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At least 595 records · Page 33

Robust Metal Additive Manufacturing Process Selection and Development for Aerospace Components

Metal additive manufacturing (AM) is a generic term that captures a variety of fabrication techniques. Each of these manufacturing process has unique advantages, applications for use, and challenges. The most common AM processes in use include Powder Bed Fusion (PBF) and Directed Energy Deposition (DED) as well as many solid state processes. While detailed research has been conducted among many of the processes including parameters and material properties, navigating which processes are best to select is difficult as it is based on component requirements. The focus of this presentation is to provide an overview of considerations for each of metal AM process selection for aerospace components based on various attributes. These attributes include geometric considerations, metallurgical characteristics, cost basis, post-processing and maturity of the processes. The data for these trade selections are based on studies that NASA as performed internally and with academic and industry partners. These studies include multiple AM build experiments to evaluate (1) geometric variations and constraints within the processes, (2) alloy characterization and mechanical testing, (3) pathfinder component development and hotfire evaluations, and (4) certification approaches. This presentation summarizes these results and meant to introduce various considerations when designing a metal AM component.

Additive Manufacturing↗

Metal Additive Manufacturing Process Selection and Development for Propulsion Components

Metal additive manufacturing (AM) is a generic term that captures a variety of fabrication processes. Each of these manufacturing process has unique advantages and challenges for use in aerospace propulsion applications. The most commonly used AM processes include Powder Bed Fusion (PBF), Directed Energy Deposition (DED), and solid-state processes as in Cold Spray, Ultrasonic Additive Manufacturing, and Additive Friction Stir Deposition. While detailed research has been conducted among many of the AM processes to mature processing parameters and material properties, navigating which processes are best to select is difficult as it is based on specific component requirements. The focus of this presentation is to provide an overview of considerations for each of metal AM process selection for aerospace components based on various key attributes. These key attributes include geometric considerations, metallurgical characteristics, cost basis, post-processing and maturity of the processes. The data for these trade selections are based on studies that NASA as performed internally and with academic and industry partners. These studies include multiple AM build experiments to evaluate (1) geometric variations and constraints within the processes, (2) alloy characterization and mechanical testing, (3) pathfinder component development and hot-fire evaluations, and (4) certification approaches. This presentation summarizes these results and is meant to introduce specific examples which show what to consider when designing a metal AM component for aerospace propulsion applications.

Additive Manufacturing↗

Metal Additive Manufacturing Process Selection and Development Lifecycle for Propulsion Components

Metal additive manufacturing (AM) is a generic term that captures a variety of fabrication processes. Each of these manufacturing process has unique advantages and challenges for use in aerospace propulsion applications. The most commonly used AM processes include Powder Bed Fusion (PBF), Directed Energy Deposition (DED), and solid-state processes as in Cold Spray, Ultrasonic Additive Manufacturing, and Additive Friction Stir Deposition. While detailed research has been conducted among many of the AM processes to mature processing parameters and material properties, navigating which processes are best to select is difficult as it is based on specific component requirements. The focus of this presentation is to provide an overview of considerations for each of metal AM process selection for aerospace components based on various key attributes. These key attributes include geometric considerations, metallurgical characteristics, cost basis, post-processing and maturity of the processes. The data for these trade selections are based on studies that NASA as performed internally and with academic and industry partners. These studies include multiple AM build experiments to evaluate (1) geometric variations and constraints within the processes, (2) alloy characterization and mechanical testing, (3) pathfinder component development and hot-fire evaluations, and (4) certification approaches. This presentation summarizes these results and is meant to introduce specific examples which show what to consider when designing a metal AM component for aerospace propulsion applications.

Paul Gradl↗

Enumeration and Fluorescence In Situ Hybridization of Microbial Bioburden on Cleanroom Surfaces

