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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 NTRS2011

Unintended Consequences: How Qualification Constrains Innovation

The development and implementation of new materials and manufacturing processes for aerospace application is often hindered by the high cost and long time span associated with current qualification procedures. The data requirements necessary for material and process qualification are extensive and often require millions of dollars and multiple years to complete. Furthermore, these qualification data can become obsolete for even minor changes to the processing route. This burden is a serious impediment to the pursuit of revolutionary new materials and more affordable processing methods for air vehicle structures. The application of integrated computational materials engineering methods to this problem can help to reduce the barriers to rapid insertion of new materials and processes. By establishing predictive capability for the development of microstructural features in relation to processing and relating this to critical property characteristics, a streamlined approach to qualification is possible. This paper critically examines the advantages and challenges to a modeling-assisted qualification approach for aerospace structural materials. An example of how this approach might apply towards the emerging field of additive manufacturing is discussed in detail.

Brice, Craig A.↗
DOE OSTI2025

Summary of Graphite Data Stored within NDMAS

The Graphite Technology Development Project provides data to support the design of graphite core components within specific reactor service conditions of the next generation of high-temperature, gas-cooled nuclear reactors. Physical, mechanical, and thermal properties of nuclear grade graphite were characterized for specimens that were unirradiated, irradiated, and irradiated under various stress conditions. The material properties include diameter, length, mass, density, compressive strength, tensile strength, flexural strength, modulus, resistivity, thermal diffusivity, and thermal expansion coefficient. Baseline graphite specimens are unirradiated from different grades (2114, IG-110, NBG-17, NBG-18, and PCEA) and different types used in different characterization tests (compressive, flexural, tensile, one-inch cylinder, and quarter-inch cylinder). The Advanced Graphite Creep (AGC) irradiation specimens are from a much larger number of grades and cylinder types (creep, piggyback, and pencil). For baseline graphite, characterization data for 7,756 specimens extracted from thirteen graphite billets were captured to the NDMAS database. For AGC experiments, four irradiation campaigns have been completed: AGC-1, AGC-2, AGC-3, and AGC-4. The ongoing HDG-1 (High-Dose Graphite) experiment, which began irradiation with Cycle 168B on August 26, 2020, includes specimens previously irradiated in AGC-2 in addition to the specimens originally destined for AGC-5.. Besides the characterization data, the AGC data includes irradiation monitoring and physics data representing the irradiation conditions of AGC specimens. Currently, all data for AGC-1, AGC-2, and AGC-3 have been captured to the NDMAS database. Only AGC-4 pre-irradiation and irradiation monitoring data have been captured, and HDG-1 pre-irradiation data are in process of being captured for unirradiated specimens. To date, a total of 38,149 material property records have been captured into NDMAS database for baseline and AGC specimens. All characterization data are qualified for use according to their perspective data verification reports. For the AGC irradiation campaigns, a total of 41,502 qualified physics calculation records were added for AGC-1, AGC-2, and AGC-3. Finally, a total of 173,698,505 AGC irradiation monitoring data records (thermocouple temperature, gas flow rate, gas pressure, gas moisture, applied load, and specimen displacement) have been captured to NDMAS; the majority of those records (~94%) are qualified data records.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1994

BSM Delta Qualification 2, volume 3, book 2

This report, presented in three volumes, provides the results of a two-motor Delta Qualification 2 program conducted in 1993 to certify the following enhancements for incorporation into booster separation motor (BSM0 flight hardware: vulcanized-in-place nozzle aft closure insulation; new iso-static ATJ bulk graphite throat insert material, adhesive EA9394 for bonding the nozzle throat, igniter grain rod/centering insert/igniter case; deletion of the igniter adapter insulator ring; deletion of the igniter adapter/igniter case interface RTV; and deletion of loctite from igniter retainer plate threads. The enhancements above directly resulted from (1) the BSM total quality management (TQM) team initiatives to enhance the BSM producibility, and (2) the necessity to qualify new throat insert and adhesive systems to replace existing materials that will not be available. Testing was completed at both the component and motor levels. Component testing was accomplished to screen candidate materials (e.g., throat materials, adhesive systems) and to optimize processes (e.g., aft closure insulator vulcanization approach) prior to their incorporation into the test motors. Motor testing--consisting of two motors, randomly selected by USBI's on-site quality personnel from production lot AAY, which were modified to accept the enhancements -- was completed to provide the final qualification of the enhancements for incorporation into flight hardware. Volume 3, Book 2 provides various supporting documentation to the previous volumes with regards to the testing of the two Delta qualification units: data acceptance records, thermal conditioning analysis, igniter adapter thermal flake analysis, laboratory adhesive (EA-9394) qualification report, throat insert thermal/structural analysis, Delta Qualification Nonconformance Reports (NCR's), O-ring seating tests, and interim test report for vulcanization process qualification.

