump height non-uniformity and dendritic growth are observed and at lower current densities, less than or equal to 60 mA/cm 2 , uniform, continuous bump height occurred.

36 MATERIALS SCIENCE↗
NASA NTRSDate not supplied

Laser Beam Welding Advancements for In-Space Servicing, Assembly, and Manufacturing

NASA is currently working to develop in-space servicing, assembly, and manufacturing (ISAM) capabilities for low Earth orbit and the lunar surface. One crucial technology for this effort is laser beam welding. Laser systems can perform joining, cleaning, cutting, and repair activities, which will enable the construction of large in-space structures that could not fit on a single launch vehicle, such as trusses for solar panels, radiators, or communications infrastructure. Multiple projects studying laser welding for space applications are currently underway at NASA Marshall Space Flight Center. One of these, the DIsk-Shaped Configurable and Modular vAcuum uNit (DISCMAN), is a compact vacuum chamber designed to support parameter development for laser welding in microgravity. It contains a rotating platen with weld samples made from aluminum, steel, and titanium, a high-power infrared laser, and integrated pumps for pulling vacuum inside the sample cartridge. The DISCMAN payload is planned to launch to the International Space Station, where welds will be performed under sustained microgravity inside the Bishop Airlock. Another effort underway at Marshall is the Lunar Assembly and Servicing by Autonomous Robotics (LASAR) initiative. This project uses a space-rated robotic arm equipped with a laser weld head, wire feeder, and multiple cameras to perform welds in a thermal vacuum chamber simulating the lunar surface environment. Some of these welds are done on snowflake joints, which are specially designed to slot together to join segments of trussN structures, allowing for the construction of tall surface infrastructure. DISCMAN, LASAR, and other projects are being carried out to advance the technological maturity of in-space laser beam welding, collect data to inform computational models, and learn reliable processes for creating weld joints in space. This work supports NASA’s greater goals to expand humanity’s presence in low Earth orbit, establish a permanent moon base, and eventually send crewed missions to Mars and beyond.

Manufacturing↗
NASA NTRSDate not supplied

Laser Beam Welding Advancements for In-Space Servicing, Assembly, and Manufacturing

NASA is currently working to develop in-space servicing, assembly, and manufacturing (ISAM) capabilities for low Earth orbit and the lunar surface. One crucial technology for this effort is laser beam welding. Laser systems can perform joining, cleaning, cutting, and repair activities, which will enable the construction of large in-space structures that could not fit on a single launch vehicle, such as trusses for solar panels, radiators, or communications infrastructure. Multiple projects studying laser welding for space applications are currently underway at NASA Marshall Space Flight Center. One of these, the DIsk-Shaped Configurable and Modular vAcuum uNit (DISCMAN), is a compact vacuum chamber designed to support parameter development for laser welding in microgravity. It contains a rotating platen with weld samples made from aluminum, steel, and titanium, a high-power infrared laser, and integrated pumps for pulling vacuum inside the sample cartridge. The DISCMAN payload is planned to launch to the International Space Station, where welds will be performed under sustained microgravity inside the Bishop Airlock. Another effort underway at Marshall is the Lunar Assembly and Servicing by Autonomous Robotics (LASAR) initiative. This project uses a space-rated robotic arm equipped with a laser weld head, wire feeder, and multiple cameras to perform welds in a thermal vacuum chamber simulating the lunar surface environment. Some of these welds are done on snowflake joints, which are specially designed to slot together to join segments of trussN structures, allowing for the construction of tall surface infrastructure. DISCMAN, LASAR, and other projects are being carried out to advance the technological maturity of in-space laser beam welding, collect data to inform computational models, and learn reliable processes for creating weld joints in space. This work supports NASA’s greater goals to expand humanity’s presence in low Earth orbit, establish a permanent moon base, and eventually send crewed missions to Mars and beyond.

