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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 NTRS1992

A generic model for creep rupture lifetime estimation on fibrous ceramic composites

Because of their high strength and toughness at elevated temperatures, fiber reinforced ceramic composites such as SiC(f)/SiC and SiC(f)/Si3N4 have become candidates for next-generation turbine engine materials. A generic model is proposed for assessing the lifetime of this class of materials when subjected to long-term creep rupture conditions. This 2D model consists of interfacial cracks growing between square grains and rectangular fibers in the direction normal to the principal tensile stress axis. Neglecting transient effects, the total lifetime is derived based on the criterion that rupture is due to coalescence of adjacent cracks. Lifetime is inversely proportional to crack growth rate, volume fraction, and aspect ratio of the fibers; but extremely sensitive to the applied stress, due to the high power of the V-K(I) law. This lifetime estimation seems to be in fair agreement with the creep rupture data of SiC(w)/Si3N4 composite with 0 and 30 vol percent reinforcement tested at 1250 C in air. TEM performed on the postcrept specimens revealed that creep damage is predominantly in the form of microcracks at matrix/matrix as well as fiber/matrix interfaces, approximately in accord with the model simulation.

Chuang, Tze-Jer↗
NASA NTRS2015

X-Ray Optics at NASA Marshall Space Flight Center

NASA's Marshall Space Flight Center (MSFC) engages in research, development, design, fabrication, coating, assembly, and testing of grazing-incidence optics (primarily) for x-ray telescope systems. Over the past two decades, MSFC has refined processes for electroformed-nickel replication of grazing-incidence optics, in order to produce high-strength, thin-walled, full-cylinder x-ray mirrors. In recent years, MSFC has used this technology to fabricate numerous x-ray mirror assemblies for several flight (balloon, rocket, and satellite) programs. Additionally, MSFC has demonstrated the suitability of this technology for ground-based laboratory applications-namely, x-ray microscopes and cold-neutron microscopes and concentrators. This mature technology enables the production, at moderately low cost, of reasonably lightweight x-ray telescopes with good (15-30 arcsecond) angular resolution. However, achieving arcsecond imaging for a lightweight x-ray telescope likely requires development of other technologies. Accordingly, MSFC is conducting a multi-faceted research program toward enabling cost-effective production of lightweight high-resolution x-ray mirror assemblies. Relevant research topics currently under investigation include differential deposition for post-fabrication figure correction, in-situ monitoring and control of coating stress, and direct fabrication of thin-walled full-cylinder grazing-incidence mirrors.

X-ray Optics↗
NASA NTRS2015

X-Ray Optics at NASA Marshall Space Flight Center

NASA's Marshall Space Flight Center (MSFC) engages in research, development, design, fabrication, coating, assembly, and testing of grazing-incidence optics (primarily) for x-ray telescope systems. Over the past two decades, MSFC has refined processes for electroformed-nickel replication of grazing-incidence optics, in order to produce high-strength, thin-walled, full-cylinder x-ray mirrors. In recent years, MSFC has used this technology to fabricate numerous x-ray mirror assemblies for several flight (balloon, rocket, and satellite) programs. Additionally, MSFC has demonstrated the suitability of this technology for ground-based laboratory applications-namely, x-ray microscopes and cold-neutron microscopes and concentrators. This mature technology enables the production, at moderately low cost, of reasonably lightweight x-ray telescopes with good (15-30 arcsecond) angular resolution. However, achieving arcsecond imaging for a lightweight x-ray telescope likely requires development of other technologies. Accordingly, MSFC is conducting a multi-faceted research program toward enabling cost-effective production of lightweight high-resolution x-ray mirror assemblies. Relevant research topics currently under investigation include differential deposition for post-fabrication figure correction, in-situ monitoring and control of coating stress, and direct fabrication of thin-walled full-cylinder grazing-incidence mirrors.

X-ray telescope↗
NASA NTRS1981

Structural requirements and technology needs of geostationary platforms

To identify structural requirements and technology needs of the geostationary platforms, two design alternatives are analyzed with respect to utilities accommodation, interface, and strength and stiffness requirements. Alternative 1 is comprised of 6,800 kg (15,000 lb) platform modules, each delivered to low earth orbit (LEO) with an attached orbit transfer vehicle (OTV) in a single Shuttle flight, deployed, and transferred to a geostationary constellation of platforms. Alternative 2 is made up of 16,800 kg (37,000 lb) platform modules, each delivered to LEO, deployed, mated to a 2 stage OTV (delivered to LEO in two additional Shuttle flights) and transferred to GEO for docking with other modules to form a single large platform. The top candidates for deployable structure elements are the expandable truss beam and the Astromast. The beam, fabricated of graphite/epoxy with a designed coefficient of thermal expansion of zero, provides good packaging density and high strength and stiffness per unit weight. The Astromast provides the best packaging density, but lacks the strength and stiffness required for the platform payloads. A graphite/epoxy mast with the Astromast packaging density is an advancement in technology needed for optimizing the geostationary platform designs.

