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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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NASA NTRS2013

Woven TPS Enabling Missions Beyond Heritage Carbon Phenolic

WTPS is a new approach to producing TPS architectures that uses precisely engineered 3D weaving techniques to customize material characteristics needed to meet specific missions requirements for protecting space vehicles from the intense heating generated during atmospheric entry. Using WTPS, sustainable, scalable, mission-optimized TPS solutions can be achieved with relatively low life cycle costs compared with the high costs and long development schedules currently associated with material development and certification. WTPS leverages the mature state-of-the-art weaving technology that has evolved from the textile industry to design TPS materials with tailorable performance. Currently, missions anticipated encountering heat fluxes in the range of 1500 4000 Wcm2 and pressures greater than 1.5 atm are limited to using fully dense Carbon Phenolic. However, fully dense carbon phenolic is only mass efficient at higher heat fluxes greater than 4000 Wcm2), and current mission designs suffer this mass inefficiency for lack of an alternative mid-density TPS. WTPS not only bridges this mid-density TPS gap but also offers a replacement for carbon phenolic, which itself requires a significant and costly redevelopment effort to re-establish its capability for use in the high heat flux missions recently prioritized in the NRC Decadal survey, including probe missions to Venus, Saturn and Neptune. This presentation will overview the WTPS concept and present some results from initial testing completed comparing WTPS architectures to heritage carbon phenolic.

ablators↗

NASA NTRS1979

Subscale solid motor nozzle tests, phase 4 and nozzle materials screening and thermal characterization, phase 5

Subscale solid motor nozzles containing a baseline material or low cost materials to be considered as potential replacements for the baseline material are designed and tested. Data are presented from tests of four identically designed 2.5 inch throat diameter nozzles and one 7 inch throat diameter nozzle. The screening of new candidate low cost materials, as well as their thermophysical and thermochemical characterization is also discussed.

Arnold, J.↗

NASA NTRS2003

Semiselective Optoelectronic Sensors for Monitoring Microbes

Sensor systems are under development for use in real-time detection and quantitation of microbes in water without need for sampling. These systems include arrays of optical sensors; miniature, portable electronic data-acquisition circuits; and optoelectronic interfaces between the sensor arrays and data-acquisition circuits. These systems are intended for original use in long-term, inline monitoring of waterborne micro-organisms in water-reclamation systems aboard future spacecraft. They could also be adapted to similar terrestrial uses with respect to municipal water supplies, stored drinking water, and swimming water; for detecting low-level biological contamination in biotechnological, semiconductor, and pharmaceutical process streams; and in verifying the safety of foods and beverages. In addition, they could be adapted to monitoring of airborne microbes and of surfaces (e.g., to detect and/or quantitate biofilms). The designs of the sensors in these systems are based partly on those of sensors developed previously for monitoring airborne biological materials. The designs exploit molecular- recognition and fluorescence-spectroscopy techniques, such that in the presence of micro-organisms of interest, fluorescence signals change and the changes can be measured. These systems are characterized as semiselective because they respond to classes of micro-organisms and can be used to discriminate among the classes. This semiselectivity is a major aspect of the design: It is important to distinguish between (1) the principle of detection and quantitation of classes of micro-organisms by use of these sensors and (2) the principle of detection and quantitation of individual microbiological species by means of prior immuno-diagnostic and/or molecular-biology techniques. Detection of classes (in contradistinction to species) is particularly valuable when the exact nature of a contaminant is unknown.

Tabacco, Mary Beth↗

NASA NTRS1999

Accelerator-Based Studies of Heavy Ion Interactions Relevant to Space Biomedicine

