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At least 559 records · Page 31

The Development of Lightweight Electronics Enclosures for Space Applications

This paper outlines the end to end effort to produce lightweight electronics enclosures for NASA GSFC electronics applications with the end goal of presenting an array of lightweight box options for a flight opportunity. Topics including the development of requirements, design of three different boxes, utilization of advanced materials and processes, and analysis and test will be discussed. Three different boxes were developed independently and in parallel. A lightweight machined Aluminum box, a cast Aluminum box and a composite box were designed, fabricated, and tested both mechanically and thermally. There were many challenges encountered in meeting the requirements with a non-metallic enclosure and the development of the composite box employed several innovative techniques.

Fenske, Matthew T.↗

Advanced Ablative Insulators and Methods of Making Them

Advanced ablative (more specifically, charring) materials that provide temporary protection against high temperatures, and advanced methods of designing and manufacturing insulators based on these materials, are undergoing development. These materials and methods were conceived in an effort to replace the traditional thermal-protection systems (TPSs) of re-entry spacecraft with robust, lightweight, better-performing TPSs that can be designed and manufactured more rapidly and at lower cost. These materials and methods could also be used to make improved TPSs for general aerospace, military, and industrial applications.

Congdon, William M.↗

Computer design synthesis of a below knee-Syme prosthesis

A detailed design synthesis analysis of the BK Syme prosthesis is provided, to determine the socket's cutout orientation size and shape, cutout fillet shape, socket wall thickness distribution and the reinforced fiber distribution in the socket wall, for a minimally stressed structurally safe lightweight prosthesis. For analysis purposes, the most adverse socket loading is obtained at the push-off stage of gait; this loading is idealized as an axial in-plane loading on the bottom edge of the circular cylindrical socket shell whose top edge is considered fixed. Finite element stress analysis of the socket shell (with uniform and graded wall thickness) are performed for various orientations of the cutout and for various types of corner fillets. A lateral cutout with a streamline fillet is recommended. The wall material (i.e., thickness) distribution is determined so as to minimize the stresses, while ensuring that the wall material's stress limits are not exceeded. For such a maximally stressed lightweight socket shell, the panels in the neighborhood of the cutout are checked to ensure that they do not buckle under their acquired stresses. A fiber-reinforced laminated composite socket shell is also analyzed in order to recommend optimum variables in orientations and densities of reinforcing fibers.

Elangovan, P. T.↗

Lightweight, Flexible Solar Cells on Stainless Steel Foil and Polymer for Space and Stratospheric Applications

The availability of low-cost, lightweight and reliable photovoltaic (PV) modules is an important component in reducing the cost of satellites and spacecraft. In addition, future high-power spacecraft will require lightweight PV arrays with reduced stowage volume. In terms of the requirements for low mass, reduced stowage volume, and the harsh space environment, thin film amorphous silicon (a-Si) alloy cells have several advantages over other material technologies (1). The deposition process is relatively simple, inexpensive, and applicable to large area, lightweight, flexible substrates. The temperature coefficient has been found to be between -0.2 and -0.3 %/degC for high-efficiency triple-junction a-Si alloy cells, which is superior for high temperature operation compared to crystalline Si and triple-junction GaAs/InGaP/Ge devices at 0.53 %/degC and 0.45 %/degC, respectively (2). As a result, the reduction in efficiency at high temperature typical in space conditions is less for a-Si alloy cells than for their crystalline counterparts. Additionally, the a-Si alloy cells are relatively insensitive to electron and proton bombardment. We have shown that defects that are created by electrons with energies between 0.2 to 2 MeV with fluence up to 1x10(exp 15) e/sq cm and by protons with energy in the range 0.3 MeV to 5 MeV with fluence up to 1x10(exp 13) p/sq cm can be annealed out at 70 C in less than 50 hours (1). Further, modules incorporating United Solar s a-Si alloy cells have been tested on the MIR space station for 19 months with only minimal degradation (3). For stratospheric applications, such as the high altitude airship, the required PV arrays are typically of considerably higher power than current space arrays. Airships typically have a large area available for the PV, but weight is of critical importance. As a result, low cost and high specific power (W/kg) are key factors for airship PV arrays. Again, thin-film a-Si alloy solar cell technology is well suited to such applications.

