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At least 577 records · Page 32

Additive Manufacturing and Hot-Fire Testing of Bimetallic GRCop-84 and C-18150 Channel-Cooled Combustion Chambers Using Powder Bed Fusion and Inconel 625 Hybrid Directed Energy Deposition

Additive manufacturing (AM) is an advanced fabrication technique that is demonstrating tremendous potential to reduce fabrication lead times and costs for liquid rocket engine components. The additive manufacturing technology lends itself to fabricate components with complex features such as internal coolant channels in combustion chambers that would otherwise require complex manufacturing operations. A requirement for high performance engines is to use high conductivity, high strength materials such as copper-alloys for combustion chamber liners to provide adequate wall temperatures and meet subsequent structural margins. A further requirement of this configuration is to minimize weight by defining and fabricating material in discrete locations as required. NASA and Industry partner, Virgin Orbit, have been working to advance these technologies through development of bimetallic additive manufacturing techniques under a public-private partnership through NASA’s Announcement of Collaborative Opportunity (ACO). This partnership is advancing a bimetallic hybrid additively manufactured combustion chamber that integrates Powder Bed Fusion (PBF), specifically Selective Laser Melting (SLM), and Directed Energy Deposition (DED) blown powder techniques to optimize the chamber materials and subsequent assembly. The SLM process is being developed for the combustion chamber liner to use copper-alloys GRCop-84 (Copper-Chrome-Niobium) or C-18150 (Copper-Chrome-Zirconium). The hybrid DED blown powder technology is used to apply an integrated structural jacket and manifolds using an Inconel 625 superalloy on the outer surface of the SLM copper liner. The hybrid DED technology being used on this program is a DMG Mori Seiki AM machining center which integrates the DED blown powder with an integral subtractive (traditional) machining to minimize overall setups. A series of chambers were fabricated using these techniques with GRCop-84/Inconel 625 and C-18150/Inconel and hot-fire tested at NASA Marshall Space Flight Center (MSFC) in LOX/Kerosene (RP-1). This paper describes the process development to integrate these AM technologies into an integrated bimetallic assembly, the design of the chamber, results from hot-fire testing, and further development.

Gradl, Paul R.↗

Additive Manufacturing and Hot-fire Testing of Bimetallic GRCop-84 and C-18150 Channel-Cooled Combustion Chambers using Powder Bed Fusion and Inconel 625 Hybrid Directed Energy Deposition

Additive manufacturing (AM) is an advanced fabrication technique that is demonstrating tremendous potential to reduce fabrication lead times and costs for liquid rocket engine components. The additive manufacturing technology lends itself to fabricate components with complex features such as internal coolant channels in combustion chambers that would otherwise require complex manufacturing operations. A requirement for high performance engines is to use high conductivity, high strength materials such as copper-alloys for combustion chamber liners to provide adequate wall temperatures and meet subsequent structural margins. A further requirement of this configuration is to minimize weight by defining and fabricating material in discrete locations as required. NASA and Industry partner, Virgin Orbit, have been working to advance these technologies through development of bimetallic additive manufacturing techniques under a public-private partnership through NASA’s Announcement of Collaborative Opportunity (ACO). This partnership is advancing a bimetallic hybrid additively manufactured combustion chamber that integrates Powder Bed Fusion (PBF), specifically Selective Laser Melting (SLM), and Directed Energy Deposition (DED) blown powder techniques to optimize the chamber materials and subsequent assembly. The SLM process is being developed for the combustion chamber liner to use copper-alloys GRCop-84 (Copper-Chrome-Niobium) or C-18150 (Copper-Chrome-Zirconium). The hybrid DED blown powder technology is used to apply an integrated structural jacket and manifolds using an Inconel 625 superalloy on the outer surface of the SLM copper liner. The hybrid DED technology being used on this program is a DMG Mori Seiki AM machining center which integrates the DED blown powder with an integral subtractive (traditional) machining to minimize overall setups. A series of chambers were fabricated using these techniques with GRCop-84/Inconel 625 and C-18150/Inconel and hot-fire tested at NASA Marshall Space Flight Center (MSFC) in LOX/Kerosene (RP-1). This paper describes the process development to integrate these AM technologies into an integrated bimetallic assembly, the design of the chamber, results from hot-fire testing, and further development.