Robotics↗
DOE OSTI2023

Optimizing foreground mitigation for CMB lensing with combined multifrequency and geometric methods

Here, a key challenge for current and upcoming cosmic microwave background lensing measurements is their sensitivity to biases from extragalactic foregrounds, such as Sunyaev-Zel'dovich signals or cosmic infrared background emission. Several methods have been developed to mitigate these lensing foreground biases, dividing broadly into multifrequency cleaning approaches and modifications to the estimator geometry, but how to optimally combine these methods has not yet been explored in detail. In this paper, we examine which combination of lensing foreground mitigation strategies is best able to reduce the impact of foreground contamination for a Simons Observatory-like experiment while preserving maximal signal-to-noise. Although the optimal combination obtained depends on whether bias reduction or variance reduction is prioritized and on whether polarization data is used, generally, we find that combinations involving both geometric (profile hardening, source hardening, or shear) and multifrequency (symmetric cleaning) methods perform best. For lensing power spectrum measurements from temperature (polarization and temperature), our combined estimator methods are able to reduce the bias below σ/4 or 0.3% (0.1%), a factor of 16 (30) lower than the standard quadratic estimator bias, at a modest signal-to-noise cost of only 18% (12%). In contrast, single-method foreground-mitigation approaches struggle to reduce the bias to a negligible level below σ/2 without incurring a large noise penalty. For upcoming and current experiments, our combined methods therefore represent a promising approach for making lensing measurements with negligible foreground bias.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2024

The Atacama Cosmology Telescope: Mitigating the Impact of Extragalactic Foregrounds for the DR6 Cosmic Microwave Background Lensing Analysis

We investigate the impact and mitigation of extragalactic foregrounds for the cosmic microwave background (CMB) lensing power spectrum analysis of Atacama Cosmology Telescope (ACT) data release 6 (DR6) data. Two independent microwave sky simulations are used to test a range of mitigation strategies. We demonstrate that finding and then subtracting point sources, finding and then subtracting models of clusters, and using a profile bias-hardened lensing estimator together reduce the fractional biases to well below statistical uncertainties, with the inferred lensing amplitude, A lens , biased by less than 0.2σ. We also show that another method where a model for the cosmic infrared background (CIB) contribution is deprojected and high-frequency data from Planck is included has similar performance. Other frequency-cleaned options do not perform as well, either incurring a large noise cost or resulting in biased recovery of the lensing spectrum. In addition to these simulation-based tests, we also present null tests on the ACT DR6 data for sensitivity of our lensing spectrum estimation to differences in foreground levels between the two ACT frequencies used, while nulling the CMB lensing signal. These tests pass whether the nulling is performed at the map or bandpower level. The CIB-deprojected measurement performed on the DR6 data is consistent with our baseline measurement, implying that contamination from the CIB is unlikely to significantly bias the DR6 lensing spectrum. This collection of tests gives confidence that the ACT DR6 lensing measurements and cosmological constraints presented in companion papers to this work are robust to extragalactic foregrounds.

79 ASTRONOMY AND ASTROPHYSICS↗
NASA NTRS1988

Robust vector quantization for noisy channels

The paper briefly discusses techniques for making vector quantizers more tolerant to tranmsission errors. Two algorithms are presented for obtaining an efficient binary word assignment to the vector quantizer codewords without increasing the transmission rate. It is shown that about 4.5 dB gain over random assignment can be achieved with these algorithms. It is also proposed to reduce the effects of error propagation in vector-predictive quantizers by appropriately constraining the response of the predictive loop. The constrained system is shown to have about 4 dB of SNR gain over an unconstrained system in a noisy channel, with a small loss of clean-channel performance.

Demarca, J. R. B.↗
NASA NTRS1989

Measuring Bearing Wear Via Weight Loss

Wear in critical parts of bearings measured via amounts of weight lost during use. Technique applicable in general to bearings made of nonporous materials. Weight-loss measurements easier, faster, more precise, and less likely to damage measured parts. Weight-loss measurements performed in clean rooms and under constraint of extreme cleanliness for compatability with liquid oxygen.

Keba, John E.↗
NASA NTRS2011

Effects of Inlet Distortion on Aeromechanical Stability of a Forward-Swept High-Speed Fan

Concerns regarding noise, propulsive efficiency, and fuel burn are inspiring aircraft designs wherein the propulsive turbomachines are partially (or fully) embedded within the airframe; such designs present serious concerns with regard to aerodynamic and aeromechanic performance of the compression system in response to inlet distortion. Separately, a forward-swept high-speed fan was developed to address noise concerns of modern podded turbofans; however this fan encounters aeroelastic instability (flutter) as it approaches stall. A three-dimensional, unsteady, Navier-Stokes computational fluid dynamics code is applied to analyze and corroborate fan performance with clean inlet flow. This code, already validated in its application to assess aerodynamic damping of vibrating blades at various flow conditions, is modified and then applied in a computational study to preliminarily assess the effects of inlet distortion on aeroelastic stability of the fan. Computational engineering application and implementation issues are discussed, followed by an investigation into the aeroelastic behavior of the fan with clean and distorted inlets.

