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At least 613 records · Page 34

All sources NASA NTRS DOE OSTI

NASA NTRS1966

Insulated Engine, 100-Pound Thrust

The design and test results of an insulated, 100-pound thrust engine capable of delivering high performance, providing long, steady state and pulse mode endurance, and maintaining a low outside surface temperature of 4000 F, are presented. Included are descriptions of the injector designs and insulation materials investigated, plus a discussion of the thermal analysis and test results. Continuous operation in excess of 29 minutes, and start capability in excess of 4900 pulses, have been demonstrated. To allow the use of available chamber materials and coating systems under insulated conditions, the major challenge to the designer was to define an injector design that would provide gas temperatures and performance of a predetermined value. The solution was the development of an unbalanced, 8-element triplet injector having an unequal fuel distribution within each element, capable of providing a specific impulse in excess of 290 pounds at reduced wall temperatures. The design consists of a columbium chamber and nozzle utilizing a silicide coating, a columbium injector, a composite insulation system of aluminum oxide

Roth, N. R.↗

NASA NTRS2016

Heatshield for Extreme Entry Environment Technology (HEEET) Development Status

The Heat shield for Extreme Entry Environment Technology (HEEET) Project is a NASA STMD and SMD co-funded effort. The goal is to develop and mission infuse a new ablative Thermal Protection System that can withstand extreme entry. It is targeted to support NASAs high priority missions, as defined in the latest decadal survey, to destinations such as Venus and Saturn in-situ robotic science missions. Entry into these planetary atmospheres results in extreme heating. The entry peak heat-flux and associated pressure are estimated to be between one and two orders of magnitude higher than those experienced by Mars Science Laboratory or Lunar return missions. In the recent New Frontiers community announcement NASA has indicated that it is considering providing an increase to the PI managed mission cost (PIMMC) for investigations utilizing the Heat Shield for Extreme Entry Environment Technology (HEEET) and in addition, NASA is considering limiting the risk assessment to only their accommodation on the spacecraft and the mission environment. The HEEET ablative TPS utilizes 3D weaving technology to manufacture a dual layer material architecture. The 3-D weaving allows for flat panels to be woven. The dual layer consists of a top layer designed to withstand the extreme external environment while the inner or insulating layer by design, is designed to achieve low thermal conductivity, and it keeps the heat from conducting towards the structure underneath. Both arc jet testing combined with material properties have been used to develop thermal response models that allows for comparison of performance with heritage carbon phenolic. A 50 mass efficiency is achieved by the dual layer construct compared to carbon phenolic for a broad range of missions both to Saturn and Venus. The 3-D woven flat preforms are molded to achieve the shape as they are compliant and then resin infusion with curing forms a rigid panels. These panels are then bonded on to the aeroshell structure. Gaps exist between the panels and these gaps have to be filled with seams. The seam material then has to be bonded on to adjacent panels and also to the structure. The heat-shield assembly is shown in Figure 1. One of the significant challenges we have overcome recently is the design, development and testing of the seam. HEEET material development and the seam concept development have utilized some of the unique test capabilities available in the US. The various test facilities utilized in thermal testing along with the entry environment for Saturn and Venus missions are shown in Figure 2. The HEEET project is currently in its 3rd year of a four-year development. Figure 3 illustrates the key accomplishments to date and the challenges yet to be overcome before the technology is ready for mission infusion. This proposed presentation will cover both progress that has been made in the HEEET project and also the challenges to be overcome that is highlighted in Figure 3. Objective of the HEEET project is to mature the system in time to support the next New Frontiers opportunity and we believe we are well along the way to mission infuse HEEET.

