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NASA NTRS2011

Progress Towards the Development of a Long-Lived Venus Lander Duplex System

NASA has begun the development of a combined Stirling cycle power and cooling system (duplex) to enable the long-lived surface exploration of Venus and other harsh environments in the solar system. The duplex system will operate from the heat provided by decaying radioisotope plutonium-238 or its substitute. Since the surface of Venus has a thick, hot, and corrosive atmosphere, it is a challenging proposition to maintain sensitive lander electronics under survivable conditions. This development effort requires the integration of: a radioisotope or fission heat source; heat pipes; high-temperature, corrosion-resistant material; multistage cooling; a novel free-displacer Stirling convertor for the lander; and a minimal vibration thermoacoustic Stirling convertor for the seismometer. The first year effort includes conceptual system design and control studies, materials development, and prototype hardware testing. A summary of these findings and test results is presented in this report.

Dyson, Rodger, W.↗

NASA NTRS2014

NASA Glenn Research Center Support of the ASRG Project

A high efficiency radioisotope power system is being developed for long-duration NASA space science missions. The U.S. Department of Energy (DOE) managed a flight contract with Lockheed Martin Space Systems Company (LMSSC) to build Advanced Stirling Radioisotope Generators (ASRGs), with support from NASA Glenn Research Center (GRC). Sunpower Inc. held two parallel contracts to produce Advanced Stirling Convertors (ASCs), one with DOELockheed Martin to produce ASC-F flight units, and one with GRC for the production of ASC-E3 engineering unit pathfinders that are built to the flight design. In support of those contracts, GRC provided testing, materials expertise, government furnished equipment, inspections, and related data products to DOELockheed Martin and Sunpower. The technical support includes material evaluations, component tests, convertor characterization, and technology transfer. Material evaluations and component tests have been performed on various ASC components in order to assess potential life-limiting mechanisms and provide data for reliability models. Convertor level tests have been used to characterize performance under operating conditions that are representative of various mission conditions. Technology transfers enhanced contractor capabilities for specialized production processes and tests. Despite termination of flight ASRG contract, NASA continues to develop the high efficiency ASC conversion technology under the ASC-E3 contract. This paper describes key government furnished services performed for ASRG and future tests used to provide data for ongoing reliability assessments.

Technology Transfer↗

NASA NTRS2015

NASA Glenn Research Center Support of the Advanced Stirling Radioisotope Generator Project

A high-efficiency radioisotope power system was being developed for long-duration NASA space science missions. The U.S. Department of Energy (DOE) managed a flight contract with Lockheed Martin Space Systems Company to build Advanced Stirling Radioisotope Generators (ASRGs), with support from NASA Glenn Research Center. DOE initiated termination of that contract in late 2013, primarily due to budget constraints. Sunpower, Inc., held two parallel contracts to produce Advanced Stirling Convertors (ASCs), one with Lockheed Martin to produce ASC-F flight units, and one with Glenn for the production of ASC-E3 engineering unit "pathfinders" that are built to the flight design. In support of those contracts, Glenn provided testing, materials expertise, Government-furnished equipment, inspection capabilities, and related data products to Lockheed Martin and Sunpower. The technical support included material evaluations, component tests, convertor characterization, and technology transfer. Material evaluations and component tests were performed on various ASC components in order to assess potential life-limiting mechanisms and provide data for reliability models. Convertor level tests were conducted to characterize performance under operating conditions that are representative of various mission conditions. Despite termination of the ASRG flight development contract, NASA continues to recognize the importance of high-efficiency ASC power conversion for Radioisotope Power Systems (RPS) and continues investment in the technology, including the continuation of the ASC-E3 contract. This paper describes key Government support for the ASRG project and future tests to be used to provide data for ongoing reliability assessments.

Technology Transfer↗

NASA NTRS2016

Experimental Investigation of the Distribution of Shock Effects in Regolith Impact Ejecta Using an Ejecta Recovery Chamber

Because the mass-flux of solar system meteoroids is concentrated in the approx. 200 microns size range, small-scale impacts play a key role in driving the space weathering of regoliths on airless bodies. Quantifying this role requires improved data linking the mass, density and velocity of the incoming impactors to the nature of the shock effects produced, with particular emphasis on effects, such as production of impact melt and vapor, that drive the optical changes seen in space weathered regoliths. Of particular importance with regard to space weathering is understanding not only the composition of the shock melt created in small-scale impacts, but also how it is partitioned volumetrically between the local impact site and more widely distributed ejecta. To improve the ability of hypervelocity impact experiments to obtain this type of information, we have developed an enclosed sample target chamber with multiple-geometry interior capture cells for in-situ retention of ejecta from granular targets. A key design objective was to select and test capture cell materials that could meet three requirements: 1) Capture ejecta fragments traveling at various trajectories and velocities away from the impact point, while inducing minimal additional damage relative to the primary shock effects; 2) facilitate follow-up characterization of the ejecta either on or in the cell material by analytical SEM, or ex-situ by microprobe, TEM and other methods; and 3) enable the trajectories of the captured and characterized ejecta to be reconstructed relative to the target.

