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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 667 records · Page 37

All sources NASA NTRS DOE OSTI

NASA NTRS1993

Precision alignment and mounting apparatus

An alignment and mounting apparatus for mounting two modules (10,12) includes a first portion having a cylindrical alignment pin (16) projecting normal to a module surface, a second portion having a three-stage alignment guide (18) including a shoehorn flange (34), a Y-slot (42) and a V-block (22) which sequentially guide the alignment pin (16) with successively finer precision and a third portion in the form of a spring-loaded captive fastener (20) for connecting the two modules after alignment is achieved.

Preston, Dennis R.↗

NASA NTRS1992

Removable hand hold

A hand hold utilizes joining mechanisms which comprises two different mounting brackets that are permanently fastened to a supporting structure. A slide plate is disposed at one end of the hand rail or hand hold which mates with one of the mounting brackets. A securing member is disposed at the opposite end of the hand rail/hand hold which connects with the other mounting bracket by means of a locking device. The slide plate has a central tapered tongue with two matching slots disposed on each side thereof.

Corrigan, Robert D.↗

NASA NTRS2001

Low loss pole configuration for multi-pole homopolar magnetic bearings

A new pole configuration for multi-pole homopolar bearings proposed in this invention reduces rotational losses caused by eddy-currents generated when non-uniform flux distributions exist along the rotor surfaces. The new homopolar magnetic bearing includes a stator with reduced pole-to-pole and exhibits a much more uniform rotor flux than with large pole-to-pole gaps. A pole feature called a pole-link is incorporated into the low-loss poles to provide a uniform pole-to-pole gap and a controlled path for pole-to-pole flux. In order to implement the low-loss pole configuration of magnetic bearings with small pole-to-pole gaps, a new stator configuration was developed to facilitate installation of coil windings. The stator was divided into sector shaped pieces, as many pieces as there are poles. Each sector-shaped pole-piece can be wound on a standard coil winding machine, and it is practical to wind precision layer wound coils. To achieve maximum actuation efficiency, it is desirable to use all the available space for the coil formed by the natural geometric configuration. Then, the coils can be wound in a tapered shape. After winding, the sectored-pole-pieces are installed into and fastened by bonding or other means, to a ring of material which encloses the sectored-pole-pieces, forming a complete stator.

Blumenstock, Kenneth A.↗

NASA NTRS2005

Heat exchanger panel

The present invention relates to a heat exchanger panel which has broad utility in high temperature environments. The heat exchanger panel has a first panel, a second panel, and at least one fluid containment device positioned intermediate the first and second panels. At least one of the first panel and the second panel have at least one feature on an interior surface to accommodate the at least one fluid containment device. In a preferred embodiment, each of the first and second panels is formed from a high conductivity, high temperature composite material. Also, in a preferred embodiment, the first and second panels are joined together by one or more composite fasteners.

Warburton, Robert E.↗

NASA NTRS2005

Magnetoresistive flux focusing eddy current flaw detection

A giant magnetoresistive flux focusing eddy current device effectively detects deep flaws in thick multilayer conductive materials. The probe uses an excitation coil to induce eddy currents in conducting material perpendicularly oriented to the coil's longitudinal axis. A giant magnetoresistive (GMR) sensor, surrounded by the excitation coil, is used to detect generated fields. Between the excitation coil and GMR sensor is a highly permeable flux focusing lens which magnetically separates the GMR sensor and excitation coil and produces high flux density at the outer edge of the GMR sensor. The use of feedback inside the flux focusing lens enables complete cancellation of the leakage fields at the GMR sensor location and biasing of the GMR sensor to a location of high magnetic field sensitivity. In an alternate embodiment, a permanent magnet is positioned adjacent to the GMR sensor to accomplish the biasing. Experimental results have demonstrated identification of flaws up to 1 cm deep in aluminum alloy structures. To detect deep flaws about circular fasteners or inhomogeneities in thick multilayer conductive materials, the device is mounted in a hand-held rotating probe assembly that is connected to a computer for system control, data acquisition, processing and storage.

Wincheski, Russell A.↗

NASA NTRS1984

Fuel cell design and assembly

The present invention is directed to a novel bipolar cooling plate, fuel cell design and method of assembly of fuel cells. The bipolar cooling plate used in the fuel cell design and method of assembly has discrete opposite edge and means carried by the plate defining a plurality of channels extending along the surface of the plate toward the opposite edges. At least one edge of the channels terminates short of the edge of the plate defining a recess for receiving a fastener.