Thermal Protection System↗

NASA NTRS2016

Heat-shield for Extreme Entry Environment Technology (HEEET) Development Status

The Heat shield for Extreme Entry Environment Technology (HEEET) Project is a NASA STMD and SMD co-funded effort. The goal is to develop and mission infuse a new ablative Thermal Protection System that can withstand extreme entry. It is targeted to support NASA's high priority missions, as defined in the latest decadal survey, to destinations such as Venus and Saturn in-situ robotic science missions. Entry into these planetary atmospheres results in extreme heating. The entry peak heat-flux and associated pressure are estimated to be between one and two orders of magnitude higher than those experienced by Mars Science Laboratory or Lunar return missions. In the recent New Frontiers community announcement NASA has indicated that it is considering providing an increase to the PI managed mission cost (PIMMC) for investigations utilizing the Heat Shield for Extreme Entry Environment Technology (HEEET) and in addition, NASA is considering limiting the risk assessment to only their accommodation on the spacecraft and the mission environment. The HEEET ablative TPS utilizes 3D weaving technology to manufacture a dual layer material architecture. The 3-D weaving allows for flat panels to be woven. The dual layer consists of a top layer designed to withstand the extreme external environment while the inner or insulating layer by design, is designed to achieve low thermal conductivity, and it keeps the heat from conducting towards the structure underneath. Both arc jet testing combined with material properties have been used to develop thermal response models that allows for comparison of performance with heritage carbon phenolic. A 50% mass efficiency is achieved by the dual layer construct compared to carbon phenolic for a broad range of missions both to Saturn and Venus. The 3-D woven flat preforms are molded to achieve the shape as they are compliant and then resin infusion with curing forms a rigid panels. These panels are then bonded on to the aeroshell structure. Gaps exist between the panels and these gaps have to be filled with seams. The seam material then has to be bonded on to adjacent panels and also to the structure. The heat-shield assembly is shown in Figure 1. One of the significant challenges we have overcome recently is the design, development and testing of the seam. HEEET material development and the seam concept development have utilized some of the unique test capabilities available in the US. The various test facilities utilized in thermal testing along with the entry environment for Saturn and Venus missions are shown in Figure 2. The HEEET project is currently in it's 3rd year of a four-year development. Figure 3 illustrates the key accomplishments to-date and the challenges yet to be overcome before the technology is ready for mission infusion. This proposed presentation will cover both progress that has been made in the HEEET project and also the challenges to be overcome that is highlighted in Figure 3. Objective of the HEEET project is to mature the system in time to support the next New Frontiers opportunity and we believe we are well along the way to mission infuse HEEET.

TPS↗

NASA NTRS1997

Test Method Designed to Evaluate Cylinder Liner-Piston Ring Coatings for Advanced Heat Engines

Research on advanced heat engine concepts, such as the low-heat-rejection engine, have shown the potential for increased thermal efficiency, reduced emissions, lighter weight, simpler design, and longer life in comparison to current diesel engine designs. A major obstacle in the development of a functional advanced heat engine is overcoming the problems caused by the high combustion temperatures at the piston ring/cylinder liner interface, specifically at top ring reversal (TRR). Therefore, advanced cylinder liner and piston ring materials are needed that can survive under these extreme conditions. To address this need, researchers at the NASA Lewis Research Center have designed a tribological test method to help evaluate candidate piston ring and cylinder liner materials for advanced diesel engines.

Radil, Kevin C.↗

NASA NTRS1976

Breadboard CO2 and humidity control system

A regenerable CO2 and humidity control system is being developed for potential use on shuttle as an alternate to the baseline lithium hydroxide (LiOH)/condensing heat exchanger system. The system utilizes a sorbent material, designated HS-C, to adsorb CO2 and water vapor from the cabin atmosphere. The material is regenerated by exposing it to space vacuum. A half-size breadboard system, utilizing a flight representative HS-C canister, was designed, built, and performance tested to shuttle requirements for total CO2 and total humidity removal. The use of a new chemical matrix material allowed significant optimization of the system design by packing the HS-C chemical into the core of a heat exchanger which is manifolded to form two separate and distinct beds. Breadboard system performance was proven by parametric testing and simulated mission testing over the full range of shuttle crew sizes and metabolic loadings. Vacuum desorption testing demonstrated considerable savings in previously projected shuttle vacuum duct sizing.