Evaluation of the effects of space radiation on the crews of long duration space missions must take into account the interactions of high energy atomic nuclei in spacecraft and planetary habitat shielding and in the bodies of the astronauts. These heavy ions (i.e. heavier than hydrogen), while relatively small in number compared to the total galactic cosmic ray (GCR) charged particle flux, can produce disproportionately large effects by virtue of their high local energy deposition: a single traversal by a heavy charged particle can kill or, what may be worse, severely damage a cell. Research into the pertinent physics and biology of heavy ion interactions has consequently been assigned a high priority in a recent report by a task group of the National Research Council. Fragmentation of the incident heavy ions in shielding or in the human body will modify an initially well known radiation field and thereby complicate both spacecraft shielding design and the evaluation of potential radiation hazards. Since it is impractical to empirically test the radiation transport properties of each possible shielding material and configuration, a great deal of effort is going into the development of models of charged particle fragmentation and transport. Accurate nuclear fragmentation cross sections (probabilities), either in the form of measurements with thin targets or theoretical calculations, are needed for input to the transport models, and fluence measurements (numbers of fragments produced by interactions in thick targets) are needed both to validate the models and to test specific shielding materials and designs. Fluence data are also needed to characterize the incident radiation field in accelerator radiobiology experiments. For a number of years, nuclear fragmentation measurements at GCR-like energies have been carried out at heavy ion accelerators including the LBL Bevalac, Saturne (France), the Synchrophasotron and Nuklotron (Dubna, Russia), SIS-18 (GSI, Germany), the Alternating Gradient Synchrotron at Brookhaven National Laboratory (BNL AGS) and the Heavy Ion Medical Accelerator (HIMAC) in Chiba, Japan. Until fairly recently most of these experiments were done to investigate fundamental problems in nuclear physics, but with the increasing interest in heavy charged particles on the part of the space flight, radiobiology and radiotherapy communities, an increasing number of experiments are being directed at these areas. Some of these measurements are discussed in references therein. Over the past several years, our group has taken cross section and fluence data at the AGS and HIMAC for several incident beams with nuclear charge, Z, between 6 and 26 at energies between 290 and 1050 MeV/nucleon. Iron (Z = 26) has been studied most extensively, since it is the heaviest ion present in significant numbers in the GCR. Targets have included tissue-equivalent and proposed shielding materials, as well as a variety of elemental targets for cross section measurements. Most of the data were taken along the beam axis, but measurements have been made off-axis, as well. Here we present selected data and briefly discuss some implications for spacecraft and planetary habitat design.

Miller, J.↗

NASA NTRS2013

Woven TPS Enabling Missions Beyond Heritage Carbon Phenolic

NASAs Office of the Chief Technologist (OCT) Game Changing Division recently funded an effort to advance a Woven TPS (WTPS) concept. WTPS is a new approach to producing TPS architectures that uses precisely engineered 3D weaving techniques to customize material characteristics needed to meet specific missions requirements for protecting space vehicles from the intense heating generated during atmospheric entry. Using WTPS, sustainable, scalable, mission-optimized TPS solutions can be achieved with relatively low life cycle costs compared with the high costs and long development schedules currently associated with material development and certification. WTPS leverages the mature state-of-the-art weaving technology that has evolved from the textile industry to design TPS materials with tailorable performance. Currently, missions anticipated encountering heat fluxes in the range of 1500 4000 Wcm2 and pressures greater than 1.5 atm are limited to using fully dense Carbon Phenolic. However, fully dense carbon phenolic is only mass efficient at higher heat fluxes g(reater than 4000 Wcm2), and current mission designs suffer this mass inefficiency for lack of an alternative mid-density TPS. WTPS not only bridges this mid-density TPS gap but also offers a replacement for carbon phenolic, which itself requires a significant and costly redevelopment effort to re-establish its capability for use in the high heat flux missions recently prioritized in the NRC Decadal survey, including probe missions to Venus, Saturn and Neptune. This presentation will overview the WTPS concept and present some results from initial testing completed comparing WTPS architectures to heritage carbon phenolic.

Woven Thermal protection materials↗

NASA NTRS2013

Composite Design and Manufacturing Development for Human Spacecrafts

The Structural Engineering Division at the NASA Johnson Space Center (JSC) has begun work on lightweight, multi‐functional pressurized composite structures. The first candidate vehicle for technology development is the Multi‐Mission Space Exploration Vehicle (MMSEV) cabin, known as the Gen 2B cabin, which has been built at JSC by the Robotics Division. Of the habitable MMSEV vehicle prototypes designed to date, this is the first one specifically analyzed and tested to hold internal pressure and the only one made out of composite materials. This design uses a laminate base with zoned reinforcement and external stringers, intended to demonstrate certain capabilities, and to prepare for the next cabin design, which will be a composite sandwich panel construction with multi‐functional capabilities. As part of this advanced development process, a number of new technologies were used to assist in the design and manufacturing process. One of the methods, new to JSC, was to build the Gen 2B cabin with Out of Autoclave technology to permit the creation of larger parts with fewer joints. An 8‐ply pre‐preg layup was constructed to form the cabin body. Prior to lay‐up, a design optimization software called FiberSIM was used to create each ply pattern. This software is integrated with Pro/Engineer to allow for customized draping of each fabric ply over the complex tool surface. Slits and darts are made in the software model to create an optimal design that maintains proper fiber placement and orientation. The flat pattern of each ply is then exported and sent to an automated cutting table where the patterns are cut out of graphite material. Additionally, to assist in lay‐up, a laser projection system (LPT) is used to project outlines of each ply directly onto the tool face for accurate fiber placement and ply build‐up. Finally, as part of the OoA process, a large oven was procured to post‐cure each part. After manufacturing complete, the cabin underwent modal and pressure testing (currently in progress at date of writing) and will go on to be outfitted and used for further ops usage.