Christoffersen, R.↗

NASA NTRS2017

Verification and Validation Process for Progressive Damage and Failure Analysis Methods in the NASA Advanced Composites Consortium

The Advanced Composites Consortium is a US Government/Industry partnership supporting technologies to enable timeline and cost reduction in the development of certified composite aerospace structures. A key component of the consortium's approach is the development and validation of improved progressive damage and failure analysis methods for composite structures. These methods will enable increased use of simulations in design trade studies and detailed design development, and thereby enable more targeted physical test programs to validate designs. To accomplish this goal with confidence, a rigorous verification and validation process was developed. The process was used to evaluate analysis methods and associated implementation requirements to ensure calculation accuracy and to gage predictability for composite failure modes of interest. This paper introduces the verification and validation process developed by the consortium during the Phase I effort of the Advanced Composites Project. Specific structural failure modes of interest are first identified, and a subset of standard composite test articles are proposed to interrogate a progressive damage analysis method's ability to predict each failure mode of interest. Test articles are designed to capture the underlying composite material constitutive response as well as the interaction of failure modes representing typical failure patterns observed in aerospace structures.

Wanthal, Steven↗

NASA NTRS2017

The Iodine Satellite (iSAT) Propellant Feed System - Design and Development

The development, modeling, and testing of components and subsystems required to feed iodine propellant to a 200-W Hall thruster and cathode are described. This work aims to address design deficiencies and issues associated with the propellant feed system that were revealed by an integrated thruster-cathode-feed system test. The feed system design is modified to use materials that are more resistant to the highly-reactive nature of iodine propellant. Dynamic modeling indicates that the inclusion of additional constraints on feed system tubing will reduce the vibrationally-induced stresses that occur during launch. Full spacecraft thermal modeling show that the feed system heater power levels are sufficient to heat the tank and propellant lines to operating temperatures, where iodine in the tank is sublimed to supply propellant for operation and the tubing is elevated in temperature to keep propellant from redepositing to block the flow. Experiments are conducted to demonstrate that is it possible through the application of heating to clear an iodine deposit blocking the flow. Deposits in the low-pressure portion of the system near the exit to vacuum are shown to be relatively easy to remove in this manner while blockages forming upstream nearer to the higher-pressure propellant tank require significantly more effort to remove. Fluid flow modeling of the feed system is performed, exhibiting some qualitative agreement with experimental data. However, the highly viscous nature of the fluid flow and the dependence of the component flow coefficients on the Reynolds number are likely causes of the generally-poor quantitative agreement between the modeling results and experimentally-measured fluid flow properties.

Polzin, Kurt A.↗

NASA NTRS2019

GRCop-42 Development and Hot-fire Testing Using Additive Manufacturing Powder Bed Fusion for Channel-Cooled Combustion Chambers

GRCop-42 is a high conductivity, high-strength dispersion strengthened copper-alloy for use in high heat flux applications such as liquid rocket engine combustion devices. This alloy is part of the family of NASA-developed GRCop, copper-chrome-niobium alloys. GRCop alloys were developed for harsh environments specific to regeneratively-cooled combustion chambers and nozzles with good oxidation resistance. Significant development was completed on the GRCop-84 and GRCop-42 alloys in the extruded wrought form demonstrating feasibility for combustion chambers. NASA has recently developed a process for additive manufacturing, specifically Powder Bed Fusion (PBF) or Selective Laser Melting (SLM), of GRCop-42 to establish parameters, characterize the material, and complete testing of components with complex internal features. This evolution of the GRCop-42 was based on the successful predecessor development work using GRCop-84 with the motivation of establishing a new copper-alloy option for use in NASA, government, and industry programs with SLM. A few advantages have been shown with the GRCop-42 that include higher conductivity and faster build speeds over the GRCop-84, and a simplified powder supply chain. Initial property development has shown that it is possible to produce high density builds with strengths equivalent to wrought GRCop-42 and a conductivity greater than GRCop-84. The GRCop-42 has completed process development and initial properties have been established. Several demonstrator combustion chambers have also been fabricated with the SLM GRCop-42 that include integral channels and closeouts. Additional test units have been fabricated and are completing substantial hot-fire testing to demonstrate performance of the material, process, and design.