Boehm, A. M.↗

DOE OSTI2021

Failure Analysis of a New Polyamide-Based Fluoropolymer-Free Backsheet After Combined-Accelerated Stress Testing

The viability of novel coextruded, fluoropolymer-free backsheets for photovoltaic (PV) modules has been questioned as a result of a large number of early-life backsheet failures in PV installations containing one of the earliest co-extruded polyamide (PA)-based backsheet to reach the market, “AAA.” New PV reliability testing protocols have been recently developed and applied to backsheets to reproduce failures observed in the field and evaluate the durability of novel backsheet materials and designs prior to commercialization. A new co-extruded PA-based backsheet was tested using combined-accelerated stress testing (C-AST) and demonstrated a greater lifetime than AAA, and some other fluoropolymer-based backsheets such as polyvinylidene fluoride. The improved PA-based backsheet also eventually failed by through-thickness cracking. Using surface and bulk material characterization techniques, we performed a comprehensive study of material properties before and after the stress testing. Aging of the backsheet resulted in an increase of surface roughness by erosion of the outer PA layer. However the failure is more likely related to an increase in crystallinity of the polyolefin core layer reducing the backsheet tearing energy. The analysis can ultimately inform on the specific weaknesses of the materials so that the manufacturer can improve the backsheet design to extend its lifetime.

14 SOLAR ENERGY↗

NASA NTRS1982

Long term compatibility of nitrogen tetroxide with metals - Results at the ten-year milestone

Analyses and results are reported of a test program to establish the effects of long-term (10 years or more) contact of materials with nitrogen textroxide MON-1 for the purpose of designing chemical propulsion system components which can be used for current as well as future planetary spacecraft. The test materials included aluminum alloy, corrosion-resistant steel, titanium alloy, and nickel. The weight and appearance of each specimen were observed, including the presence of deposits, etching, pitting, and cracking. Aluminum alloy and steel were rated satisfactory with minor reservations, titanium alloy was satisfactory, and nickel was unsatisfactory. Criteria for ratings are shown.

Moran, C. M.↗

NASA NTRS2026

Mechanical Design and Operation of a Novel Lunar Environment Structural Test Rig (LESTR)

The Lunar Environment Structural Test Rig (LESTR) was developed to address a critical gap in mechanical property data for metal alloy wire materials under lunar-relevant conditions down to 40 K. Conventional aerospace material databases provide thermophysical properties for bulk metals over a wide temperature range, but validated mechanical and physical property data below 77 K, particularly for small-diameter wires, remain limited and are generally the exception rather than the rule. These conditions are essential for Artemis mission hardware such as shape memory alloy (SMA) rover tires. LESTR’s design requirements were to combine a high-stiffness electrodynamic load frame with closed- cycle cryogenic cooling, high-vacuum capability (10–6 torr), and noncontact optical strain measurement to enable tensile, four-point bend, and fatigue testing of wires or other materials and geometries at temperatures from 40 to 125 K. These considerable requirements were merged with the need to lower the barrier of testing for the end user as measured in terms of cost-per-test cycle, safety improvement, and reduction in upkeep costs associated with state-of-the-art solutions associated with cryomechanical material characterization. The system incorporates modular gripping and alignment fixtures; precision thermal management using cryocoolers and embedded heaters; and integrated instrumentation for displacement, load, temperature, and vacuum control. Calibration procedures establish correlations between tooling and specimen temperature, ensuring accurate thermal conditions across the design envelope unbound by cryofluid conditions in heritage immersion-based test systems. Initial validation tests using Inconel (Special Metals Corp.) wire demonstrated accurate ultimate strength and post-yield behavior. The load frame operation was also verified under representative service conditions, including thermal cycling and prolonged fatigue loading. By generating mechanical property data at ultralow temperatures, LESTR fills a critical gap in existing materials databases and provides a scalable platform for iterative alloy development and durability assessment for planetary hardware. This capability supports NASA’s long-term objectives for surface exploration by enabling design confidence for components operating in extreme cryogenic environments.