Introduction: Microorganisms are everywhere on Earth, even in the cleanest of places. Spacecraft assembly cleanrooms can harbor low levels of living and dead microbial cells (e.g., [1,2]), and cleanroom bioburden can also include organic molecules from industrial sources and in situ biomass. Life detection missions require careful attention to avoid contaminants that can be easily convoluted with analytical targets. We are evaluating epifluorescent microscopy and fluorescence in situ hybridization (FISH) as methods to complement organic contamination detection techniques. Epifluorescent cell counting offers an accurate and cost-effective way to quantify low levels of surface biomass. FISH could allow for the identification of residual organisms, and can be targeted to detect active populations of specific organisms such as bacteria known to resist cleaning procedures. This effort is part of a larger study that is concentrated on characterizing the surface and airborne molecular organic contamination background in Johnson Space Center (JSC) Astromaterials curation laboratories and Goddard Space Flight Center (GSFC) spacecraft assembly rooms, and understanding contaminants in the context of cleaning procedures and residual bioburden. Methods: Samples were collected by swabbing surfaces in ISO 5 and ISO 7 equivalent cleanrooms at JSC. Swabs for FISH were fixed in 4% paraformaldehyde (PFA) for 3 hours and then stored in 1:1 ethanol:PBS, while swabs for cell counting were stored in 4% PFA until analysis to avoid any cell loss during centrifugation that could impact quantification of very low biomass samples. Cell counting was performed with SYBR Gold as in [3], but adapted for very low biomass. FISH was performed as in [4], using DAPI as a counterstain for all DNA-containing cells. Negative controls included wells with no probe applied, to test for natural fluorescence, as well as the nonsense probe NONEUB (reverse complement of EUB338) to evaluate non-specific probe binding. Results and Discussion: Cleanroom surfaces had 102-103 cells cm-2. The extremely low biomass of these samples was challenging for enumeration, and required careful and routine use of “field” and laboratory blanks. FISH was performed with the general archaeal and bacterial probes ARCH915 and EUB338 (EUBMIX, [4]), probe GAMBET ([4]), and PSE227, which targets the genus Pseudomonas [5]). The latter two probes were selected because Pseudomonas spp. and other Gammaproteobacteria have not been isolated from cleanroom surfaces but do appear frequently in rRNA gene libraries from these surfaces. While some active bacteria were identified (Fig. 1c), most cells detectable by DAPI did not have a strong or any fluorescent signal (e.g., Fig. 1d), indicating that the vast majority of cells are dead or inactive. This suggests that cleaning protocols are effective at inactivating microbial contaminants, but that dead or inactive cells can remain on surfaces. Cells were often clumped in a weakly autofluorescent matrix, possibly biofilm material (Fig. 1c,d). We also observed other particulate material that was collected by the swabs, including apparent textile fibers (Fig. 1b). Our results are consistent with other studies that show that the bioburden present in clean rooms includes active, dormant, and dead cells. We will discuss how FISH and epifluorescent cell counting could be applied in planetary protection protocols, including the advantages and disadvantages of FISH and cell counting for routine use, as well as different possible applications for more specialized FISH procedures. References: [1] Moissl-Eichinger et al. (2015) Sci Rep, 5, 9156 [2] Hendrickson et al. (2021) Microbiome, 9, 238 [3] Jones et al. (2017) Appl Environ Microbiol, 83, e00909-17 [4] Jones et al. (2015) Appl Environ Microbiol, 81, 1242-1250. [5] Watt et al. (2006) Environ Microbiol, 8, 871-884

C J Huff↗

On the impact of communication complexity in the design of parallel numerical algorithms

This paper describes two models of the cost of data movement in parallel numerical algorithms. One model is a generalization of an approach due to Hockney, and is suitable for shared memory multiprocessors where each processor has vector capabilities. The other model is applicable to highly parallel nonshared memory MIMD systems. In the second model, algorithm performance is characterized in terms of the communication network design. Techniques used in VLSI complexity theory are also brought in, and algorithm independent upper bounds on system performance are derived for several problems that are important to scientific computation.

Gannon, D.↗

On the impact of communication complexity on the design of parallel numerical algorithms

This paper describes two models of the cost of data movement in parallel numerical alorithms. One model is a generalization of an approach due to Hockney, and is suitable for shared memory multiprocessors where each processor has vector capabilities. The other model is applicable to highly parallel nonshared memory MIMD systems. In this second model, algorithm performance is characterized in terms of the communication network design. Techniques used in VLSI complexity theory are also brought in, and algorithm-independent upper bounds on system performance are derived for several problems that are important to scientific computation.

Gannon, D. B.↗

To-date spacecraft applications and demonstration testing results, and future product development for new molecular adsorber technologies

The use of molecular adsorbers, in order to aid in the reduction of the spacecraft contamination levels, is discussed. Molecular adsorbers are characterized by an extremely large surface area, molecularly-porous substructure, and processing charged sites capable of retaining molecular contaminant species. Molecular adsorbers were applied on two Hubble Space Telescope servicing missions, as well as on the tropical rainfall measuring mission. The use of molecular adsorbers carries the potential for low cost, easy fabrication and integration of reliable means for reducing the contamination level around spacecraft.

Thomson, Shaun↗

Asymmetric Supercapacitor for Long-Duration Power Storage

A document discusses a project in which a series of novel hybrid positive electrode materials was developed and tested in asymmetric capacitors with carbon negative electrodes. The electrochemical performance of the hybrid capacitors was characterized by cyclic voltammetry and a DC charge/discharge test. The hybrid capacitor exhibited ideal capacitor behavior with an extended operating voltage of 1.6 V in aqueous electrolyte, and energy density higher than activated carbon-based supercapacitors. Nanostructured MnO2 is a promising material for electrochemical capacitors (ECS) because of its low cost, environmentally friendly nature, and reasonably high specific capacitance. The charge capacity of the capacitors can be further improved by increasing the specific surface area of the MnO2 electrode material. The power density and space radiation stability of the capacitors can be enhanced by coating the MnO2 nanoparticles with conducting polymers. The conducting polymer coating also helps in radiation-hardening the ECS.