Herrick, Gregory P.↗
NASA NTRS2011

Higher Magnification Imaging of the Polished Aluminum Collector Returned from the Genesis Mission

The polished aluminum collector (previously referred to as the polished aluminum kidney) was intended for noble gas analysis for the Gene-sis mission. The aluminum collector, fabricated from alloy 6061T, was polished for flight with alumina, then diamond paste. Final cleaning was performed by soak-ing and rinsing with hexane, then isopropanol, and last-ly megasonically energized ultrapure water prior to installation. It was mounted inside the collector canister on the thermal shield at JSC in 2000. The polished aluminum collector was not surveyed microscopically prior to flight.

Rodriquez, Melissa C.↗
NASA NTRS2004

Manufacturing High-Quality Carbon Nanotubes at Lower Cost

A modified electric-arc welding process has been developed for manufacturing high-quality batches of carbon nanotubes at relatively low cost. Unlike in some other processes for making carbon nanotubes, metal catalysts are not used and, consequently, it is not necessary to perform extensive cleaning and purification. Also, unlike some other processes, this process is carried out at atmospheric pressure under a hood instead of in a closed, pressurized chamber; as a result, the present process can be implemented more easily. Although the present welding-based process includes an electric arc, it differs from a prior electric-arc nanotube-production process. The welding equipment used in this process includes an AC/DC welding power source with an integral helium-gas delivery system and circulating water for cooling an assembly that holds one of the welding electrodes (in this case, the anode). The cathode is a hollow carbon (optionally, graphite) rod having an outside diameter of 2 in. (approximately equal to 5.1 cm) and an inside diameter of 5/8 in. (approximately equal to 1.6 cm). The cathode is partly immersed in a water bath, such that it protrudes about 2 in. (about 5.1 cm) above the surface of the water. The bottom end of the cathode is held underwater by a clamp, to which is connected the grounding cable of the welding power source. The anode is a carbon rod 1/8 in. (approximately equal to 0.3 cm) in diameter. The assembly that holds the anode includes a thumbknob- driven mechanism for controlling the height of the anode. A small hood is placed over the anode to direct a flow of helium downward from the anode to the cathode during the welding process. A bell-shaped exhaust hood collects the helium and other gases from the process. During the process, as the anode is consumed, the height of the anode is adjusted to maintain an anode-to-cathode gap of 1 mm. The arc-welding process is continued until the upper end of the anode has been lowered to a specified height above the surface of the water bath. The process causes carbon nanotubes to form in the lowest 2.5 cm of the anode. It also causes a deposit reminiscent of a sandcastle to form on the cathode. The nanotube-containing material is harvested. The cathode and anode can then be cleaned (or the anode is replaced, if necessary) and the process repeated to produce more nanotubes. Tests have shown that the process results in approximately equal to 50-percent yield of carbon nanotubes (mostly of the single-wall type) of various sizes. Whereas the unit cost of purified single-wall carbon nanotubes produced by other process is about $1,000/g in the year 2000, it has been estimated that for the present process, the corresponding cost would be about $10/g.

Benavides, Jeanette M.↗
NASA NTRS2014

Assessing Fan Flutter Stability in the Presence of Inlet Distortion Using One-way and Two-way Coupled Methods

Concerns regarding noise, propulsive efficiency, and fuel burn are inspiring aircraft designs wherein the propulsive turbomachines are partially (or fully) embedded within the airframe; such designs present serious concerns with regard to aerodynamic and aeromechanic performance of the compression system in response to inlet distortion. Previously, a preliminary design of a forward-swept high-speed fan exhibited flutter concerns in cleaninlet flows, and the present author then studied this fan further in the presence of off-design distorted in-flows. Continuing this research, a three-dimensional, unsteady, Navier-Stokes computational fluid dynamics code is again applied to analyze and corroborate fan performance with clean inlet flow and now with a simplified, sinusoidal distortion of total pressure at the aerodynamic interface plane. This code, already validated in its application to assess aerodynamic damping of vibrating blades at various flow conditions using a one-way coupled energy-exchange approach, is modified to include a two-way coupled time-marching aeroelastic simulation capability. The two coupling methods are compared in their evaluation of flutter stability in the presence of distorted in-flows.