Source record↗
NASA NTRS2019

X-57 Mod 2 Motor Thermal Analysis

This work covers the refinement of thermal models from design estimates to actual fabricated performance. Matching the experimental data of the first fully electrified version of the X-57 Maxwell experimental vehicle requires high fidelity thermal analysis to sufficiently capture the electric motor and inverter temperature profiles. Qualification test data of the motors and inverters is used to validate finite element analysis models used to simulate thermal performance over mission transients. An additional thermal-hydraulic models is used to estimate flow characteristics through the propulsor nacelle and component heat sinks. After calibration of the higher order models, overall component sizing and peak temperature constraints can be distilled to reduced order models, to improve modelflexibility and utility.

Chin, Jeffrey C.↗
NASA NTRS2009

Composite Overwrap Pressure Vessels: Mechanics and Stress Rupture Lifting Philosophy

The NASA Engineering and Safety Center (NESC) has been conducting an independent technical assessment to address safety concerns related to the known stress rupture failure mode of filament wound pressure vessels in use on Shuttle and the International Space Station. The Shuttle s Kevlar-49 (DuPont) fiber overwrapped tanks are of particular concern due to their long usage and the poorly understood stress rupture process in Kevlar-49 filaments. Existing long term data show that the rupture process is a function of stress, temperature and time. However due to the presence of load sharing liners and the complex manufacturing procedures, the state of actual fiber stress in flight hardware and test articles is not clearly known. Indeed nonconservative life predictions have been made where stress rupture data and lifing procedures have ignored the contribution of the liner in favor of applied pressure as the controlling load parameter. With the aid of analytical and finite element results, this paper examines the fundamental mechanical response of composite overwrapped pressure vessels including the influence of elastic plastic liners and degraded/creeping overwrap properties. Graphical methods are presented describing the non-linear relationship of applied pressure to Kevlar-49 fiber stress/strain during manufacturing, operations and burst loadings. These are applied to experimental measurements made on a variety of vessel systems to demonstrate the correct calibration of fiber stress as a function of pressure. Applying this analysis to the actual qualification burst data for Shuttle flight hardware revealed that the nominal fiber stress at burst was in some cases 23 percent lower than what had previously been used to predict stress rupture life. These results motivate a detailed discussion of the appropriate stress rupture lifing philosophy for COPVs including the correct transference of stress rupture life data between dissimilar vessels and test articles.

Thesken, John C.↗
NASA NTRS2007

Composite Overwrap Pressure Vessels: Mechanics and Stress Rupture Lifing Philosophy

The NASA Engineering and Safety Center (NESC) has been conducting an independent technical assessment to address safety concerns related to the known stress rupture failure mode of filament wound pressure vessels in use on Shuttle and the International Space Station. The Shuttle's Kevlar-49 fiber overwrapped tanks are of particular concern due to their long usage and the poorly understood stress rupture process in Kevlar-49 filaments. Existing long term data show that the rupture process is a function of stress, temperature and time. However due to the presence of load sharing liners and the complex manufacturing procedures, the state of actual fiber stress in flight hardware and test articles is not clearly known. Indeed non-conservative life predictions have been made where stress rupture data and lifing procedures have ignored the contribution of the liner in favor of applied pressure as the controlling load parameter. With the aid of analytical and finite element results, this paper examines the fundamental mechanical response of composite overwrapped pressure vessels including the influence of elastic-plastic liners and degraded/creeping overwrap properties. Graphical methods are presented describing the non-linear relationship of applied pressure to Kevlar-49 fiber stress/strain during manufacturing, operations and burst loadings. These are applied to experimental measurements made on a variety of vessel systems to demonstrate the correct calibration of fiber stress as a function of pressure. Applying this analysis to the actual qualification burst data for Shuttle flight hardware revealed that the nominal fiber stress at burst was in some cases 23% lower than what had previously been used to predict stress rupture life. These results motivate a detailed discussion of the appropriate stress rupture lifing philosophy for COPVs including the correct transference of stress rupture life data between dissimilar vessels and test articles.

Thesken, John C.↗
NASA NTRS1970

Development of a silver-zinc battery system

Summary report is described of historical documentation and detailed design data for development of silver-zinc battery for use on Surveyor spacecraft. Electrical and physical characteristics of battery models are included, along with data on qualification, acceptance, solar-thermal-vacuum, mission simulation testing, and actual flight performance.

Moses, A. J.↗
NASA NTRS1973

A north-south stationkeeping ion thruster system for ATS-F

A one millipound cesium ion thruster system experiment designed for the ATS-F satellite will be used to demonstrate north-south stationkeeping for synchronous satellites. Development effort leading to the present design will be described and test data for qualification and flight acceptance tests will be presented. These include a review of EMI evaluations tests made with the power conditioning subsystem and the thruster simulator, and an extended system operational test. During the extended test, 90 on-off cycles simulated thruster operation in orbit. A planned 18,000 hour ground test of a flight qualified thruster will be discussed.

James, E.↗
NASA NTRS1988

Acceptance and qualification test results of the 20 km electromechanical tether for TSS-1

Acceptance and qualification tests have been performed on the TSS-1 flight tether and its associated qualification tether. Acceptance testing during production included periodic measurement of conductor resistance, off-line breakstrength tests on strength member samples, continuous measurement of the insulation layer voltage withstand capability, and a continuous mechanical proof-loading procedure during the tether jacketing operation. The qualification test sequence consisted of thermal vacuum, voltage withstand and breakstrength tests on samples taken from the production runs for both the qualification and flight tethers. This paper will analyze the acceptance and qualification test data, respectively. Results indicate that the completed flight tether exceeds the design requirements for the TSS-1 mission.