LESTR↗

NASA NTRS1978

Center punched solar cell module development effort

The results are given of an advanced module development program with the objective of providing a low cost solar cell mechanical interconnect design. The design approach, which avoids soldering or welding operations, lends itself to automated assembly techniques thus supporting the Low-Cost Silicon Solar Array Project goals. The first group of six modules contained aluminum contact cells and the second group of six modules contained silver-titanium-palladium contact cells. Extensive component and environmental testing at the module level showed that reliable cell mechanical interconnection can be achieved when utilizing the proper electrical contact materials and pressures. A discussion is given of the module design, manufacturing procedure, test program, significant problem areas and solutions, and conclusions and recommendations as formulated and conducted by XEOS.

Ross, R. E.↗

NASA NTRS2016

Testing of Space Suit Materials for Mars

Human missions to Mars may require radical changes in our approach to EVA suit design. A major challenge is the balance of building a suit robust enough to complete 50 EVAs in the dirt under intense UV exposure without losing mechanical strength or compromising its mobility. We conducted ground testing on both current and new space suit materials to determine performance degradation after exposure to 2500 hours of Mars mission equivalent UV. This testing will help mature the material technologies and provide performance data that can be used by not only the space suit development teams but for all Mars inflatable and soft goods derived structures from airlocks to habitats.

Larson, Kristine↗

DOE OSTI2023

Energy Efficiency Improvement Approaches in Ice Related Processes

A detailed survey of ice mold and evaporator metal surfaces, physical structures, operational conditions, materials of construction, design of different equipment was reviewed and analyzed. A reliable test methodology was developed to measure the ice adhesion strength of different materials and geometries identified. The developed test setup was successfully employed in measuring the ice adhesion strength on both tubular and planar substrate geometries of metals including copper, aluminum, stainless steel. Application of advanced polymer materials in lowering the adhesion strength of ice was confirmed where the measured strength was lowered by 50-70% depending on the material and geometry. Additionally, utilization of induced ultrasonic vibration in further lowering the ice harvesting energy was confirmed on multiple materials and geometries. Durability of the coating enhancement was also confirmed in a thermal cycling test under realistic operating conditions.

36 MATERIALS SCIENCE↗

NASA NTRS1975

Development of fire resistant electronic configurations for use in oxygen enriched environments

The flammability requirements of the various manned space programs have required development of electronic configurations that would eliminate any flammability hazard to crews or missions. Initial test and development efforts were directed at the development of nonflammable or self-exsinguishing materials. It was soon realized that a more relevant approach in eliminating flammability hazards was to consider materials as to their application and configuration. Design concepts for electronic black boxes and modules were tested in oxygen enriched atmospheres, and it was found that various types of sealed configurations would generally eliminate any flammability hazard. The type of configuration and its construction was found to be of more importance in the elimination of flammability hazards in electronic configurations than the types of materials utilized in them. The design concepts developed for fire hazard free electronic configurations for use in manned space programs of electronic configurations for use in manned space programs are applicable for the design of electronic hardware for any use or environment.

F. J. Smith↗

DOE OSTI2023

Recent Radioactive Material Package Testing Experiences at Oak Ridge National Laboratory