aeroelasticity↗
NASA NTRS2017

Low-Reynolds Number Aerodynamics of an 8.9 Percent Scale Semispan Swept Wing for Assessment of Icing Effects

Aerodynamic assessment of icing effects on swept wings is an important component of a larger effort to improve three-dimensional icing simulation capabilities. An understanding of ice-shape geometric fidelity and Reynolds and Mach number effects on the iced-wing aerodynamics is needed to guide the development and validation of ice-accretion simulation tools. To this end, wind-tunnel testing and computational flow simulations were carried out for an 8.9%-scale semispan wing based upon the Common Research Model airplane configuration. The wind-tunnel testing was conducted at the Wichita State University 7 ft x 10 ft Beech wind tunnel from Reynolds numbers of 0.8×10(exp 6) to 2.4×10(exp 6) and corresponding Mach numbers of 0.09 to 0.27. This paper presents the results of initial studies investigating the model mounting configuration, clean-wing aerodynamics and effects of artificial ice roughness. Four different model mounting configurations were considered and a circular splitter plate combined with a streamlined shroud was selected as the baseline geometry for the remainder of the experiments and computational simulations. A detailed study of the clean-wing aerodynamics and stall characteristics was made. In all cases, the flow over the outboard sections of the wing separated as the wing stalled with the inboard sections near the root maintaining attached flow. Computational flow simulations were carried out with the ONERA elsA software that solves the compressible, three-dimensional RANS equations. The computations were carried out in either fully turbulent mode or with natural transition. Better agreement between the experimental and computational results was obtained when considering computations with free transition compared to turbulent solutions. These results indicate that experimental evolution of the clean wing performance coefficients were due to the effect of three-dimensional transition location and that this must be taken into account for future data analysis. This research also confirmed that artificial ice roughness created with rapid-prototype manufacturing methods can generate aerodynamic performance effects comparable to grit roughness of equivalent size when proper care is exercised in design and installation. The conclusions of this combined experimental and computational study contributed directly to the successful implementation of follow-on test campaigns with numerous artificial ice-shape configurations for this 8.9% scale model.

Aerodynamics↗
NASA NTRS2017

Low-Reynolds Number Aerodynamics of an 8.9 Percent Scale Semispan Swept Wing for Assessment of Icing Effects

Aerodynamic assessment of icing effects on swept wings is an important component of a larger effort to improve three-dimensional icing simulation capabilities. An understanding of ice-shape geometric fidelity and Reynolds and Mach number effects on the iced-wing aerodynamics is needed to guide the development and validation of ice-accretion simulation tools. To this end, wind-tunnel testing and computational flow simulations were carried out for an 8.9 percent-scale semispan wing based upon the Common Research Model airplane configuration. The wind-tunnel testing was conducted at the Wichita State University 7 by 10 ft Beech wind tunnel from Reynolds numbers of 0.8×10(exp 6) to 2.4×10(exp 6) and corresponding Mach numbers of 0.09 to 0.27. This paper presents the results of initial studies investigating the model mounting configuration, clean-wing aerodynamics and effects of artificial ice roughness. Four different model mounting configurations were considered and a circular splitter plate combined with a streamlined shroud was selected as the baseline geometry for the remainder of the experiments and computational simulations. A detailed study of the clean-wing aerodynamics and stall characteristics was made. In all cases, the flow over the outboard sections of the wing separated as the wing stalled with the inboard sections near the root maintaining attached flow. Computational flow simulations were carried out with the ONERA elsA software that solves the compressible, threedimensional RANS equations. The computations were carried out in either fully turbulent mode or with natural transition. Better agreement between the experimental and computational results was obtained when considering computations with free transition compared to turbulent solutions. These results indicate that experimental evolution of the clean wing performance coefficients were due to the effect of three-dimensional transition location and that this must be taken into account for future data analysis. This research also confirmed that artificial ice roughness created with rapid-prototype manufacturing methods can generate aerodynamic performance effects comparable to grit roughness of equivalent size when proper care is exercised in design and installation. The conclusions of this combined experimental and computational study contributed directly to the successful implementation of follow-on test campaigns with numerous artificial ice-shape configurations for this 8.9 percent scale model.

Aerodynamics↗