Beernink, Kevin↗

Lightweight Vacuum Jacket for Cryogenic Insulation

The feasibility of producing a lightweight vacuum jacket using state-of-the-art technology and materials was examined. Design and analytical studies were made on a full-scale, orbital maneuvering system fuel tank. Preliminary design details were made for the tank assembly, including an optimized vacuum jacket and multilayer insulation system. A half-scale LH2 test model was designed and fabricated, and a force/stiffness proof test was conducted on the vacuum jacket. A vacuum leak rate of .000001 atmosphere ml of helium per second was measured, approximately 1500 hours of vacuum pressure were sustained, and 29 vacuum-pressure cycles were experienced prior to failure.

Barclay, D. L.↗

Composite lattice structure

A lattice type structural panel concept which exploits the unidirectional character of filamentary advanced composite materials was described. This lattice has potential for applications where stiff lightweight structures are needed such as large area panels for space satellites. Formulae are presented to calculate the panel weight and plate bending stiffness. This analysis indicates that structures with significantly lighter weight than conventional minimum gauge sandwich construction can be fabricated. A suggested fabrication procedure is also presented along with photographs of some typical panels.

Rhodes, M. D.↗

Lightweight Vacuum Jacket for Cryogenic Insulation - Appendices to Final Report

The feasibility is demonstrated of producing a lightweight vacuum jacket using state-of-the-art technology and materials. Design and analytical studies were made on an orbital maneuvering system fuel tank. Preliminary design details were completed for the tank assembly which included an optimized vacuum jacket and multilayered insulation system. A half-scale LH2 test model was designed and fabricated and a force/stiffness proof test was conducted on the vacuum jacket. A vacuum leak rate of 0.00001 was measured, approximately 1500 hours of vacuum pressure was sustained, and 29 vacuum pressure cycles were experienced prior to failure. For vol. 1, see N75-26192.

Barclay, D. L.↗

Component technology for space power systems

Progress made by NASA toward implementation of equipment for the conversion, management, and distribution of voltage power in space applications are reviewed. Work has been carried forward on components such as bipolar transistors, deep impurity semiconductors, conductors, dielectrics, magnetic devices, and rotary power transfer. Specific programs for the high voltage systems have included research on lightweight, low-cost conductors featuring graphite fibers containing electron donor materials for wires and cables with reduced mass and the conductivity of copper. Attention has also been given p-n junction technology for high-speed, high-current, high-voltage materials and diamond-like dielectric films which are hard, have high dielectric strength, and can operate up to 300 C. A transistor has been fabricated with a voltage of 1200 V at 100 A, with a gain of 10 and a 0.5 microsec rise/fall time. A 25 kW transformer has also been built which performs at 20 kHz with an efficiency of 99.2%.

Finke, R. C.↗

NASA ACTS Multibeam Antenna (MBA) System

The design of the Advanced Communications Technology Satellite MBA system, which provides both spot beam and scanning beam coverage to both high and low burst rates data-users is examined. The MBA consists of receive and transmit antennas installed on a common precision mounting platform that is integrated to the bus through three flexures; a lightweight system with low thermal distortion is obtained by using composite materials for the MBA structures. The RF design, which is a Cassegrain reflector with a large equivalent focal length/aperture size, is described. Consideration is given to the position of the feed in order to minimize scan loss and sidelobe levels, the size of the subreflector in order to minimize feed spillover, and antenna performance degradation caused by reflector surface distortion. Breadbroad model test result reveal that the maximum sidelobe level outside the 2.5 HPBW region is -30 dB or lower relative to the power.