Myerhoff, Alfred↗

NASA NTRS1987

Self-locking double retention redundant pull pin release

A double-retention redundant pull pin release system is disclosed. The system responds to a single pull during an intentional release operation. A spiral-threaded main pin is seated in a mating bore in a housing, which main pin has a flange fastened thereon at the part of the main pin which is exterior to the housing. Accidental release tends to rotate the main pin. A secondary pin passes through a slightly oversized opening in the flange and is seated in a second bore in the housing. The pins counteract against one another to prevent accidental release. A frictional lock is shared between the main and secondary pins to enhance further locking of the system. The secondary pin, in response to a first pull, is fully retracted from its bore and flange hole. Thereafter the pull causes the main pin to rotate free of the housing to release, for example, a parachute mechanism.

Killgrove, Thomas O.↗

NASA NTRS2004

Variable pressure washer

A variable pressure washer has two interlocking channel rings separated by a channel and retained by a captive set of fasteners. Within the channel between the rings are multiple rows of springs having at least two different spring moduli. The washer is particularly suited for use with a polar boss assembly secured to a bulkhead of a pressure vessel such as of propellent tank dome structure where the washer allows for the substantially uniform deflection of multiple O-rings as affected by the curved structure.

Smeltzer, III, Stanley S.↗

NASA NTRS2003

Thermal insulating conformal blanket

The conformal thermal insulating blanket may have generally rigid batting material covered by an outer insulating layer formed of a high temperature resistant woven ceramic material and an inner insulating layer formed of a woven ceramic fiber material. The batting and insulating layers may be fastened together by sewing or stitching using an outer mold layer thread fabricated of a high temperature resistant material and an inner mold layer thread of a ceramic fiber material. The batting may be formed to a composite structure that may have a firmness factor sufficient to inhibit a pillowing effect after the stitching to not more than 0.03 inch. The outer insulating layer and an upper portion of the batting adjacent the outer insulating layer may be impregnated with a ceramic coating material.

Barney, Andrea↗

NASA NTRS2008

Stereomicroscope Inspection of Polished Aluminum Collector 50684.0

The Genesis polished aluminum "kidney" collector was damaged during the hard landing of the capsule on September 8, 2004 in the Utah desert. The kidney was introduced into the Genesis (ISO class 4) cleanroom laboratory on November 4, 2004 and stored under nitrogen cover gas. The collector is currently fastened to a highly polished stainless steel plate for secure handling. Curatorial work at JSC has made successful subdivision and subsequent allocation of samples from the kidney.

Rodriquez, M. C.↗

NASA NTRS2008

Structural Efficiency of Stitched Rod-Stiffened Composite Panels with Stiffener Crippling

The structural efficiency of rod-stiffened stitched specimens is evaluated to determine their weight saving potential if the stiffeners were allowed to buckle at less than or equal to design ultimate load. Analytical and experimental results from rod-stiffened and blade-stiffened single-stiffener specimens are presented. In both cases, skin and flanges were stitched together through-the-thickness prior to curing. No mechanical fasteners were used for the assembly. Specimens were loaded to failure in axial compression. Failure modes are discussed. Finite element and experimental results agree for the response of the structures. For some specimen configurations, improved structural efficiency can be obtained by allowing stiffeners to buckle at design limit load rather than requiring that buckling not occur prior to design ultimate load. In addition, through-the-thickness stitching can change the failure mechanism by suppressing delamination between skin and flange. A parametric study is presented herein which describes the possible weight savings with this approach.

Jegley, Dawn C.↗

NASA NTRS2008

Numerical Characterization of a Composite Bonded Wing-Box

The development of composite wing structures has focused on the use of mechanical fasteners to join heavily-loaded areas, while bonded joints have been used only for select locations. The focus of this paper is the examination of the adhesive layer in a generic bonded wing box that represents a "fastenerless" or unitized structure in order to characterize the general behavior and failure mechanisms. A global/local approach was applied to study the response of the adhesive layer using a global shell model and a local shell/solid model. The wing box was analyzed under load to represent a high-g up-bending condition such that the strains in the composite sandwich face sheets are comparable to an expected design allowable. The global/local analysis indicates that at these wing load levels the strains in the adhesive layer are well within the adhesive's elastic region, such that yielding would not be expected in the adhesive layer. The global/local methodology appears to be a promising approach to evaluate the structural integrity of the adhesively bonded structures.