Oak Ridge National Laboratory (ORNL) was a pioneer in the testing of radioactive material shipping packages and has been performing such tests for over 50 years. Currently, except for Type B thermal tests, testing is performed at the purpose-built Packaging Research Facility that is located at the National Transportation Research Center - a U.S. Department of Energy User Facility. Packages used for the transportation of Type B quantities of radioactive materials must be capable of meeting normal conditions of transportation (NCT) requirements and hypothetical accident conditions (HAC) requirements as defined in Title 10 Code of Federal Regulations (CFR) Part 71. Evaluation of package designs to these criteria typically involves a combination of analysis and physical testing. Required physical tests include free drop, crush, puncture, penetration, compression, vibration, water spray, water immersion, and thermal. The Oak Ridge National Laboratory (ORNL) Packaging Evaluation Facility (PEF) at the National Transportation Research Center (NTRC) provides an inclusive testing capability for a wide variety of packages needed for shipment of radioactive materials. Since PATRAM 2019, ORNL has performed several sets of tests including testing of two designs of the Defense Program Package (DPP-3 and DPP-1) and several Special Form Capsules. This paper provides an overview of the testing performed as well as a summary of advancements made to the ORNL package testing program during that time.

Martinez, Oscar↗

DOE OSTI2020

Filtration Performance Results: Sierra Peaks Material No. 4

Sandia National Laboratories (SNL) assessed the filtration performance of materials from Sierra Peaks to identify alternatives which may perform similarly to materials used in FDA-approved N95 respirators. This work is meant to characterize the aerosol performance of materials to give Sierra Peaks information for them to determine if they elect to submit masks made using these materials for follow-on N95 certification testing at an accredited facility. The R&D testbed used is a large-scale filtration system designed to test commercial filter boxes. System modifications were performed to simulate, where possible, parameters defined by the National Institute for Occupational Safety and Health (NIOSH) for certification of filter materials for N95 respirators (NIOSH 2019). The system is a pull-through design. Air enters through a Laminar Flow Element (LFE) and the volumetric flow is measured based on the pressure drop across the LFE. Pressure is measured via a Pressure Transducer (PT). The air then passes through a High Efficiency Particulate Air (HEPA) filter to purge the air of ambient airborne particulates. Test aerosol is injected into the flow shortly after and mixing is induced via a coarse mesh. The airflow is allowed to fully develop prior to arriving at the test section. The aerosol then passes through the test material mounted in a box in the test section. Pressure drop across the test article is measured and aerosol sampling probes measure the aerosol concentrations upstream and downstream of the sample. The air passes through a second HEPA filter prior to being exhausted to ambient by a blower. A Topas aerosol generator is used to produce the test aerosol from Sodium Chloride (NaC1) dissolved in deionized (DI) water. Generated aerosol passes through a heated mixing chamber and a desiccant dryer to produce nanosized solid-state particulates. A dilution loop allows for the aerosol concentration to be regulated. The aerosol sampling probes upstream and downstream of the test section are aligned with the flow path. These are ducted directly to the aerosol sizing and counting instruments. A Laser Aerosol Spectrometer (LAS) was used for data collection in the original configuration of the system and was also used for initial testing in this project. Because the lower measurement range for the LAS is 90 nanometers (nm), the LAS was switched out for a more complicated Scanning Mobility Particle Sizer (SMPS) spectrometer system. The SMPS is comprised of an Electrostatic Classifier (EC), Differential Mobility Analyzer (DMA), and a Condensation Particle Counter (CPC). This enabled data collection at 75 nm, the particle size called out in the NIOSH guidelines.

36 MATERIALS SCIENCE↗

NASA NTRSDate not supplied

Database Design Strategies for Coordinated Simulation and Testing in Additive Manufacturing

The qualification and certification (Q&C) process presents a significant challenge for widespread adoption of additive manufacturing (AM) materials and processes for aerospace applications. A relational database framework will be presented as a tool for data curation of coordinated experimental and computational materials modeling research activities. A comparison of relational and hierarchical data structures in this domain will be emphasized through the evolution of a database design strategy. This framework’s mission is to support the advancement of computational materials-informed Q&C by providing the necessary data infrastructure to trace reliability and reproducibility measures through unified AM materials simulation and experimental testing. FAIR (findable, accessible, interoperable, and reusable) data will be highlighted as a necessary precursor for automation of specific actions, which ultimately reduces the time and expense burden for Q&C. The discussion will be mostly limited to back-end design elements, though a few front-end user experience examples will also be shared.