Stone, G. R.↗
NASA NTRS2003

Superalloy Disk With Dual-Grain Structure Spin Tested

Advanced nickel-base disk alloys for future gas turbine engines will require greater temperature capability than current alloys, but they must also continue to deliver safe, reliable operation. An advanced, nickel-base disk alloy, designated Alloy 10, was selected for evaluation in NASA s Ultra Safe Propulsion Project. Early studies on small test specimens showed that heat treatments that produced a fine grain microstructure promoted high strength and long fatigue life in the bore of a disk, whereas heat treatments that produced a coarse grain microstructure promoted optimal creep and crack growth resistance in the rim of a disk. On the basis of these results, the optimal combination of performance and safety might be achieved by utilizing a heat-treatment technology that could produce a fine grain bore and coarse grain rim in a nickel-base disk. Alloy 10 disks that were given a dual microstructure heat treatment (DMHT) were obtained from NASA s Ultra-Efficient Engine Technology (UEET) Program for preliminary evaluation. Data on small test specimens machined from a DMHT disk were encouraging. However, the benefit of the dual grain structure on the performance and reliability of the entire disk still needed to be demonstrated. For this reason, a high temperature spin test of a DMHT disk was run at 20 000 rpm and 1500 F at the Balancing Company of Dayton, Ohio, under the direction of NASA Glenn Research Center personnel. The results of that test showed that the DMHT disk exhibited significantly lower crack growth than a disk with a fine grain microstructure. In addition, the results of these tests could be accurately predicted using a two-dimensional, axisymmetric finite element analysis of the DMHT disk. Although the first spin test demonstrated a significant performance advantage associated with the DMHT technology, a second spin test on the DMHT disk was run to determine burst margin. The disk burst in the web at a very high speed, over 39 000 rpm, in line with the predicted location and speed. Furthermore, significant growth of the disk was observed before failure, in line with predictions, clearly demonstrating the reliability and safety of the DMHT technology. Although successful spin testing in Ultra Safe's Nickel Disk Program represents a significant milestone for DMHT technology, realistic engine operation will require repeated loading of a DMHT nickel disk. For this reason, a cyclic spin test study of DMHT nickel disk technology has been proposed to start in fiscal year 2003 under NASA's Aviation Safety Program. The goal of this program will be to determine the fatigue failure mechanism in DMHT nickel disks, thereby demonstrating the reliability and safety of DMHT technology under repetitive loading conditions encountered in realistic engine operation.

Gayda, John↗
NASA NTRS1991

Control algorithm implementation for a redundant degree of freedom manipulator

This project's purpose is to develop and implement control algorithms for a kinematically redundant robotic manipulator. The manipulator is being developed concurrently by Odetics Inc., under internal research and development funding. This SBIR contract supports algorithm conception, development, and simulation, as well as software implementation and integration with the manipulator hardware. The Odetics Dexterous Manipulator is a lightweight, high strength, modular manipulator being developed for space and commercial applications. It has seven fully active degrees of freedom, is electrically powered, and is fully operational in 1 G. The manipulator consists of five self-contained modules. These modules join via simple quick-disconnect couplings and self-mating connectors which allow rapid assembly/disassembly for reconfiguration, transport, or servicing. Each joint incorporates a unique drive train design which provides zero backlash operation, is insensitive to wear, and is single fault tolerant to motor or servo amplifier failure. The sensing system is also designed to be single fault tolerant. Although the initial prototype is not space qualified, the design is well-suited to meeting space qualification requirements. The control algorithm design approach is to develop a hierarchical system with well defined access and interfaces at each level. The high level endpoint/configuration control algorithm transforms manipulator endpoint position/orientation commands to joint angle commands, providing task space motion. At the same time, the kinematic redundancy is resolved by controlling the configuration (pose) of the manipulator, using several different optimizing criteria. The center level of the hierarchy servos the joints to their commanded trajectories using both linear feedback and model-based nonlinear control techniques. The lowest control level uses sensed joint torque to close torque servo loops, with the goal of improving the manipulator dynamic behavior. The control algorithms are subjected to a dynamic simulation before implementation.

