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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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At least 649 records · Page 36
All sourcesNASA NTRSDOE OSTI
NASA NTRS2018

Discrete Assemblers Utilizing Conventional Motion Systems

An alternative to additive manufacturing is disclosed, introducing an end-to-end workflow in which discrete building blocks are reversibly joined to produce assemblies called digital materials. Described is the design of the bulk-material building blocks and the devices that are assembled from them. Detailed is the design and implementation of an automated assembler, which takes advantage of the digital material structure to avoid positioning errors within a large tolerance. To generate assembly sequences, a novel CAD/CAM workflow is described for designing, simulating, and assembling digital materials. The structures assembled using this process have been evaluated, showing that the joints perform well under varying conditions and that the assembled structures are functionally precise.

Langford, William Kai↗
NASA NTRSDate not supplied

A Parallelized Oxidation-Driven Surface Recession Framework in DSMC Code, SPARTA

Spacecrafts rely on ablative thermal protection systems (TPS) made of composites consisting of a carbon-based reinforcement and a polymeric matrix. These materials are designed to withstand high-temperature oxidation and surface recession during re-entry into the Earth's atmosphere. However, ablation occurs due to a complex interplay of thermal, mechanical, and chemical factors, making it challenging to determine the individual impact of each on the TPS's overall degradation. In this study, we have developed an ablation model that can leverage a finite rate carbon oxidation model to predict material recession and surface states more accurately. Stochastic PArallel Rarified-gas Time-accurate Analyzer (SPARTA), a direct-simulation Monte Carlo (DSMC) code, is modified to allow oxidation-driven ablation of implicitly defined carbon surfaces. In SPARTA, implicit surfaces are generated from the grid corner point values via a marching cubes algorithm, therefore creating a new set of surface elements every time ablation is performed. The finite-rate oxidation model developed by Gopalan et. al can perform both gas-surface and pure-surface reactions and is now adapted to tally surface data on a per grid cell basis. The ablation functionality was also adjusted so once the reactions have occurred, the number of reactions leading to CO formation can be converted to corner point reduction values; therefore, carbon removal is directly proportional to surface recession. We also briefly discuss some unique challenges associated with parallelizing this dynamic surface state and geometry. Finally, we analyze the performance of this parallelized implicit chemistry model with simple 2D and 3D benchmark cases by producing surface state statistics, area changes over time, and visualization across a range of surface temperatures and processors with and without load-balancing.

DSMC↗
NASA NTRS2013

Selection and Manufacturing of Membrane Materials for Solar Sails

Commercial metallized polyimide or polyester films and hand-assembly techniques are acceptable for small solar sail technology demonstrations, although scaling this approach to large sail areas is impractical. Opportunities now exist to use new polymeric materials specifically designed for solar sailing applications, and take advantage of integrated sail manufacturing to enable large-scale solar sail construction. This approach has, in part, been demonstrated on the JAXA IKAROS solar sail demonstrator, and NASA Langley Research Center is now developing capabilities to produce ultrathin membranes for solar sails by integrating resin synthesis with film forming and sail manufacturing processes. This paper will discuss the selection and development of polymer material systems for space, and these new processes for producing ultrathin high-performance solar sail membrane films.

Bryant, Robert G.↗
NASA NTRS2012

Elements of Nondestructive Examination for the Visual Inspection of Composite Structures

Visual inspection (VI) of composite structures provides an effective, wide field survey to ensure design and material compliance is maintained for the entire service life of the manufactured component. Visual inspection is one of the most commonly used nondestructive inspection methods to assess surface defects on composites. By applying visual inspection elements, mechanical damage that could affect component residual strength can be identified and a disposition reached before a potentially catastrophic event occurs. This technique is non-contact and applied at all stages of the composite structure s processing and use. Additionally, VI is required to be performed in all service environments until decommission. By following Level I and Level II damage accept/reject criteria set forth in this document, the material review (MR) process can be initiated. This nondestructive evaluation (NDE) method should be complemented with additional NDE methods to best understand the nature of the observed indications. When VI identification is followed by interrogation using effective complimentary NDE methods, the final Material Review Board (MRB) disposition of the component can be effectively achieved. Although elements of the visual inspection method are discussed and expressly required by the various range standards (KNPR 8715.3 and AFSPCMAN 91-710), emphasis should be placed on supporting the interpretation of recorded visual observations. Sound engineering practices and procedures should be applied with the interpretation of nondestructive testing (NDT) results when the residual strength data specific to a vessel design is incomplete or absent.