Marshall, L. S.↗
NASA NTRSDate not supplied

Intelligent Control & Autonomy Branch Research Overview Research

The purpose of the subject presentation is to expose engineering students at Ohio University to ongoing work being performed by the Intelligent Control and Autonomy Branch (ICAB) at the NASA Glenn Research Center in Cleveland, Ohio. The presentation will start with some introductory material about the organization. This will be followed by an overview of Electrified Aircraft Propulsion (EAP) controls research and the ICAB’s support for the Space Launch System (SLS). One aspect of EAP is the integration of electrical motor/generators and other power systems components with turbine engine technology to create propulsion & power systems for single-aisle aircraft that are more fuel efficient and have lower emissions. The presentation will introduce some of the controls, systems health management, and modeling technologies developed by the ICAB to help realize EAP. NASA’s SLS is a super-heavy-lift launch vehicle that provides the foundation for human exploration beyond Earth’s orbit. The presentation will introduce capabilities developed by the ICAB to support the SLS Mission and Fault Management function which includes capabilities for abort, caution and warning, redundancy management, and safing. The presentation will conclude with information about internships with the NASA and the ICAB.

propulsion↗
NASA NTRS2009

One NASA PEM qualification standard : comparison of JPL and GSFC standards

Although use of Plastic Encapsulated Microelectronics (PEMs) in space applications is discouraged, their use is mandatory for selected applications involving the need for advanced technology and small packages. Various space systems designers and manufacturers have developed methods to qualify and screen PEMs. In general, each procedure is different. The purpose of this fiscal year’s investigation is to initiate a process to coordinate the efforts at various NASA centers to eventually develop a One NASA method. Part of this activity includes sharing of test data and PEM qualification methodologies. Various experts in the NASA community were identified and contacted to support this effort. We were successful in finding such experts at GSFC, APL and the Constellation office (Orion and Ares). All these experts provided typical qualification program plans. Since funding was severely restricted, it was decided to concentrate on coordination activity with GSFC. GSFC is planning a new version of IEEE-INST-002 section applying to PEMs. The GSFC expert (Dr. Alexander Teverovsky) provided a detailed assessment of the differences between the planned new version of IEEE-INST-002 and the JPL-D-19426 (JPL guideline) as well as a summary rationale for the decisions within the IEEE-INST-002. It should be noted that GSFC’s assessment of IEEE-INST-002 in the area of PEMs is not finalized. JPL is also considering changes in PEM qualification methodologies based on test data from recent qualification testing for their newer Projects (MSL, Grail, Juno). A spreadsheet delineating the differences between the JPL standard and the GSFC standard is presented.

Cooper, Mark↗
NASA NTRS1982

Development of a photovoltaic module qualification test based on combined-environment accelerated stress data

The U.S. Coast Guard has developed a qualification test to screen photovoltaic modules for utilization on marine aids to navigation. The test is based on a combined-environment of hot and cold saltwater immersion and air pressurization. The test has demonstrated a very high acceleration factor and excellent correlation of electrical failures with modules in a concurrent real-time marine exposure.

Trenchard, S. E.↗
NASA NTRS2007

Testing in Support of Fission Surface Power System Qualification

The strategy for qualifying a FSP system could have a significant programmatic impact. The US has not qualified a space fission power system since launch of the SNAP-10A in 1965. This paper explores cost-effective options for obtaining data that would be needed for flight qualification of a fission system. Qualification data could be obtained from both nuclear and non-nuclear testing. The ability to perform highly realistic nonnuclear testing has advanced significantly throughout the past four decades. Instrumented thermal simulators were developed during the 1970s and 1980s to assist in the development, operation, and assessment of terrestrial fission systems. Instrumented thermal simulators optimized for assisting in the development, operation, and assessment of modern FSP systems have been under development (and utilized) since 1998. These thermal simulators enable heat from fission to be closely mimicked (axial power profile, radial power profile, temperature, heat flux, etc.) and extensive data to be taken from the core region. For transient testing, pin power during a transient is calculated based on the reactivity feedback that would occur given measured values of test article temperature and/or dimensional changes. The reactivity feedback coefficients needed for the test are either calculated or measured using cold/warm zero-power criticals. In this way non-nuclear testing can be used to provide very realistic information related to nuclear operation. Non-nuclear testing can be used at all levels, including component, subsystem, and integrated system testing. FSP fuels and materials are typically chosen to ensure very high confidence in operation at design burnups, fluences, and temperatures. However, facilities exist (e.g. ATR, HFIR) for affordably performing in-pile fuel and materials irradiations, if such testing is desired. Ex-core materials and components (such as alternator materials, control drum drives, etc.) could be irradiated in university or DOE reactors to ensure adequate radiation resistance. Facilities also exist for performing warm and cold zero-power criticals.

Houts, Mike↗