Cohan, Steve↗
NASA NTRS2018

Development of an Inflatable Airlock for a Deep Space Gateway

Inflatable structures technology utilizes high-strength fabric materials and internal pressure to create a stiffened pressure vessel that can replace traditional metallic primary structure in a habitable spacecraft. The flexibility of fabric structures allows them to be compactly stowed for launch and expanded in space, providing significant launch volume savings. The unique construction and design flexibility of these structures can be customized for a variety of uses in space including landing bags, decelerators, long duration in-space and planetary surface habitats, and even airlocks. An airlock is often a required component of a crewed spacecraft to allow for maintenance and human exploration outside of the vehicle. Airlock designs in use today rely on complex hatches and seals connected by metallic walls. Recent developments towards the design of an inflatable airlock structure show feasibility and a significant launch volume savings over a traditional metallic design. This paper will provide a high-level summary of these projects and the current state-of-the-art in inflatable airlock development with additional references and detail about previous and on-going research, providing guidance for the design of a softgoods airlock system. The use of inflatables in space has been in development since the 1960’s for both habitats and airlocks. The first ever EVA was conducted by the USSR in 1965 using an inflatable airlock known as the Volga. This airlock was attached to the Voskhod 2 spacecraft and turned the vehicle into a dual chamber airlock. The airlock was successfully deployed, used and jettisoned after Alexey Leonov’s historic spacewalk. Additional work on human-rated inflatable structures was not continued until the late 1990’s when NASA-JSC led an effort to demonstrate these structures as feasible long-term pressurized elements with the TransHab project. The technology developed and pioneered during this project led to multiple patents and proven feasibility that inflatables could be used for large habitable structures. Following TransHab, Bigelow Aerospace continued the development of inflatable structures with technical support from NASA. This partnership eventually led to the successful flight certification, launch, attachment and deployment of the Bigelow Expandable Activities Module (BEAM) on the ISS in 2016. Inflatable and expandable airlock structures have undergone various detailed feasibility studies and testing for over 15 years, most notably with the Advanced Inflatable Airlock (AIA), Dual-Chamber Hybrid Inflatable Suitlock (DCIS), Minimalistic Advanced Soft Hatch (MASH), and Lightweight External Inflatable Airlock (LEIA). During this time, full-scale articles have been built and pressure-tested, and mock-ups and demonstrators have been constructed and evaluated. During the 2001-2003 timeframe, the AIA concept was matured through requirements development, conceptual design, subscale and full-scale engineering breadboards subjecting various test articles to deployment and pressure testing up to four times operating pressure. These tests proved the feasibility of successful deployment and structural integrity of an inflatable crewlock. Additional testing was performed in the ensuing years, as funding permitted, to further refine additional structural and deployment concepts and to understand the EVA crewmember interfaces, hatches and EVA support equipment interfaces that would be required for a fully functioning airlock. This work resulted in a refinement of the structural requirements and an accounting of the systems needed in an inflatable airlock. In 2014, the MASH project developed an ultra-lightweight airlock concept with a fabric hatch that utilized a unique pressure vessel shape to minimize structural loads around a linear seal. The concept uses an automated zipper-like seal that allows for crew egress/ingress. Most of the development work on the project thus far has focused on the design, analysis and testing of the primary structure and the zipper-like seal system is in the preliminary stages of development with a successful proof-of-concept test. As part of the 2017 LEIA effort, studies were conducted on EVA crewmember interfaces on the inside of an inflatable airlock. These efforts included the design of an internal secondary structure and placement of handholds and foot restraints to enable hatch opening, closing and translation through the airlock. Structural design, analysis and testing was completed on several secondary structure candidates. Crew interface testing was also completed using an inflatable crewlock mockup and the JSC Active Response Gravity Offload System (ARGOS) to simulate the movement of an EVA crewmember through an inflatable crewlock in microgravity. The results of these tests helped demonstrate the feasibility of utilizing an inflatable structure as an airlock and informed the required volume, hatch size, and configuration and location of translation aids for crewmembers in a microgravity crewlock. The ISS Quest airlock uses a dual-chamber design with isolated compartments known as the equipment-lock and the crewlock. The equipment-lock houses the Servicing, Performance and Checkout Equipment (SPCE) items (suit batteries, consumables, etc.) while the crewlock has limited internal hardware and is the nominally depressurized compartment during US EVAs. While inflatable dual chamber airlocks have been studied, the current state of the art emphasizes an inflatable crewlock-type structure attached to a rigid equipment-lock type or habitat structure. Since a large portion of the hardware in the equipment-lock are rigid components and connectors that are installed on the ground - and an inflatable structure does not achieve full structural capabilities until pressurized in space - a depressurized fabric structure cannot provide the capabilities of a full equipment-lock. The use of an inflatable as a crewlock, however, provides all the required capabilities for EVA operations in a small launch package that offers significant volume savings over a metallic crewlock. The functions of a traditional equipment lock, including the SPCE, could be provided by a spacecraft’s habitat module or node and not necessarily in a separate equipment lock. An inflatable crewlock would be attached to the vehicle and launched in a packed and compressed state, saving volume under the launch shroud and mass for the overall airlock element compared to a rigid crewlock. Work is currently underway to continue development of an inflatable airlock with a variety of focus areas including the consideration of crew-induced loads and interfaces, the design and development of an internal sub-structure to provide translation aids and restraints, the thermal considerations of a fabric shell depressurized during an EVA, the micrometeorite environment in deep space, and the packaging and deployment of an inflatable airlock.