Gradl, Paul↗

Component Development for Alkaline URFCs

Performance, cost, and durability of the catalyst materials are the key factors that govern commercialization of H 2 -based energy conversion devices such as unitized regenerative fuel cells (URFCs). Compared to existing battery systems, URFCs offer superior energy density and performance over prolonged operation. In addition, alkaline URFC systems, can utilize low-cost platinum group metal-free (PGM-free) catalysts, resulting in much lower overall system costs. This project seeks to address the major obstacles faced in URFC systems such as cost and efficiency and establish a URFC technical capability through the strategic partnership between UofSC and SRNL. The research focuses on the development of low-PGM and PGM-free based bifunctional oxygen catalysts and electrodes, as well as the development of a URFC testing capability at SRNL.

25 ENERGY STORAGE↗

Technical Assistance for Nikolski and St. George, Alaska

Two remote Aleutian-Pribilof communities in Alaska, Nikolski and St. George, worked with the Energy Technology Innovation Partnership Project (ETIPP) to reduce diesel reliance and strengthen reliability by developing a community energy plan.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Assessment of MSFCs Process for the Development and Activation of Space Act Agreement

Space Act Agreements (SAAs) are contractual agreements that NASA utilizes to form partnerships with researchers, industry, and academia to stimulate cutting-edge innovation within the science and technology communities. center dot This study assessed the current SAA development and activation process at Marshall Space Flight Center (MSFC) to determine if improvements could be implemented to increase productivity, decrease time to activation, and improve the quality of deliverables.

Daugherty, Rachel↗

The UCAR Africa Initiative: Recent insights, challenges, and opportunities to foster collaborative research for environmental sustainability

Africa is increasingly being exposed to the negative impacts of climate and environmental change, while having less capacity to respond compared to other continents. The vulnerability partially results from unprecedented demographic growth, urbanization, and industrialization. However, the continent has still largely been underserved by the broader Earth System Science (ESS) community, as evidenced by the limited amount of ESS data and research that cover Africa compared to other areas of the world. Here we present the recent University Corporation for Atmospheric Research (UCAR) Africa Initiative that aims to enhance environmental sustainability in Africa by fostering international collaborative research partnerships co-led by African scientists. Specifically, we outline urgent challenges and opportunities identified through an international workshop in six areas of ESS namely (1) air quality and health, (2) weather, (3) climate, (4) land and water, (5) social science perspectives, and (6) developing equitable collaboration and sustainable infrastructure. We highlight examples of successful partnerships and conclude with recommendations to advance collaborative, actionable ESS research that addresses Africa’s critical environmental challenges.

African weather and land variability↗

Recent Progress on Sonic Boom Research at NASA

Sonic boom research conducted at NASA through the Supersonics Project of the Fundamental Aeronautics Program is oriented toward understanding the potential impact of sonic boom noise on communities from new low-boom supersonic aircraft designs. Encompassing research in atmospheric propagation, structural response, and human response, NASA research contributes to knowledge in key areas needed to support development of a new noise-based standard for supersonic aircraft certification. Partnerships with several industry, government, and academic institutions have enabled the recent execution of several acoustic field studies on sonic booms. An overview of recent activities funded by NASA includes: focus boom model development and experimental validation, field experiments of structural transmission of sonic booms into large buildings, and low boom community response testing.