Rangan, Krishnaswamy K.↗

Sutter Survey: Telescope Breakthrough Enables MicroSats to Map Accessible NEOs

There are three primary reasons why it is important for NASA to develop better ways to locate and characterize Near Earth Objects (NEOs). First, NEOs are an impact hazard to the Earth and congress has mandated that NASA find 90 percent of all the Potentially Hazardous Objects (PHOs) over 140 meters by the end of 2020. NASA will fail to meet this mandate due to funding limitations and the cost and technical performance of current asteroid survey approaches. The Sutter Survey will solve this problem. Second, measuring NEO population distributions will unlock the answers to critical questions dealing with the formation and evolution of the solar system. Finally, NEOs are important targets for human exploration and they represent a virtually unlimited long term resource of valuable material for radiation shielding, propellant, and life support consumables that could make NASA'splanned deep space human exploration program affordable.

Sercel, Joel C.↗

EarthShine: Observing Our World as an Exoplanet from the Surface of the Moon

NASA’s return to the Moon coincides with explosive growth in exoplanet discovery. Missions are being formulated to search for habitable planets orbiting other stars, making this the ideal time to deploy an instrument suite to the lunar surface to help us recognize a habitable exoplanet when we see it. We present EarthShine, a technically mature, three-instrument suite to observe the whole Earth from the Moon as an exoplanet proxy. Earth Shine data will validate and improve models critical for designing missions to image and characterize exoplanets, thus informing observing strategies for flagship missions to directly image exoplanets. EarthShine will answer interconnected questions in Earth and lunar science, exoplanets, and astrobiology, related to the credo“ follow the water.” Earth Shine can take advantage of current NASA programs to conduct science from the Moon with low-cost, mature space hardware to reduce risk and assure success. Like the 1968 Apollo Earthrise image of our home planet, lonely in the black sky, the appeal of Earth Shine to a multidisciplinary array of researchers in Earth Science, Planetary Science, and astrophysics will maximize both its scientific impact and its impact on the general public.

EarthShine↗

Potential errors in using one anemometer to characterize the wind power over an entire rotor disk

Wind data collected at four levels on a 90-m tower in a prospective wind farm area are used to evaluate how well the 10-m wind speed data with and without intermittent vertical profile measurements compare with the 90-m tower data. If a standard, or even predictable, wind speed profile existed, there would be no need for a large, expensive tower. This cost differential becomes even more significant if several towers are needed to study a prospective wind farm.

Simon, R. L.↗

Mechanical Characterization of Composites and Foams for Aerospace Applications

Experimental studies to investigate the mechanical properties of ultra-lightweight polyimide foams for space applications, compression after impact (CAI) properties for low velocity impact of sandwich composites, and aspen fiber/polypropylene composites containing an interface adhesive additive, Maleic Anhydride Grafted Polypropylene (MAPP), were performed at Clark Atlanta University. Tensile, compression, flexural, and shear modulus tests were performed on TEEK foams categorized by their densities and relative cost according to ASTM specifications. Results showed that the mechanical properties of the foams increased as a function of higher price and increasing density. The CAI properties of Nomex/phenolic honeycomb core, fiberglass/epoxy facesheet sandwich composites for two damage arrangements were compared using different levels of impact energy ranging from 0 - 452 Joules. Impact on the thin side showed slightly more retention of CAI strength at low impact levels, whereas higher residual compressive strength was observed from impact on the thick side at higher impact levels. The aspen fiber/polypropylene composites studied are composed of various percentages (by weight) of aspen fiber and polypropylene ranging from 30%-60% and 40%-100%, respectively. Results showed that the MAPP increases tensile and flexural strength, while having no significant influence on tensile and flexural modulus.

Veazie, D. R.↗

Fluid Phase Separation (FPS) experiment for flight on a space shuttle Get Away Special (GAS) canister

The separation of fluid phases in microgravity environments is of importance to environmental control and life support systems (ECLSS) and materials processing in space. A successful fluid phase separation experiment will demonstrate a proof of concept for the separation technique and add to the knowledge base of material behavior. The phase separation experiment will contain a premixed fluid which will be exposed to a microgravity environment. After the phase separation of the compound has occurred, small samples of each of the species will be taken for analysis on the Earth. By correlating the time of separation and the temperature history of the fluid, it will be possible to characterize the process. The experiment has been integrated into space available on a manifested Get Away Special (GAS) experiment, CONCAP 2, part of the Consortium for Materials Complex Autonomous Payload (CAP) Program, scheduled for STS-42. The design and the production of a fluid phase separation experiment for rapid implementation at low cost is presented.