Litteken, Douglas↗

NASA NTRS2015

EBF3 Design and Sustainability Considerations

Electron beam freeform fabrication (EBF3) is a cross-cutting technology for producing structural metal parts using an electron beam and wire feed in a layer-additive fashion. This process was developed by researchers at NASA Langley to specifically address needs for aerospace applications. Additive manufacturing technologies like EBF3 enable efficient design of materials and structures by tailoring microstructures and chemistries at the local level to improve performance at the global level. Additive manufacturing also facilitates design freedom by integrating assemblies into complex single-piece components, eliminating flanges, fasteners and joints, resulting in reduced size and mass. These same efficiencies that permit new design paradigms also lend themselves to supportability and sustainability. Long duration space missions will require a high degree of self-sustainability. EBF3 is a candidate technology being developed to allow astronauts to conduct repairs and fabricate new components and tools on demand, with efficient use of feedstock materials and energy.

Taminger, Karen M. B.↗

NASA NTRS1992

Orbit transfer vehicle engine technology program. Task B-6 high speed turbopump bearings

Bearing types were evaluated for use on the Orbit Transfer Vehicle (OTV) high pressure fuel pump. The high speed, high load, and long bearing life requirements dictated selection of hydrostatic bearings as the logical candidate for this engine. Design and fabrication of a bearing tester to evaluate these cryogenic hydrostatic bearings was then conducted. Detailed analysis, evaluation of bearing materials, and design of the hydrostatic bearings were completed resulting in fabrication of Carbon P5N and Kentanium hydrostatic bearings. Rotordynamic analyses determined the exact bearing geometry chosen. Instrumentation was evaluated and data acquisition methods were determined for monitoring shaft motion up to speeds in excess of 200,000 RPM in a cryogenic atmosphere. Fabrication of all hardware was completed, but assembly and testing was conducted outside of this contract.

Source record↗

NASA NTRS1981

Advanced composite aileron for L-1011 transport aircraft: Design and analysis

Detail design of the composite aileron has been completed. The aileron design is a multi-rib configuration with single piece upper and lower covers mechanically fastened to the substructure. Covers, front, spar and ribs are fabricated with graphite/epoxy tape or fabric composite material. The design has a weight savings of 23 percent compared to the aluminum aileron. The composite aileron has 50 percent fewer fasteners and parts than the metal aileron and is predicted to be cost competitive. Structural integrity of the composite aileron was verified by structural analysis and an extensive test program. Static, failsafe, and vibration analyses have been conducted on the composite aileron using finite element models and specialized computer programs for composite material laminates. The fundamental behavior of the composite materials used in the aileron was determined by coupon tests for a variety of environmental conditions. Critical details of the design were interrogated by static and fatigue tests on full-scale subcomponents and subassemblies of the aileron.

Griffin, C. F.↗

NASA NTRS1976

Solar cell array design handbook, volume 1

Twelve chapters discuss the following: historical developments, the environment and its effects, solar cells, solar cell filters and covers, solar cell and other electrical interconnections, blocking and shunt diodes, substrates and deployment mechanisms, material properties, design synthesis and optimization, design analysis, procurement, production and cost aspects, evaluation and test, orbital performance, and illustrative design examples. A comprehensive index permits rapid locating of desired topics. The handbook consists of two volumes: Volume 1 is of an expository nature while Volume 2 contains detailed design data in an appendix-like fashion. Volume 2 includes solar cell performance data, applicable unit conversion factors and physical constants, and mechanical, electrical, thermal optical, magnetic, and outgassing material properties. Extensive references are provided.