Tommy B. Yoder↗
NASA NTRS2016

Magnetic Shield Design Modeling and Validation for SWOT Spacecraft Ka-Band Extended Interaction Klystron

Two Extended Interaction Klystrons (EIKs) containing strong permanent magnets were modeled magnetically in a representative spacecraft geometry using commercial finite element modeling techniques and were validated against measurements made at varying distances. Initial modeling results for the 63 A-m2 dipole moment magnets showed that magnetic shields would be necessary in order to meet magnetic field requirements for the Surface Water and Ocean Topography (SWOT) spacecraft, which contains components that are susceptible to external DC magnetic fields. JPL and the EIK vendor proposed cold rolled steel and mu-metal as potential shield materials along with proposed thicknesses of 0.5 mm and 1.5 mm. Magnetic shields made from each of these materials were designed and modeled in software, taking highfield saturation into account. Prototype magnetic shields with these parameters were then built, measured with an existing EIK, and compared against modeling results. For single-axis field measurements along the dipole axis, modeling results were within 7 gauss of the measured values at 10 cm from the magnet, and converged to less than 1.5 gauss at distances greater than 14 cm from the magnet. Three-axis field measurements at locations of interest showed that model correlation improved to within 4 gauss at 11 cm and 2 gauss for distances ranging between 15 cm and 36 cm.

Gonzales, Edward↗
NASA NTRS1982

Development of an advanced composite aileron for the L-1011 transport aircraft

Significant improvements in structural efficiency can be achieved by the utilization of advanced composites for construction of aircraft secondary structures. Careful evaluation of alternate designs and materials for the L-1011 advanced composite inboard aileron has led to the selection of several unique material combinations and easily manufactured structural configurations. The advanced composite aileron is a direct replacement for the metal aileron with a weight savings of 23 percent. Due to the configurational simplicity of the components within the composite aileron, and because it contains 50 percent fewer parts and fasteners than the metal aileron, it is predicted that the composite aileron will be cost competitive with the metal aileron in a production environment. Structural analysis of the composite aileron, in conjunction with the design data, concept verification, and ground tests, indicates that the composite aileron design meets or exceeds structural requirements.

Griffin, C. F.↗
NASA NTRSDate not supplied

An Advanced Thermal Radiator for Global Lunar Heat Rejection

An advanced thermal radiator innovation to provide global heat rejection for Lunar exploration is described in this paper. Infrared background radiation from Lunar terrain can seriously compromise the performance of conventional thermal radiators, especially at lower latitudes. The Apollo missions boiled consumable H2O for heat rejection which would be unsustainable for long duration Lunar exploration where temperatures may exceed 250°F at the equator. The proposed innovation would provide indefinite, sustainable heat rejection for orbiting assets, rovers, landers and habitats over the entire surface of the Moon. The advanced radiator concept introduces a semi-transparent cover-glass to transmit and reflect both incident infrared radiation and solar irradiation to facilitate improved heat rejection. With sponsorship from MSFC Center Innovation Funding (CIF), two advanced radiator concepts were fabricated and evaluated inside the High Intensity Solar Environment Test (HISET) facility thermal vacuum chamber at MSFC. Using custom designed and fabricated test stands in the HISET chamber, the tests simulated both the Lunar terrestrial (inside a crater under full sun) and orbital thermal environments. A conventional radiator was also fabricated and tested under identical conditions for comparison. Test results indicate improved radiator performance (relative to conventional) in the Lunar orbital environment but the advanced radiators did not perform as well as expected in the surface environment. Correlation to thermal math models is presented and future research may consider alternate materials or designs to improve the terrestrial performance.