Loubeau, Alexandra↗

NASA Technologies that Benefit Society

Applications developed on Earth of technology needed for space flight have produced thousands of spinoffs that contribute to improving national security, the economy, productivity and lifestyle. Over the course of it s history, NASA has nurtured partnerships with the private sector to facilitate the transfer of NASA-developed technology. For every dollar spent on research and development in the space program, it receives back $7 back in the form of corporate and personal income taxes from increased jobs and economic growth. A new technology, known as Liquid-metal alloy, is the result of a project funded by NASA s Jet Propulsion Lab. The unique technology is a blend of titanium, zirconium, nickel, copper and beryllium that achieves a strength greater than titanium. NASA plans to use this metal in the construction of a drill that will help for the search of water beneath the surface of Mars. Many other applications include opportunities in aerospace, defense, military, automotive, medical instrumentation and sporting goods.Developed in the 1980 s, the original Sun Tigers Inc sunlight-filtering lens has withstood the test of time. This technology was first reported in 1987 by NASA s JPL. Two scientists from JPL were later tasked with studying the harmful effects of radiation produced during laser and welding work. They came up with a transparent welding curtain that absorbs, filters and scatters light to maximize protection of human eyes. The two scientists then began doing business as Eagle Eye Optics. Each pair of sunglasses comes complete with ultraviolet protection, dual layer scratch resistant coating, polarized filters for maximum protection against glare and high visual clarity. Sufficient evidence shows that damage to the eye, especially to the retina, starts much earlier than most people realize. Sun filtering sunglasses are important. Winglets seen at the tips of airplane wings are among aviations most visible fuel-saving, performance enhancing technology. Aerodynamics centers on two majors forces-lift and drag. Lift enables the plane to fly and drag is the resistance encountered while moving through the air. The air coming off the end of a standard wing, in a vortex, causes significant drag and turbulence, forcing the spacing between takeoffs. A Langley engineer for NASA published finding in 1976 and verified by test in 1977 that winglets produce a 7 percent increase in lift-drag ratio with a 20 percent decrease in drag. This configuration reduces emissions, allows for greater range and carry more payload and the planes fly more quietly. Winglet technology has saved 2 billion gallons of jet fuel worldwide in 2010. Aerogel represents what technology experts believe to be the best insulation material ever invented. It is very light, flexible and can withstand temperatures of minus 3000 deg F. Aerogel products will be found in everything from clothing, to building insulation to space vehicles. Corpo Nove incorporated the Spaceloft version of the NASA-developed aerogel material into this jacket which was test during an Antarctic expedition.

Griffin, Amanda↗

Transportation Energy Analytics Dashboard (TEAD)

The investment decisions within the nation’s transportation sector have traditionally been prioritized and measured against safety and travel efficiency goals. Increasingly, federal, state, and local policies are requiring consideration of energy use and emissions in the design of our transportation infrastructure. Yet the processes, analytics, and knowledge to include these new metrics into transportation decisions are lacking. Although targeted studies and before and after analysis are performed from time to time, no comprehensive real-time monitoring systems provide energy and emissions to the same level as congestion and safety. To address this gap, the Center for Advanced Transportation Technology (CATT Lab) and the Maryland Transportation Institute (MTI) at the University of Maryland (UMD), in partnership with the National Renewable Energy Laboratory (NREL), have developed a Transportation Energy Analytics Dashboard, or TEAD, to raise awareness of the energy and emission impacts to the same level of observability as that of safety and mobility concerns. The overall goal of this project was to develop and demonstrate an online tool to monitor transportation energy use and emissions in real-time and to archive this data for retrospective analysis. By combining surface transportation energy and emissions evaluation capability with more traditional safety, mobility and reliability system evaluation, our goal is for TEAD to create a dynamic new paradigm in transportation systems management and performance analyses, for both real-time traffic operations, and longer-term planning for project and program investment decision-making.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Mississippi's Strategic Resilience: A multi-systems approach to secure, reliable, and adaptable electric grid infrastructure

Mississippi’s electric grid resilience challenges are linked to an intersection of complex socioeconomic, ecological, technological, historical, and political challenges, exacerbated by increasing severe weather like flooding and tornado events. The state’s legacy of underinvestment in critical energy infrastructure, particularly in rural areas and vulnerable floodplains, have stressed an aging grid, creating long-lasting disruptions in electric service during weather-related outages. Effective emergency management and preparedness is further hampered by a lack of coordination across local, county, and regional scales. Using the TASTI-GRID platform and partnership with Oak Ridge National Laboratory (ORNL), Mississippi is developing a comprehensive regional resilience strategy to overcome energy security and reliability challenges, mitigating the impacts of natural hazards, and positioning Mississippi as a resilient and premier destination for residents, businesses, and economic development.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Some trends in aircraft design: Structures

Trends and programs currently underway on the national scene to improve the structural interface in the aircraft design process are discussed. The National Aeronautics and Space Administration shares a partnership with the educational and industrial community in the development of the tools, the criteria, and the data base essential to produce high-performance and cost-effective vehicles. Several thrusts to build the technology in materials, structural concepts, analytical programs, and integrated design procedures essential for performing the trade-offs required to fashion competitive vehicles are presented. The application of advanced fibrous composites, improved methods for structural analysis, and continued attention to important peripheral problems of aeroelastic and thermal stability are among the topics considered.