Qualification↗

DOE OSTI2026

Bayesian Optimization of Catalysis with In-Context Learning

Large language models (LLMs) can perform accurate classification with zero or few examples through in-context learning (ICL), allowing the model to observe query-relevant examples at inference time and eliminating the need for additional weight updates to generalize beyond its original training data. We extend this capability to regression with uncertainty estimation using frozen LLMs (e.g., GPT-4o, Gemini), enabling Bayesian optimization (BO) in natural language without explicit model training or feature engineering. We apply this to materials discovery by representing materials as synthesis and testing procedures for use in natural language prompts. This Bayesian, design-first approach prioritizes optimization toward target material properties before detailed characterization, in contrast to conventional experimental workflows that often emphasize characterization of suboptimal materials. On benchmarks like aqueous solubility and oxidative coupling of methane (OCM), BO-ICL matches or outperforms Gaussian processes. In live experiments on the reverse water–gas shift (RWGS) reaction, BO-ICL identifies multimetallic catalysts that approach equilibrium CO yield within 6 and 10 iterations from a pool of 3,700 and 360,000 candidates, respectively. Our method redefines materials representation and accelerates discovery, with broad applications across catalysis, materials science, and AI.

Calibration↗

NASA NTRS1993

Atomic research

Work performed by the University of Alabama in Huntsville's (UAH) Center for Applied Optics (CAO) entitled Atomic Research is documented. Atomic oxygen (AO) effects on materials have long been a critical concern in designing spacecraft to withstand exposure to the Low Earth Orbit (LEO) environment. The objective of this research effort was to provide technical expertise in the design of instrumentation and experimental techniques for analyzing materials exposed to atomic oxygen in accelerated testing at NASA/MSFC. Such testing was required to answer fundamental questions concerning Space Station Freedom (SSF) candidate materials and materials exposed to atomic oxygen aboard the Long-Duration Exposure Facility (LDEF). The primary UAH task was to provide technical design, review, and analysis to MSFC in the development of a state-of-the-art 5eV atomic oxygen beam facility required to simulate the RAM-induced low earth orbit (LEO) AO environment. This development was to be accomplished primarily at NASA/MSFC. In support of this task, contamination effects and ultraviolet (UV) simulation testing was also to be carried out using NASA/MSFC facilities. Any materials analysis of LDEF samples was to be accomplished at UAH.

Hadaway, James B.↗

NASA NTRS2019

Continued Development of a Highly Reflective Solar Coating for Cryogenic Liquid Storage in Space

State-of-the-art solar reflectors absorb 6-8 % of the sun's irradiant power, which is adequate for spacecraft thermal control; but not for storage of cryogens in tanks exposed to the Sun. A solar reflector must absorb less than 0.4% of the Sun's power, while radiating effectively in the far IR, to allow LOX storage. Hibbard realized this in 1960's, at about the same time that nearly perfect optical reflectors were developed based on particle scattering. In 2015, under funding from the NASA Innovative Advanced Concepts Program (NIAC), these breakthroughs were rediscovered. Theoretical analysis showed that a tank coated with a thick (1 cm) layer of 150 nm particles, composed of a broadband material, could allow the tank to chill to cryogenic temperatures, even in the presence of 1 AU solar irradiance. Subsequent work lead to the demonstration and testing of BaF2 based rigid coupons. Placing one of these in a cryocooler-based simulated deep space environment and irradiating with simulated sunlight has shown about 1% absorption. This is better than the state-of-the-art but not yet sufficient for LOX storage.This paper will review the background material presented above but will concentrate on work performed over the last year, including the design and build-up of the testing apparatus. Since our last publication, we have changed materials from BaF2 to Y2O3. Y2O3 has slightly higher solar absorptance, but is hydrophobic and higher index.

Swanger, Adam↗