Smeltzer, Stanley S., III↗

NASA NTRS2008

Critical Initial Flaw Size Analysis

An independent assessment was conducted to determine the critical initial flaw size (CIFS) for the flange-to-skin weld in the Ares I-X Upper Stage Simulator (USS). The USS consists of several "tuna can" segments that are approximately 216 inches in diameter, 115 inches tall, and 0.5 inches thick. A 6 inch wide by 1 inch thick flange is welded to the skin and is used to fasten adjacent tuna cans. A schematic of a "tuna can" and the location of the flange-to-skin weld are shown in Figure 1. Gussets (shown in yellow in Figure 1) are welded to the skin and flange every 10 degrees around the circumference of the "tuna can". The flange-to-skin weld is a flux core butt weld with a fillet weld on the inside surface, as illustrated in Figure 2. The welding process may create loss of fusion defects in the weld that could develop into fatigue cracks and jeopardize the structural integrity of the Ares I-X vehicle. The CIFS analysis was conducted to determine the largest crack in the weld region that will not grow to failure within 4 lifetimes, as specified by NASA standard 5001 & 5019 [1].

Dawicke, David S.↗

NASA NTRS2008

Deployable Crew Quarters

The deployable crew quarters (DCQ) have been designed for the International Space Station (ISS). Each DCQ would be a relatively inexpensive, deployable boxlike structure that is designed to fit in a rack bay. It is to be occupied by one crewmember to provide privacy and sleeping functions for the crew. A DCQ comprises mostly hard panels, made of a lightweight honeycomb or matrix/fiber material, attached to each other by cloth hinges. Both faces of each panel are covered with a layer of Nomex cloth and noise-suppression material to provide noise isolation from ISS. On Earth, the unit is folded flat and attached to a rigid pallet for transport to the ISS. On the ISS, crewmembers unfold the unit and install it in place, attaching it to ISS structural members by use of soft cords (which also help to isolate noise and vibration). A few hard pieces of equipment (principally, a ventilator and a smoke detector) are shipped separately and installed in the DCQ unit by use of a system of holes, slots, and quarter-turn fasteners. Full-scale tests showed that the time required to install a DCQ unit amounts to tens of minutes. The basic DCQ design could be adapted to terrestrial applications to satisfy requirements for rapid deployable emergency shelters that would be lightweight, portable, and quickly erected. The Temporary Early Sleep Station (TeSS) currently on-orbit is a spin-off of the DCQ.

Izenson, Michael G.↗

NASA NTRS2009

Improved Joining of Metal Components to Composite Structures

Systems requirements for complex spacecraft drive design requirements that lead to structures, components, and/or enclosures of a multi-material and multifunctional design. The varying physical properties of aluminum, tungsten, Invar, or other high-grade aerospace metals when utilized in conjunction with lightweight composites multiply system level solutions. These multi-material designs are largely dependent upon effective joining techAn improved method of joining metal components to matrix/fiber composite material structures has been invented. The method is particularly applicable to equipping such thin-wall polymer-matrix composite (PMC) structures as tanks with flanges, ceramic matrix composite (CMC) liners for high heat engine nozzles, and other metallic-to-composite attachments. The method is oriented toward new architectures and distributing mechanical loads as widely as possible in the vicinities of attachment locations to prevent excessive concentrations of stresses that could give rise to delaminations, debonds, leaks, and other failures. The method in its most basic form can be summarized as follows: A metal component is to be joined to a designated attachment area on a composite-material structure. In preparation for joining, the metal component is fabricated to include multiple studs projecting from the aforementioned face. Also in preparation for joining, holes just wide enough to accept the studs are molded into, drilled, or otherwise formed in the corresponding locations in the designated attachment area of the uncured ("wet') composite structure. The metal component is brought together with the uncured composite structure so that the studs become firmly seated in the holes, thereby causing the composite material to become intertwined with the metal component in the joining area. Alternately, it is proposed to utilize other mechanical attachment schemes whereby the uncured composite and metallic parts are joined with "z-direction" fasteners. The resulting "wet" assembly is then subjected to the composite-curing heat treatment, becoming a unitary structure. It should be noted that this new art will require different techniques for CMC s versus PMC's, but the final architecture and companion curing philosophy is the same. For instance, a chemical vapor infiltration (CVI) fabrication technique may require special integration of the pre-form and