Choung, Youn H.↗

Ceramic Honeycomb Panels

Ceramic honeycomb panels serve as lightweight, heat-resistant structural members. Depending on choice of ceramic materials, panels expected to withstand temperatures as high as 1,800 degree C. Honeycomb structure made by vapor-depositing ceramic on fabric substrate woven in honeycomb pattern, then eliminating substrate by oxidizing it. Fabric made of loosely woven polymer such as polyacrylonitrile. Impregnated with organic binder such as phenolic resin for stiffness.

Cagliostro, Domenick E.↗

Mixed-Mode-Bending Delamination Apparatus

Mixed-mode-bending delamination apparatus generates two types of delamination stress simultaneously in specimen from single externally applied point load. In technique, indivial mode I and mode II contributions to delamination in specimen analyzed by use of simple beam-theory equations, eliminating need for time-consuming, difficult numerical analysis. Allows wider range of mode I/mode II ratios than possible with many other methods. Mixed-mode delamination testing of interest in all fields utilizing composite materials, used mostly in aerospace field, but also used in automobiles, lightweight armored military vehicles, boats, and sporting equipment. Useful in general lumber, plywood, and adhesive industries, as well.

Crews, John H., Jr.↗

Welding in space and the construction of space vehicles by welding; Proceedings of the Conference, New Carrollton, MD, Sept. 24-26, 1991

The present conference discusses such topics in spacecraft welding as the NASA Long Duration Exposure Facility's evidence on material properties degradation, EVA/telerobotic construction techniques, welding of the superfluid helium on-orbit transfer flight demonstration tanks and hardware, electron-beam welding of aerospace vehicles, variable-polarity plasma arc keyhole welding of Al, aircraft experiments of low-gravity fusion welding, flash-butt welding of Al alloys, and a computer-aided handbook for space welding fabrication. Also discussed are the welded nozzle extension for Ariane launch vehicles, the existence of on-orbit cold-welding, structural materials performance in long-term space service, high-strength lightweight alloys, steels, and heat-resistant alloys for aerospace welded structures, the NASA-Goddard satellite repair program, and the uses of explosion welding and cutting in aerospace engineering.

Source record↗

Development of Metal Matrix Composites for NASA'S Advanced Propulsion Systems

The state-of-the-art development of several aluminum and copper based Metal Matrix Composites (MMC) for NASA's advanced propulsion systems will be presented. The presentation's goal is to provide an overview of NASA-Marshall Space Flight Center's planned and on-going activities in MMC for advanced liquid rocket engines such as the X-33 vehicle's Aerospike and X-34 Fastrac engine. The focus will be on lightweight and environmental compatibility with oxygen and hydrogen of key MMC materials, within each NASA's new propulsion application, that will provide a high payoff for NASA's reusable launch vehicle systems and space access vehicles. Advanced MMC processing techniques such as plasma spray, centrifugal casting, pressure infiltration casting will be discussed. Development of a novel 3D printing method for low cost production of composite preform, and functional gradient MMC to enhanced rocket engine's dimensional stability will be presented.

Lee, Jonathan A.↗

Electron Beam-Cure Polymer Matrix Composites: Processing and Properties

Researchers from NASA and Oak Ridge National Laboratory are evaluating a series of electron beam curable composites for application in reusable launch vehicle airframe and propulsion systems. Objectives are to develop electron beam curable composites that are useful at cryogenic to elevated temperatures (-217 C to 200 C), validate key mechanical properties of these composites, and demonstrate cost-saving fabrication methods at the subcomponent level. Electron beam curing of polymer matrix composites is an enabling capability for production of aerospace structures in a non-autoclave process. Payoffs of this technology will be fabrication of composite structures at room temperature, reduced tooling cost and cure time, and improvements in component durability. This presentation covers the results of material property evaluations for electron beam-cured composites made with either unidirectional tape or woven fabric architectures. Resin systems have been evaluated for performance in ambient, cryogenic, and elevated temperature conditions. Results for electron beam composites and similar composites cured in conventional processes are reviewed for comparison. Fabrication demonstrations were also performed for electron beam-cured composite airframe and propulsion piping subcomponents. These parts have been built to validate manufacturing methods with electron beam composite materials, to evaluate electron beam curing processing parameters, and to demonstrate lightweight, low-cost tooling options.