Rauschenbach, H. S.↗

NASA NTRS2005

High-Temperature Structures, Adhesives, and Advanced Thermal Protection Materials for Next-Generation Aeroshell Design

The next generation of planetary exploration vehicles will rely heavily on robust aero-assist technologies, especially those that include aerocapture. This paper provides an overview of an ongoing development program, led by NASA Langley Research Center (LaRC) and aimed at introducing high-temperature structures, adhesives, and advanced thermal protection system (TPS) materials into the aeroshell design process. The purpose of this work is to demonstrate TPS materials that can withstand the higher heating rates of NASA's next generation planetary missions, and to validate high-temperature structures and adhesives that can reduce required TPS thickness and total aeroshell mass, thus allowing for larger science payloads. The effort described consists of parallel work in several advanced aeroshell technology areas. The areas of work include high-temperature adhesives, high-temperature composite materials, advanced ablator (TPS) materials, sub-scale demonstration test articles, and aeroshell modeling and analysis. The status of screening test results for a broad selection of available higher-temperature adhesives is presented. It appears that at least one (and perhaps a few) adhesives have working temperatures ranging from 315-400 C (600-750 F), and are suitable for TPS-to-structure bondline temperatures that are significantly above the traditional allowable of 250 C (482 F). The status of mechanical testing of advanced high-temperature composite materials is also summarized. To date, these tests indicate the potential for good material performance at temperatures of at least 600 F. Application of these materials and adhesives to aeroshell systems that incorporate advanced TPS materials may reduce aeroshell TPS mass by 15% - 30%. A brief outline is given of work scheduled for completion in 2006 that will include fabrication and testing of large panels and subscale aeroshell test articles at the Solar-Tower Test Facility located at Kirtland AFB and operated by Sandia National Laboratories. These tests are designed to validate aeroshell manufacturability using advanced material systems, and to demonstrate the maintenance of bondline integrity at realistically high temperatures and heating rates. Finally, a status is given of ongoing aeroshell modeling and analysis efforts which will be used to correlate with experimental testing, and to provide a reliable means of extrapolating to performance under actual flight conditions. The modeling and analysis effort includes a parallel series of experimental tests to determine TSP thermal expansion and other mechanical properties which are required for input to the analysis models.

Collins, Timothy J.↗

NASA NTRS1999

A Discussion of Zero Spring Rate Mechanisms Used for the Active Isolation Mount Experiment

In the summer of 1995 the Structural Dynamics Branch at NASA Langley Research Center set out to conceive a small, lightweight, low frequency isolation mount that could be used for spaceflight experiments. The Engineering Design Branch undertook the task of developing the isolation mount. This report describes the engineering process that led to three phases of a study entitled "Active Isolation Mounts" (AIM). A zero spring rate mechanism was used to achieve low fundamental frequencies for a payloads in the 1 to 10 pound range. It worked by balancing both a positive and a negative stiffness so that the net result was a small positive stiffness. The study demonstrated devices that could reduce the initial corner frequency by a factor of six for brief periods and a factor of two for extended periods. The designs were relatively simple and minimized weight, volume, and power. They could be scaled down and they were made of spaceflight compatible materials. All designs offered the ability to continuously vary the fundamental frequency. Yet, the goal of reducing the frequency by an order of magnitude was not achieved because the systems were too unstable at low frequencies. There was a trade between performance and stability.

Teter, John E., Jr.↗

NASA NTRS2007

Design and Optimization of Composite Gyroscope Momentum Wheel Rings

Stress analysis and preliminary design/optimization procedures are presented for gyroscope momentum wheel rings composed of metallic, metal matrix composite, and polymer matrix composite materials. The design of these components involves simultaneously minimizing both true part volume and mass, while maximizing angular momentum. The stress analysis results are combined with an anisotropic failure criterion to formulate a new sizing procedure that provides considerable insight into the design of gyroscope momentum wheel ring components. Results compare the performance of two optimized metallic designs, an optimized SiC/Ti composite design, and an optimized graphite/epoxy composite design. The graphite/epoxy design appears to be far superior to the competitors considered unless a much greater premium is placed on volume efficiency compared to mass efficiency.

Bednarcyk, Brett A.↗

NASA NTRS1988

The 1988 overview of free-piston Stirling technology for space power at the NASA Lewis Research Center

The completion of the Space Power Demonstrator Engine (SPDE) testing is discussed, terminating with the generation of 25 kW of engine power from a dynamically-balanced opposed-piston Stirling engine at a temperature ratio of 2.0. Engine efficiency was greater than 22 percent. The SPDE recently was divided into 2 separate single cylinder engines, Space Power Research Engine (SPRE), that serves as test beds for the evaluation of key technology disciplines, which include hydrodynamic gas bearings, high efficiency linear alternators, space qualified heat pipe heat exchangers, oscillating flow code validation, and engine loss understanding. The success of the SPDE at 650 K has resulted in a more ambitious Stirling endeavor, the design, fabrication, test, and evaluation of a designed-for-space 25 kW per cylinder Stirling Space Engine (SSE) to operate at a hot metal temperature of 1050 K using superalloy materials. This design is a low temperature confirmation of the 1300 K design. It is the 1300 K free-piston Stirling power conversion system that is the ultimate goal. The first two phases of this program, the 650 K SPDE and the 1050 K SSE are emphasized.