Deep Space Exploration↗
NASA NTRS2004

TiAl Scramjet Inlet Flap Subelement Designed and Fabricated

Next-generation launch vehicles are being designed with turbine-based combined cycle (TBCC) propulsion systems having very aggressive thrust/weight targets and long lives. Achievement of these goals requires advanced materials in a wide spectrum of components. TiAl has been identified as a potential backstructure material for maintainable composite panel heat exchangers (HEX) in the inlet, combustor, and nozzle section of a TBCC propulsion system. Weight reduction is the primary objective of this technology. Design tradeoff studies have assessed that a TiAl structure, utilizing a high-strength, hightemperature TiAl alloy called Gamma MET PX,1 reduce weight by 41 to 48 percent in comparison to the baseline Inconel 718 configuration for the TBCC propulsion system inlet, combustor, and nozzle. A collaborative effort between the NASA Glenn Research Center, Pratt & Whitney, Engineering Evaluation & Design, PLANSEE AG (Austria), and the Austrian Space Agency was undertaken to design, manufacture, and validate a Gamma-MET PX TiAl structure for scramjet applications. The TiAl inlet flap was designed with segmented flaps to improve manufacturability, to better control thermal distortion and thermal stresses, and to allow for maintainable HEX segments. The design philosophy was to avoid excessively complicated shapes, to minimize the number of stress concentrations, to keep the part sizes reasonable to match processing capabilities, and to avoid risky processes such as welding. The conceptual design used a standard HEX approach with a double-pass coolant concept for centrally located manifolds. The flowpath side was actively cooled, and an insulation package was placed on the external side to save weight. The inlet flap was analyzed structurally, and local high-stress regions were addressed with local reinforcements.

Draper, Susan L.↗
NASA NTRS2014

Manufacturing Challenges Associated with the Use of Metal Matrix Composites in Aerospace Structures

Metal Matrix Composites (MMCs) consist of a metal alloy reinforced with ceramic particles or fibers. These materials possess a very high strength to weight ratio, good resistance to impact and wear, and a number of other properties which make them attractive for use in aerospace and defense applications. MMCs have found use in the space shuttle orbiter's structural tubing, the Hubble Space Telescope's antenna mast, control surfaces and propulsion systems for aircraft, and tank armors. The size of MMC components is severely limited by difficulties encountered in joining these materials using fusion welding. Melting of the material results in formation of an undesirable phase (formed when molten Aluminum reacts with the reinforcement) which leaves a strength depleted region along the joint line. Friction Stir Welding (FSW) is a relatively nascent solid state joining technique developed at The Welding Institute (TWI) in 1991. The process was first used at NASA to weld the super lightweight external tank for the Space Shuttle. Today FSW is used to join structural components of the Delta IV, Atlas V, and Falcon IX rockets as well as NASA's Orion Crew Exploration Vehicle and Space Launch System. A current focus of FSW research is to extend the process to new materials, such as MMCs, which are difficult to weld using conventional fusion techniques. Since Friction Stir Welding occurs below the melting point of the workpiece material, this deleterious phase is absent in FSW-ed MMC joints. FSW of MMCs is, however, plagued by rapid wear of the welding tool, a consequence of the large discrepancy in hardness between the steel tool and the reinforcement material. This chapter summarizes the challenges encountered when joining MMCs to themselves or to other materials in structures. Specific attention is paid to the influence of process variables in Friction Stir Welding on the wear process characterizes the effect of process parameters (spindle speed, traverse rate, and length of joint) on the wear process. A phenomenological model of the wear process was constructed based on the rotating plug model of Friction Stir Welding. The effectiveness of harder tool materials (such as Tungsten Carbide, high speed steel, and tools with diamond coatings) to combat abrasive wear is also explored. In-process force, torque, and vibration signals are analyzed to assess the feasibility of in situ monitoring of tool shape changes as a result of wear (an advancement which would eliminate the need for off-line evaluation of tool condition during joining). Monitoring, controlling, and reducing tool wear in FSW of MMCs is essential to implementation of these materials in structures (such as launch vehicles) where they would be of maximum benefit. The work presented here is extendable to machining of MMCs, where wear of the tool is also a limiting factor.