Semmes, Edmund↗

NASA NTRS2009

High-Temperature Modal Survey of a Hot-Structure Control Surface

NASA Dryden is directing a program to test a Carbon-Silicon Carbide (C/SiC) Ruddervator Subcomponent Test Article (RSTA). The RSTA is a truncated version of the full-scale X-37 hot-structure control surface incorporating all major features including the metallic spindle and five major C/SiC quasi isotropic lay-up components secured with C/SiC fasteners. As part of NASA's Aeronautics Research Mission Directorate Hypersonics program, the RSTA will undergo thermal-structural testing to develop an extensive database for future structural design and analysis methodology validation. Ground Vibration Tests (GVTs) are routinely conducted for model validation in supporting flutter analysis for subsonic and supersonic vehicles; however, for hypersonic vehicle applications, GVT techniques are not well-established. New fabrication technologies, high-temperature materials systems, and sensors offer new opportunities to develop techniques for performing GVTs at elevated temperatures. The RSTA is comprised of materials whose stiffness both increases and decreases with increasing temperature. The impact of this type of material system interaction must be understood as it will ultimately affect hypersonic flutter analysis. The test objectives are to perform room-temperature GVTs, develop the capability to conduct high-temperature GVTs and to compare and generate an understanding of the modal characteristics which capture RSTA's material interaction when subjected to temperature varying conditions.

Spivey, Natalie D.↗

NASA NTRS2009

Development and Evaluation of the Next Generation of Meteoroid and Orbital Debris Shields

Recent events such as the Chinese anti-satellite missile test in January 2007 and the collision between a Russian Cosmos satellite and US Iridium satellite in February 2009 are responsible for a rapid increase in the population of orbital debris in Low Earth Orbit (LEO). Without active debris removal strategies the debris population in key orbits will continue to increase, requiring enhanced shielding capabilities to maintain allowable penetration risks. One of the more promising developments in recent years for meteoroid and orbital debris shielding (MMOD) is the application of open cell foams. Although shielding onboard the International Space Station is the most capable ever flown, the most proficient configuration (stuffed Whipple shield) requires an additional ~30% of the shielding mass for non-ballistic requirements (e.g. stiffeners, fasteners, etc.). Open cell foam structures provide similar mechanical performance to more traditional structural components such as honeycomb sandwich panels, as well as improved projectile fragmentation and melting as a result of repeated shocking by foam ligaments. In this paper, the preliminary results of an extensive hypervelocity impact test program on next generation MMOD shielding configurations incorporating open-cell metallic foams are reported.

Christiansen, E.↗

NASA NTRS2008

Precision Cleaning - Path to Premier

ITT Space Systems Division s new Precision Cleaning facility provides critical cleaning and packaging of aerospace flight hardware and optical payloads to meet customer performance requirements. The Precision Cleaning Path to Premier Project was a 2007 capital project and is a key element in the approved Premier Resource Management - Integrated Supply Chain Footprint Optimization Project. Formerly precision cleaning was located offsite in a leased building. A new facility equipped with modern precision cleaning equipment including advanced process analytical technology and improved capabilities was designed and built after outsourcing solutions were investigated and found lacking in ability to meet quality specifications and schedule needs. SSD cleans parts that can range in size from a single threaded fastener all the way up to large composite structures. Materials that can be processed include optics, composites, metals and various high performance coatings. We are required to provide verification to our customers that we have met their particulate and molecular cleanliness requirements and we have that analytical capability in this new facility. The new facility footprint is approximately half the size of the former leased operation and provides double the amount of throughput. Process improvements and new cleaning equipment are projected to increase 1st pass yield from 78% to 98% avoiding $300K+/yr in rework costs. Cost avoidance of $350K/yr will result from elimination of rent, IT services, transportation, and decreased utility costs. Savings due to reduced staff expected to net $4-500K/yr.

Mackler, Scott E.↗