Thermal Control System↗
NASA NTRS2016

Magnetic Shield Design Modeling and Validation for SWOT Spacecraft Ka-Band Extended Interaction Klystron

Two Extended Interaction Klystrons (EIKs) containing strong permanent magnets were modeled magnetically in a representative spacecraft geometry using commercial finite element modeling techniques and were validated against measurements made at varying distances. Initial modeling results for the 63 A-m2 (amperes per square meter) dipole moment magnets showed that magnetic shields would be necessary in order to meet magnetic field requirements for the Surface Water and Ocean Topography (SWOT) spacecraft, which contains components that are susceptible to external DC (Direct Current) magnetic fields. JPL (Jet Propulsion Laboratory) and the EIK vendor proposed cold rolled steel and mu-metal as potential shield materials along with proposed thicknesses of 0.5 millimeters and 1.5 millimeters. Magnetic shields made from each of these materials were designed and modeled in software, taking high-field saturation into account. Prototype magnetic shields with these parameters were then built, measured with an existing EIK, and compared against modeling results. For single-axis field measurements along the dipole axis, modeling results were within 7 gauss of the measured values at 10 centimeters from the magnet, and converged to less than 1.5 gauss at distances greater than 14 centimeters from the magnet. Three-axis field measurements at locations of interest showed that model correlation improved to within 4 gauss at 11 centimeters and 2 gauss for distances ranging between 15 centimeters and 36 centimeters.

Gonzales, Edward↗
NASA NTRS2003

Case Studies of Fatigue Life Improvement Using Low Plasticity Burnishing in Gas Turbine Engine Applications

Surface enhancement technologies such as shot peening, laser shock peening (LSP), and low plasticity burnishing (LPB) can provide substantial fatigue life improvement. However, to be effective, the compressive residual stresses that increase fatigue strength must be retained in service. For successful integration into turbine design, the process must be affordable and compatible with the manufacturing environment. LPB provides thermally stable compression of comparable magnitude and even greater depth than other methods, and can be performed in conventional machine shop environments on CNC machine tools. LPB provides a means to extend the fatigue lives of both new and legacy aircraft engines and ground-based turbines. Improving fatigue performance by introducing deep stable layers of compressive residual stress avoids the generally cost prohibitive alternative of modifying either material or design. The X-ray diffraction based background studies of thermal and mechanical stability of surface enhancement techniques are briefly reviewed, demonstrating the importance of minimizing cold work. The LPB process, tooling, and control systems are described. An overview of current research programs conducted for engine OEMs and the military to apply LPB to a variety of engine and aging aircraft components are presented. Fatigue performance and residual stress data developed to date for several case studies are presented including: * The effect of LPB on the fatigue performance of the nickel based super alloy IN718, showing fatigue benefit of thermal stability at engine temperatures. * An order of magnitude improvement in damage tolerance of LPB processed Ti-6-4 fan blade leading edges. * Elimination of the fretting fatigue debit for Ti-6-4 with prior LPB. * Corrosion fatigue mitigation with LPB in Carpenter 450 steel. *Damage tolerance improvement in 17-4PH steel. Where appropriate, the performance of LPB is compared to conventional shot peening after exposure to engine operating temperatures.

Prevey, Paul S.↗
NASA NTRS1987

SKITTER foot design

A mechanical design team was formed to design a foot for the lunar utility vehicle SKITTER. The primary design was constrained to be a ski pole design compatible with the existing femur-tibia design legs. The lunar environment had several important effects on the foot design. Three materials were investigated for the SKITTER foot: aluminum alloys, cold worked stainless steel alloys, and titanium alloys. Thin film coatings were investigated as a method of wear reduction for the foot. The performance of the foot is dependent on the action of the legs. The range of motion for the legs was determined to be vertical to 15 degrees above horizontal. An impact analysis was performed for the foot movement, but the results were determined to be inconclusive due to unknown soil parameters. The initial foot design configuration consisted of an annulus attached to the pointed pole. The annulus was designed to prevent excess sinkage. Later designs call for a conical shaped foot with a disk at the point of the tibia attachment. The conical design was analyzed for strength and deflection by two different approaches. A deformable body analysis was performed for the foot under crane load in crane position, and also under actuator load in the vertical position. In both cases, the deflection of the foot was insignificant and the stresses well below the strength of the titanium alloy.