Peters, Bruce↗

The Rocket Balloon (Rocketball): Applications to Science, Technology, and Education

Originally envisioned to study upper atmospheric phenomena, the Rocket Balloon system (or Rocketball for short) has utility in a range of applications, including sprite detection and in-situ measurements, near-space measurements and calibration correlation with orbital assets, hurricane observation and characterization, technology testing and validation, ground observation, and education. A salient feature includes the need to reach space and near-space within a critical time-frame and in adverse local meteorological conditions. It can also provide for the execution of technology validation and operational demonstrations at a fraction of the cost of a space flight. In particular, planetary entry probe proof-of-concepts can be examined. A typical Rocketball operational scenario consists of a sounding rocket launch and subsequent deployment of a balloon above a desired location. An obvious advantage of this combination is the additional mission 'hang-time' rendered by the balloon once the sounding rocket flight is completed. The system leverages current and emergent technologies at the NASA Goddard Space Flight Center and other organizations.

Esper, Jaime↗

Micro/Nanosatellite Mars Network for Global Lower Atmosphere Characterization

To address multiple key challenge areas for robotic exploration of Mars, to achieve scientific goals and reduce risk for future human missions, a micro/nanosatellite constellation for lower atmosphere characterization is proposed. A microsatellite design is discussed that can operate (1) in tandem with another microsat or (2) as a "mother-ship" to deploy a network of nanosatellites (CubeSats). Either configuration of the network would perform radio occultation-based atmospheric measurements. Advantages of the proposed network are low development cost based on an existing microsatellite bus, and proven performance of the bus to date. Continued efforts in miniaturization of instruments are needed to fully enable the mother-ship/nanosat version of the proposed network.

Tinker, Mike L.↗

Compatibility of a Diffractive Pupil and Coronagraphic Imaging

Detection and characterization of exo-earths require direct-imaging techniques that can deliver contrast ratios of 10(exp 10) at 100 milliarc-seconds or smaller angular separation. At the same time, astrometric data is required to measure planet masses and can help detect planets and constrain their orbital parameters. To minimize costs, a single space mission can be designed using a high efficiency coronograph to perform direct imaging and a diffractive pupil to calibrate wide-field distortions to enable high precision astrometric measurements. This paper reports the testing of a diffractive pupil on the high-contrast test bed at the NASA Ames Research Center to assess the compatibility of using a diffractive pupil with coronographic imaging systems. No diffractive contamination was found within our detectability limit of 2x10(exp -7) contrast outside a region of 12lambda/D and 2.5x10(exp -6) within a region spanning from 2 to 12lambda/D. Morphology of the image features suggests that no contamination exists even beyond the detectability limit specified or at smaller working angles. In the case that diffractive contamination is found beyond these stated levels, active wavefront control would be able to mitigate its intensity to 10(exp -7) or better contrast.

Bendek, Eduardo↗

Elevated Temperature, Notched Compression Performance of Out of Autoclave Processed Composites

Curved honeycomb sandwich panels composed of carbon fiber reinforced toughened-epoxy polymer facesheets are being evaluated for potential use as payload fairing components on the NASA heavy-lift space launch system (HL-SLS). These proposed composite sandwich panels provide the most efficient aerospace launch structures, and offer mass and thermal advantages when compared with existing metallic payload fairing structures. NASA and industry are investigating recently developed carbon fiber epoxy prepreg systems which can be fabricated using out-of autoclave (OOA) processes. Specifically, OOA processes using vacuum pressure in an oven and thereby significantly reducing the cost associated with manufacturing large (up to 10 m diameter) composite structures when compared with autoclave. One of these OOA composite material systems, CYCOM(R) 5320-1, was selected for manufacture of a 1/16th scale barrel portion of the payload fairing; such that, the system could be compared with the well-characterized prepreg system, CYCOM(R) 977-3, typically processed in an autoclave. Notched compression coupons for each material were obtained from the minimum-gauge flat laminate [60/-60/0]S witness panels produced in this manufacturing study. The coupons were also conditioned to an effective moisture equilibrium point and tested according to ASTM D6484M-09 at temperatures ranging from 25 C up to 177 C. The results of this elevated temperature mechanical characterization study demonstrate that, for thin coupons, the OHC strength of the OOA laminate was equivalent to the flight certified autoclave processed composite laminates; the limitations on the elevated temperature range are hot-wet conditions up to 163 C and are only within the margins of testing error. At 25 C, both the wet and dry OOA material coupons demonstrated greater OHC failure strengths than the autoclave processed material laminates. These results indicate a substantial improvement in OOA material development and processing since previous studies have consistently reported OOA material strengths on par or below those of autoclave processed composite laminates.

Grimsley, Brian W.↗