Prater, Tracie↗
NASA NTRS2013

Non-Magnetic, Tough, Corrosion- and Wear-Resistant Knives From Bulk Metallic Glasses and Composites

Quality knives are typically fabricated from high-strength steel alloys. Depending on the application, there are different requirements for mechanical and physical properties that cause problems for steel alloys. For example, diver's knives are generally used in salt water, which causes rust in steel knives. Titanium diver's knives are a popular alternative due to their salt water corrosion resistance, but are too soft to maintain a sharp cutting edge. Steel knives are also magnetic, which is undesirable for military applications where the knives are used as a tactical tool for diffusing magnetic mines. Steel is also significantly denser than titanium (8 g/cu cm vs. 4.5 g/cu cm), which results in heavier knives for the same size. Steel is hard and wear-resistant, compared with titanium, and can keep a sharp edge during service. A major drawback of both steel and titanium knives is that they must be ground or machined into the final knife shape from a billet. Since most knives have a mirrored surface and a complex shape, manufacturing them is complex. It would be more desirable if the knife could be cast into a net or near-net shape in a single step. The solution to the deficiencies of titanium, steel, and ceramic knives is to fabricate them using bulk metallic glasses (or composites). These alloys can be cast into net or near-net shaped knives with a combination of properties that exceed both titanium and steel. A commercially viable BMG (bulk metallic glass) or composite knife is one that exhibits one or all of the following properties: It is based on titanium, has a self-sharpening edge, can retain an edge during service, is hard, is non-magnetic, is corrosion-resistant against a variety of corrosive environments, is tough (to allow for prying), can be cast into a net-shape with a mirror finish and a complex shape, has excellent wear resistance, and is low-density. These properties can be achieved in BMG and composites through alloy chemistry and processing. For each desired property for knife fabrication and performance, there is an alloy development strategy that optimizes behavior. Although BMG knives have been demonstrated as far back as 1995, they never found commercial success because they had to be ground (which presented problems because the alloys contained beryllium), they weren't low cost (because they weren't cast to a net-shape), they were brittle (because they were made with a low-quality commercial material), and they had extremely poor corrosion resistance (because corrosion was not well-understood in these materials). Ultimately, these shortcomings prevented the widespread commercialization. In the current work, the inventors have applied more than a decade of research on BMGs from Caltech and JPL to develop a better understanding of how to make BMG knives that exhibit an optimal combination of properties, processing and cost. Alloys have been developed based in titanium (and other metals), that exhibit high toughness, high hardness, excellent corrosion resistance, no ferromagnetism, edge-retaining selfsharpening, and the ability to be cast like a plastic using commercially available casting techniques (currently used by commercial companies such as Liquidmetal Technologies and Visser Precision Casting). The inventors argue that depending on the application (diving, military, tactical, utility, etc.) there is an optimal combination of design and alloy composition. Moreover, with new casting technologies not available at the inception of these materials, net-shaped knives can be cast into complex shapes that require no aftermarket forming, except for sharpening using water-cooled polishing wheel. These combinations of discoveries seek to make low-cost BMG knives commercially viable products that have no equal among metal or ceramic knives. Current work at JPL focuses on net-shape casting of these alloys and testing their mechanical properties versus commercially available knives to demonstrate their benefits.

Hoffman, Douglas C.↗
NASA NTRS1964

Materials

Materials science - brittleness, fatigue, and fracture mechanics - glass-reinforced plastic, high strength metals and alloys, and refractory materials

MATERIALS SCIENCE↗
NASA NTRS1965

Thermoelectric elements diffusion-bonded to tungsten electrodes

Solid-state diffusion process bonds lead telluride and lead telluride-tin telluride thermoelectric elements to tungsten electrodes. The resulting bond is nonmagnetic and has high strength and low electrical and thermal resistance. This method is also used with tantalum electrodes.

Source record↗