Choi, Gene↗
NASA NTRS2004

Conical Magnetic Bearing Development and Magnetic Bearing Testing for Extreme Temperature Environments

The main proposed research of this grant were: to design a high-temperature, conical magnetic bearing facility, to test the high-temperature, radial magnetic bearing facility to higher speeds, to investigate different backup bearing designs and materials, to retrofit the high-temperature test facility with a magnetic thrust bearing, to evaluate test bearings at various conditions, and test several lubricants using a spiral orbit tribometer. A high-temperature, conical magnetic bearing facility has been fully developed using Solidworks. The facility can reuse many of the parts of the current high-temperature, radial magnetic bearing, helping to reduce overall build costs. The facility has the ability to measure bearing force capacity in the X, Y, and Z directions through a novel bearing mounting design. The high temperature coils and laminations, a main component of the facility, are based upon the current radial design and can be fabricated at Texas A&M University. The coil design was highly successful in the radial magnetic bearing. Vendors were contacted about fabrication of the high temperature lamination stack. Stress analysis was done on the laminations. Some of the components were procured, but due to budget cuts, the facility build up was stopped.

Keith, Theo G., Jr.↗
NASA NTRS1993

Status of the NASA Balloon Program

The NASA Balloon Program (BP) is examined in an overview of design philosophy, R&D activities, flight testing, and the development of a long-duration balloon for Antarctic use. The Balloon Recovery Program was developed to qualify the use of existing films and to design improved materials and seals. Balloon flights are described for studying the supernova SN1987a, and systems were developed to enhance balloon campaigns including mobile launch vehicles and tracking/data-acquisition systems. The technical approach to long-duration ballooning is reviewed which allows the use of payloads of up to 1350 kg for two to three weeks. The BP is responsible for the development of several candidate polyethylene balloon films as well as design/performance standards for candidate balloons. Specific progress is noted in reliability and in R&D with respect to optimization of structural design, resin blending, and extrusion.

Needleman, H. C.↗
NASA NTRS2016

We Can't Count on Repairing All Failures Going to Mars

Reliability analysis often assumes that a complex system can be kept operating indefinitely with scheduled maintenance and emergency repair using a stock of spare parts, as long as the spare parts are not depleted. This assumption seems justified for well-tested, widely used, long operational systems with a multigenerational history of failure, redesign, and reliability growth. It seems doubtful that newer, relatively untried, high technology space systems can always be repaired. We cannot assume space systems will have a low rate of random failures that can all be repaired with a few identical spares. New untried systems usually have a high initial failure rate, called infant mortality, due to errors in requirements, design, parts, materials, and operations planning. These problems can cause groups of related failures called Common Cause Failures (CCFs). The practical definition of a CCF is any failure mode that cannot be cured using identical redundant systems or spare parts. Systems with CCFs may fail repeatedly for the same reason. Can a life support system be kept operating on the way to Mars using only redundant systems and spare parts? The failure history of International Space Station (ISS) life support systems suggests that CCFs are likely to occur and will probably require design changes rather than being reparable with spare parts.