Gradl, Paul R.↗

DOE OSTI2024

Broadband 920-nm mirror thin film damage competition

The 2023 Laser Damage conference thin-film damage competition was devoted to a survey on the state-of-the-art broadband near-IR multilayer dielectric (MLD) mirrors designed for ultra-short pulsed laser applications. The requirements for the coatings were a minimum reflection of 99.5% at 45-deg incidence angle for S-polarization from 830 nm to 1010 nm and group delay dispersion (GDD) < ± 50fs 2 . The participants were allowed to select the coating materials, coating design, and coating deposition method. Samples were damage tested at a single testing facility to enable direct comparison among the participants using a 25 ± 5 fs optical parametric chirped-pulse amplification (OPCPA) laser system operating at 5 Hz. The testing results from this set of 37 samples showed that dense coatings by ion-beam sputtering (IBS), magnetron sputtering (MS), and electron-beam ion assisted deposition (e-beam IAD) exhibited highest damage initiation onset (laser-induced damage threshold or LIDT) while e-beam coatings were low performers. In addition, multilayer coatings using tantala and/or hafnia as high index materials were top performers. Furthermore, this competition included for the first time the measurement of the damage growth onset (laser-induced damage growth threshold or LDGT). This latter performance metric plays an important role in establishing the safe operational conditions for larger aperture ultrashort pulsed lasers. Information pertaining to the morphology of the damage sites and their evolution under subsequent exposure to different laser fluences leading to damage growth is presented. Finally, not all coating samples in the survey met the GDD requirements stated above and associated measurements are discussed in the context of the present and past thin-film damage competitions focused on similar broadband near-IR MLD coatings.

23 broadband high reflectors↗

NASA NTRS2002

Design and Testing of Improved Spacesuit Shielding Components

In prior studies of the current Shuttle Spacesuit (SSA), where basic fabric lay-ups were tested for shielding capabilities, it was found that the fabric portions of the suit give far less protection than previously estimated due to porosity and non-uniformity of fabric and LCVG components. In addition, overall material transmission properties were less than optimum. A number of alternate approaches are being tested to provide more uniform coverage and to use more efficient materials. We will discuss in this paper, recent testing of new material layups/configurations for possible use in future spacesuit designs.

Ware, J.↗

NASA NTRS1999

Thermal-Mechanical Stability of Single Crystal Oxide Refractive Concentrators for High-Temperature Solar Thermal Propulsion

Single crystal oxides such as yttria-stabilized zirconia (Y2O3-ZrO2), yttrium aluminum garnet (Y3Al5O12, or YAG), magnesium oxide (MgO) and sapphire (Al2O3) are candidate refractive secondary concentrator materials for high temperature solar propulsion applications. However, thermo-mechanical reliability of these components in severe thermal environments during the space mission sun/shade transition is of great concern. Simulated mission tests are important for evaluating these candidate oxide materials under a variety of transient and steady-state heat flux conditions, and thus provide vital information for the component design. In this paper, a controlled heat flux thermal shock test approach is established for the single crystal oxide materials using a 3.0 kW continuous wave CO2 laser, with a wavelength 10.6 micron. Thermal fracture behavior and failure mechanisms of these oxide materials are investigated and critical temperature gradients are determined under various temperature and heating conditions. The test results show that single crystal sapphire is able to sustain the highest temperature gradient and heating-cooling rate, and thus exhibit the best thermal shock resistance, as compared to the yttria-stabilized zirconia, yttrium aluminum garnet, and magnesium oxide.

Zhu, Dongming↗

NASA NTRS1999

Thermal-Mechanical Stability of Single Crystal Oxide Refractive Concentrators for High-Temperature Solar Thermal Propulsion