Wrenn, G.↗

Development of a Prototype Water Pump for Future Space Suit Applications

NASA s next generation of space suit systems will place new demands on the pump used to circulate cooling water through the life support system and the crew s liquid cooling garment. Long duration missions and frequent EVA require increased durability and reliability; limited resupply mass requirements demand compatibility with recycled water, and changing system design concepts demand increased tolerance for dissolved and free gas and the ability to operate over a broader range of flow rates and discharge pressure conditions. This paper describes the development of a positive displacement prototype pump to meet these needs. A gerotor based design has been adapted to meet pump performance, gas tolerance, and durability requirements while providing a small, lightweight pump assembly. This design has been detailed and implemented using materials selected to address anticipated water quality and mission needs as a prototype unit for testing in NASA laboratories. Design requirements, pump technology selection and design, performance testing and test results will be discussed.

Hartman, David↗

Development of a Prototype Water Pump for Future Space Suit Applications

NASA's next generation of space suit systems will place new demands on the pump used to circulate cooling water through the life support system and the crew's liquid cooling garment. Long duration missions and frequent EVA require increased durability and reliability; limited resupply mass requirements demand compatibility with recycled water, and changing system design concepts demand increased tolerance for dissolved and free gas and the ability to operate over a broader range of flow rates and discharge pressure conditions. This paper describes the development of a positive displacement prototype pump to meet these needs. A gerotor based design has been adapted to meet pump performance, gas tolerance, and durability requirements while providing a small, lightweight pump assembly. This design has been detailed and implemented using materials selected to address anticipated water quality and mission needs as a prototype unit for testing in NASA laboratories. Design requirements, pump technology selection and design, performance testing and test results will be discussed.

Hartman, David↗

Processing of Packing Foams Using Heat Melt Compaction

Foam is used extensively as packing material for items sent to the International Space Station (ISS). Although lightweight, foam is bulky and can occupy a large fraction of the limited ISS volume. Four chemically distinct foams have been used on the ISS. In descending order of current usage, these are Plastazote Zotek Minicel Pyrell. Processing foam with the Heat Melt Compactor (HMC), a solid waste treatment system, has been proposed to reduce the volume of foams stored on spacecraft. Prior to HMC testing, Thermogravimetric Analyses were conducted on the four foams as a precaution to ensure that the thermal decomposition temperatures were not within range of HMC operation (180C). Pyrell was not tested with the HMC because it is known to release toxic compounds and comprises less than 1.5 of total foam usage on ISS resupply flights. Zotek, Minicel, Plastazote LD24FR (low density), and Plastazote LD45FR (high density) were processed with the HMC at 130, 150 and 170C. Volume was reduced by 82.6 on average (n19; std dev4.88). Hydrocarbons and several other compounds emitted during foam processing were measured using a Total Hydrocarbon Analyzer and FTIR. Effects of process temperature and foam type on exhaust composition are discussed. Feeding of foams into the limited size opening of the HMC compaction chamber is likely to be a challenge, particularly in microgravity. Some suggestions are proposed to facilitate feeding foam into the HMC. Processing packing foam with the HMC has been shown to substantially reduce foam volume, and also has the potential benefit of producing radiation-shielding foam tiles.

Harris, Linden↗

Lightweight thermal insulation for Mars surface applications

The intent of this paper is to present a novel insulation design approach, to report the comparison testing against fiberglass batt material, and to summarize the design parameters such as effective thermal conductivity, mass, cost, and delivery time for the fiberglass batt material and this new insulation.

carbon↗