Mars↗
NASA NTRS2008

System Engineering on the Use for Ares I,V - the Simpler, the Better

The Ares I and Ares V Vehicles will utilize the J-2X rocket engine developed for NASA by the Pratt & Whitney Rocketdyne Company. The J-2X is an improved higher power version of the original J-2 engine used during the Apollo program. With higher power and updated requirements for safety and performance, the J-2X becomes a new engine using state-of-the-art design methodology, materials and manufacturing processes. The implementation of Systems Engineering (SE) principles enables the rapid J-2X development program to remain aligned with the ARES I and V vehicle programs, Meeting the aggressive development schedule is a challenge. Coordinating the best expertise thai NASA and PWR have to offer requires effectively utilizing resources at multiple sites. This presents formidable communication challenges. SE allows honest and open discussions of issues and problems. This simple idea is often overlooked in large and complex SE programs. Regular and effective meetings linking SE objectives to component designs are used to voice differences of opinions with customer and contractor in attendance so that the best mutual decisions can be made on the shortest possible schedule. Regular technical interchange meetings on secure program wide computer networks and CM processes are effective,in the "Controlled Change" process that exemplifies good SE. Good communication is a key effective SE implementation. The System of Systems approach is the vision of the Orion program which facilitates the establishment of dynamic SE processes at all levels including the engine. SE enables requirements evolution by facilitating organizational and process agility. Flow down and distribution of requirements is controlled by Allocation Reports which breakdown numerical design objectives (weight, reliability, etc.) into quanta goals for each component area. Linked databases of design and verification requirements helps eliminate redundancy and potential mistakes inherent m separated systems. Another tool, the Architecture Design Description, is being used to control J-2X system architecture and effectively communicate configuration changes to those involved in the design process. But the proof is in successful program accomplishment. The SE is the methodology being used to meet the challenge of completing J-2X engine certification 2 years ahead of any engine program ever developed at PWR. The Ares I SE system of systems has delivered according to expectations thus far. All major design reviews (SRR. PDR, CDR) have been successfully conducted to satisfy overall program objectives using SE as the basis for accomplishment. The paper describes SE tools and techniques utilized to achieve this success.

Kelly, William↗
NASA NTRS1987

A prediction model of the depth-of-discharge effect on the cycle life of a storage cell

Cycle life requirements are very high for batteries used in aerospace applications in low Earth orbit. The data base required to establish confidence in a particular cell design is thus both extensive and expensive. Reliable accelerated cycle life testing and performance decay modeling represent attractive alternatives to real-time tests of cycle life. In light of certain long-term cycle life test results, this paper examines a very simple performance decay model developed earlier. Application of that model to available data demonstrates a rigid relationship between a battery's expected cycle life and the depth of discharge of cycling. Further, modeling analysis of the data suggests that a significantly improved cycle life can be obtained with advanced components, materials, and designs; and that cycle life can be reliably predicted from the results of accelerated testing.

Thaller, Lawrence H.↗
NASA NTRS1987

A prediction model of the depth-of-discharge effect on the cycle life of a storge cell

Cycle life requirements are very high for batteries used in aerospace applications in low earth orbit. The data base required to establish confidence in a particular cell design is thus both extensive and expensive. Reliable accelerated cycle life testing and performance decay modeling represent attractive alternatives to real-time tests of cycle life. In light of certain long-term cycle life test results, this paper examines a very simple performance decay model developed earlier. Application of that model to available data demonstrates a rigid relationship between a battery's expected cycle life and the depth of discharge of cycling. Further, modeling analysis of the data suggests that a significantly improved cycle life can be obtained with advanced components, materials, and designs; and that cycle life can be reliably predicted from the results of accelerated testing.

Thaller, Lawrence H.↗
NASA NTRS1961

Exploratory Environmental Tests of Several Heat Shields

Exploratory tests have been conducted with several conceptual radiative heat shields of composite construction. Measured transient temperature distributions were obtained for a graphite heat shield without insulation and with three types of insulating materials, and for a metal multipost heat shield, at surface temperatures of approximately 2,000 F and 1,450 F, respectively, by use of a radiant-heat facility. The graphite configurations suffered loss of surface material under repeated irradiation. Temperature distribution calculated for the metal heat shield by a numerical procedure was in good agreement with measured data. Environmental survival tests of the graphite heat shield without insulation, an insulated multipost heat shield, and a stainless-steel-tile heat shield were made at temperatures of 2,000 F and dynamic pressures of approximately 6,000 lb/sq ft, provided by an ethylene-heated jet operating at a Mach number of 2.0 and sea-level conditions. The graphite heat shield survived the simulated aerodynamic heating and pressure loading. A problem area exists in the design and materials for heat-resistant fasteners between the graphite shield and the base structure. The insulated multipost heat shield was found to be superior to the stainless-steel-tile heat shield in retarding heat flow. Over-lapped face-plate joints and surface smoothness of the insulated multi- post heat shield were not adversely affected by the test environment. The graphite heat shield without insulation survived tests made in the acoustic environment of a large air jet. This acoustic environment is random in frequency and has an overall noise level of 160 decibels.

Goodman, George P.↗