Brooks, G. W.↗

Spacecraft 2000 program overview

The goals are to identify the critical need and technologies for spacecraft of the 21st century, and to recommend technology development and validation programs and possible government/industrial roles and partnerships. The objectives of the workshop are to increase awareness and exchange ideas among participants, highlight the spacecraft as a focal point for technology, and facilitate industry-government coordination.

Bercaw, Robert W.↗

Propulsion Controls and Health Management Research at NASA Glenn Research Center

With the increased emphasis on aircraft safety, enhanced performance and affordability, and the need to reduce the environmental impact of aircraft, there are many new challenges being faced by the designers of aircraft propulsion systems. The Controls and Dynamics Technology Branch at NASA Glenn Research Center (GRC) in Cleveland, Ohio, is leading and participating in various projects in partnership with the U.S. aerospace industry and academia to develop advanced controls and health management technologies that will help meet these challenges. These technologies are being developed with a view towards making the concept of "Intelligent Engines" a reality. The major research activities of the Controls and Dynamics Technology Branch are described in the following.

Garg, Sanjay↗

Fan Noise Control Using Herschel-quincke Resonators

The research effort proposed for this NASA NRA is mainly experimental. In addition, Virginia Tech is working in partnership with Goodrich Aerospace, Aerostructures Group for the analytical development needed to support the experimental endeavor, i.e. model development, design, and system studies. In this project, Herschel-Quincke (HQ)liner technology experiments will be performed at the NASA Glenn Active Noise Control Fan (ANCF) facility. A schematic of both inlet and aft HQ-liner systems installed in the ANCF rig as well as a picture of the Glenn facility is shown. The main goal is to simultaneously test in both the inlet and bypass duct sections. The by-pass duct will have HQ-systems in both the inner and outer duct walls. The main advantages of performing tests at the ANCF facility are that the effect of the inlet HQ-system on the by-pass HQ-system and vice versa, can be accurately determined from the in-duct modal data. Another significant advantage is that it offers the opportunity to assess (on a common basis) the proposed noise reduction concept on the ANCF rig which in the past has been used for assessing other active and passive noise reduction strategies.

Burdisso, Ricardo A.↗

A Comprehensive Plan for the Long-Term Calibration and Validation of Oceanic Biogeochemical Satellite Data

The primary objective of this planning document is to establish a long-term capability and validating oceanic biogeochemical satellite data. It is a pragmatic solution to a practical problem based primarily o the lessons learned from prior satellite missions. All of the plan's elements are seen to be interdependent, so a horizontal organizational scheme is anticipated wherein the overall leadership comes from the NASA Ocean Biology and Biogeochemistry (OBB) Program Manager and the entire enterprise is split into two components of equal sature: calibration and validation plus satellite data processing. The detailed elements of the activity are based on the basic tasks of the two main components plus the current objectives of the Carbon Cycle and Ecosystems Roadmap. The former is distinguished by an internal core set of responsibilities and the latter is facilitated through an external connecting-core ring of competed or contracted activities. The core elements for the calibration and validation component include a) publish protocols and performance metrics; b) verify uncertainty budgets; c) manage the development and evaluation of instrumentation; and d) coordinate international partnerships. The core elements for the satellite data processing component are e) process and reprocess multisensor data; f) acquire, distribute, and archive data products; and g) implement new data products. Both components have shared responsibilities for initializing and temporally monitoring satellite calibration. Connecting-core elements include (but are not restricted to) atmospheric correction and characterization, standards and traceability, instrument and analysis round robins, field campaigns and vicarious calibration sites, in situ database, bio-optical algorithm (and product) validation, satellite characterization and vicarious calibration, and image processing software. The plan also includes an accountability process, creating a Calibration and Validation Team (to help manage the activity), and a discussion of issues associated with the plan's scientific focus.