Slaby, Jack G.↗

NASA NTRS2023

Pulse Response of the Short-Wave Infrared Detection System of the Ocean Color Instrument for the NASA PACE Mission

The Ocean Color Instrument (OCI) on NASA’s Plankton, Aerosol, Cloud, ocean Ecosystem (PACE) mission is a hyperspectral Earth imager with a spatial resolution of 1 km x 1 km and a spectral resolution of 5 nm in 2.5 nm steps over 342-887 nm. In addition, OCI provides 7 discrete bands in the 940-2260 nm Short-Wave InfraRed (SWIR) range. The front-end optical imager is a rotating mirror-based system that images the ground scene onto a slit with an instantaneous field of view of 16 km x 1 km. For the SWIR bands, the slit-image is re-imaged onto a 16x1 micro-lens array that effectively acts as the focal plane since each lens element is fiber coupled to wavelength filtered InGaAs and HgCdTe Photo Diodes (PDs). The pulse response of the detection system is critical to OCI SWIR performance. We find that PDs introduce an inherent slow tail in the pulse response due to slow diffusion moving carriers in their n and p regions. We show that this introduces response errors ranging from 1 down to 0.01 % for up to tens of science pixels after the pulse depending on the PD design and materials. It is shown that the response is distinctly different for the InGaAs and HgCdTe PDs. We explain how the front-end design can further increase this error. Finally, we detail the cause of the slow pulse response tail, how to model it, its impact on OCI performance and how it is characterized and corrected to meet OCI requirements.

ocean color↗

NASA NTRSDate not supplied

Pulse Response of the Short-Wave Infrared Detection System of the Ocean Color Instrument for the NASA Pace Mission

ocean color↗

NASA NTRS2006

Review of Current State of the Art and Key Design Issues With Potential Solutions for Liquid Hydrogen Cryogenic Storage Tank Structures for Aircraft Applications

Due to its high specific energy content, liquid hydrogen (LH2) is emerging as an alternative fuel for future aircraft. As a result, there is a need for hydrogen tank storage systems, for these aircraft applications, that are expected to provide sufficient capacity for flight durations ranging from a few minutes to several days. It is understood that the development of a large, lightweight, reusable cryogenic liquid storage tank is crucial to meet the goals of and supply power to hydrogen-fueled aircraft, especially for long flight durations. This report provides an annotated review (including the results of an extensive literature review) of the current state of the art of cryogenic tank materials, structural designs, and insulation systems along with the identification of key challenges with the intent of developing a lightweight and long-term storage system for LH2. The broad classes of insulation systems reviewed include foams (including advanced aerogels) and multilayer insulation (MLI) systems with vacuum. The MLI systems show promise for long-term applications. Structural configurations evaluated include single- and double-wall constructions, including sandwich construction. Potential wall material candidates are monolithic metals as well as polymer matrix composites and discontinuously reinforced metal matrix composites. For short-duration flight applications, simple tank designs may suffice. Alternatively, for longer duration flight applications, a double-wall construction with a vacuum-based insulation system appears to be the most optimum design. The current trends in liner material development are reviewed in the case that a liner is required to minimize or eliminate the loss of hydrogen fuel through permeation.

Mital, Subodh K.↗

NASA NTRS1982

Development of high strength, high temperature ceramics

Improvement in the high-pressure turbopumps, both fuel and oxidizer, in the Space Shuttle main engine were considered. The operation of these pumps is limited by temperature restrictions of the metallic components used in these pumps. Ceramic materials that retain strength at high temperatures and appear to be promising candidates for use as turbine blades and impellers are discussed. These high strength materials are sensitive to many related processing parameters such as impurities, sintering aids, reaction aids, particle size, processing temperature, and post thermal treatment. The specific objectives of the study were to: (1) identify and define the processing parameters that affect the properties of Si3N4 ceramic materials, (2) design and assembly equipment required for processing high strength ceramics, (3) design and assemble test apparatus for evaluating the high temperature properties of Si3N4, and (4) conduct a research program of manufacturing and evaluating Si3N4 materials as applicable to rocket engine applications.

Hall, W. B.↗