Hooker, Stanford B.↗

QuEST: Qualifying Environmentally Sustainable Technologies

TEERM focuses its validation efforts on technologies that have shown promise in laboratory testing, but lack testing under realistic or field environment. Mature technologies have advantages over those that are still in the developmental stage such as being more likely to be transitioned into a working environment. One way TEERM begins to evaluate the suitability of technologies is through Technology Readiness Levels (TRLs). TRLs are a systematic metric/measurement system that supports assessments of the maturity of a particular technology and the consistent comparison of maturity between different types of technology. TEERM generally works on demonstrating/validating alternatives that fall within TRLs 5-9. In instances where a mature technology does not exist for a particular Agency application, TEERM works with technology development groups and programs such as NASA's Innovative Partnerships Program (IPP). The IPP's purpose is to identify and document available technologies in light of NASA's needs, evaluate and prioritize those technologies, and reach out to find new partners. All TEERM projects involve multiple partners. Partnering reduces duplication of effort that otherwise might occur if individuals worked their problems alone. Partnering also helps reduce individual contributors' shares of the total cost of technology validation. Through collaboration and financial commitment from project stakeholders and third-party sources, it is possible to fully fund expensive demonstration/validation efforts.

Brown, Christina↗

NASA's Lunar Polar Ice Prospector, RESOLVE: Mission Rehearsal in Apollo Valley

After the completion of the Apollo Program, space agencies didn't visit the moon for many years. But then in the 90's, the Clementine and Lunar Prospector missions returned and showed evidence of water ice at the poles. Then in 2009 the Lunar Crater Observation and Sensing Satellite indisputably showed that the Cabeus crater contained water ice and other useful volatiles. Furthermore, instruments aboard the Lunar Reconnaissance Orbiter (LRO) show evidence that the water ice may also be present in areas that receive several days of continuous sunlight each month. However, before we can factor this resource into our mission designs, we must understand the distribution and quantity of ice or other volatiles at the poles and whether it can be reasonably harvested for use as propellant or mission consumables. NASA, in partnership with the Canadian Space Agency (CSA), has been developing a payload to answer these questions. The payload is named RESOLVE. RESOLVE is on a development path that will deliver a tested flight design by the end of 2014. The team has developed a Design Reference Mission using LRO data that has RESOLVE landing near Cabeus Crater in May of2016. One of the toughest obstacles for RESOLVE's solar powered mission is its tight timeline. RESOLVE must be able to complete its objectives in the 5-7 days of available sunlight. The RESOLVE team must be able to work around obstacles to the mission timeline in real time. They can't afford to take a day off to replan as other planetary missions have done. To insure that this mission can be executed as planned, a prototype version of RESOLVE was developed this year and tested at a lunar analog site on Hawaii, known as Apollo Valley, which was once used to train the Apollo astronauts. The RESOLVE team planned the mission with the same type of orbital imagery that would be available from LRO. The simulation team prepositioned a Lander in Apollo Valley with RESOLVE on top mounted on its CSA rover. Then the mission simulation began as the operations team's consoles came alive with data and images. They executed the mission just like the real mission with lunar communications delays and limited bandwidth and a realistic remote mission control room. This paper will describe the RESOLVE payload in detail and describe the results of the mission simulation in Hawaii.

Larson, William E.↗

High-Capacity, High-Voltage Composite Oxide Cathode Materials

This SBIR project integrates theoretical and experimental work to enable a new generation of high-capacity, high-voltage cathode materials that will lead to high-performance, robust energy storage systems. At low operating temperatures, commercially available electrode materials for lithium-ion (Li-ion) batteries do not meet energy and power requirements for NASA's planned exploration activities. NEI Corporation, in partnership with the University of California, San Diego, has developed layered composite cathode materials that increase power and energy densities at temperatures as low as 0 degC and considerably reduce the overall volume and weight of battery packs. In Phase I of the project, through innovations in the structure and morphology of composite electrode particles, the partners successfully demonstrated an energy density exceeding 1,000 Wh/kg at 4 V at room temperature. In Phase II, the team enhanced the kinetics of Li-ion transport and electronic conductivity at 0 degC. An important feature of the composite cathode is that it has at least two components that are structurally integrated. The layered material is electrochemically inactive; however, upon structural integration with a spinel material, the layered material can be electrochemically activated and deliver a large amount of energy with stable cycling.

Hagh, Nader M.↗