Zhu, Dongming↗

DOE OSTI2025

AGC-2 Graphite Preirradiation Data Analysis Report

This report describes the specimen loading order and documents all preirradiation examination material property measurement data for graphite specimens contained within the Second Advanced Graphite Capsule (AGC 2) irradiation capsule. The AGC 2 capsule is the second in six planned irradiation capsules comprising the Advanced Graphite Creep (AGC) test series. The AGC test series is used to irradiate graphite specimens in order to garner quantitative data necessary for predicting the irradiation behavior and operating performance of new nuclear grade graphites. This testing will ascertain the in service behavior of the graphite for pebble bed and prismatic very high temperature reactor designs. Similar to the First Advanced Graphite Capsule (AGC 1) preirradiation examination report, material property tests were conducted on specimens from 18 nuclear grade graphite types. However, AGC 2 tested an increased number of specimens (i.e., 512) prior to loading them into the AGC 2 irradiation assembly. All AGC 2 specimen testing was conducted at Idaho National Laboratory from July 2009 to August 2010. This report also details the specimen loading methodology for graphite specimens inside the AGC 2 irradiation capsule. The AGC 2 capsule design requires “matched pair” creep specimens that have similar dose levels above and below the neutron flux profile mid plane. This provides similar specimens with and without an applied load. Analysis in this document utilizes the neutron flux profile calculated for the AGC 2 capsule design, the capsule dimensions, and the size (i.e., length) of the selected graphite specimens to create a stacking order that produces “matched pairs” of graphite specimens above and below the AGC 2 capsule elevation mid point, thus providing specimens with similar neutron dose levels.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1982

Celion/Larc-160 graphite/polyimide composite processing techniques and properties

Weight savings in the range from 25 to 35 percent could be achieved on Space Shuttle orbiter components and the thermal protection system (TPS) by employing a suitable graphite/polyimide (Gr/Pi) composite material system as a substitute for the baseline aluminum structural material. Predicted weight savings are based on the superior strength and stiffness-to-density ratios of Gr/Pi composite material over metallic counterparts. Specific strength and stiffness properties of Celion/Larc-160 composite laminates are compared with aluminum and titanium alloys. Aspects of materials and processes development are discussed, taking into account Celion/Larc-160 composite cure cycle and tooling evolution, complex shaped component process development, mechanical and physical properties testing and results, and structural element design fabrication, testing, and results. Attention is given to a demonstration of materials and processing technology, and a Celion/Larc-160 materials and processes summary is presented.

Jones, J. S.↗

NASA NTRS2006

Apparatus for Hot Impact Testing of Material Specimens

An apparatus for positioning and holding material specimens is a major subsystem of a system for impact testing of the specimens at temperatures up to 1,500 C. This apparatus and the rest of the system are designed especially for hot impact testing of advanced ceramics, composites, and coating materials. The apparatus includes a retaining fixture on a rotating stage on a vertically movable cross support driven by a linear actuator. These components are located below a furnace wherein the hot impact tests are performed (see Figure 1). In preparation for a test, a specimen is mounted on the retaining fixture, then the cross support is moved upward to raise the specimen, through an opening in the bottom of the furnace, to the test position inside the furnace. On one side of the furnace there is another, relatively small opening on a direct line to the specimen. Once the specimen has become heated to the test temperature, the test is performed by using an instrumented external pressurized-gas-driven gun to shoot a projectile through the side opening at the specimen.

Pawlik, Ralph J.↗

NASA NTRS1982

Instabilities of geared couplings: Theory and practice

The use of couplings for high speed turbocompressors or pumps is essential to transmit power from the driver. Typical couplings are either of the lubricated gear or dry diaphragm type design. Gear couplings have been the standard design for many years and recent advances in power and speed requirements have pushed the standard design criteria to the limit. Recent test stand and field data on continuous lube gear type couplings have forced a closer examination of design tolerances and concepts to avoid operational instabilities. Two types of mechanical instabilities are reviewed in this paper: (1) entrapped fluid, and (2) gear mesh instability resulting in spacer throw-out onset. Test stand results of these types of instabilities and other directly related problems are presented together with criteria for proper coupling design to avoid these conditions. An additional test case discussed shows the importance of proper material selection and processing and what can happen to an otherwise good design.

Kirk, R. G.↗

NASA NTRS1972

Fatigue and fail-safe design features of the DC-10 airplane

The philosophy and methods used in the design of the DC-10 aircraft to assure structural reliability against cracks under repeated service loads are described in detail. The approach consists of three complementary parts: (1) the structure is designed to be fatigue resistant for a crack-free life of 60,000 flight hours; (2) inasmuch as small undetected cracks could develop from other sources, such as material flaws and manufacturing preloads, the structure also is designed to arrest and control cracks within a reasonable service-inspection interval; and (3) a meaningful service-inspection program has been defined on the basis of analysis and test experience from the design development program. This service-inspection program closes the loop to assure the structural integrity of the DC-10 airframe. Selected materials, fasteners, and structural arrangements are used to achieve these design features with minimum structural weight and with economy in manufacturing and maintenance. Extensive analyses and testing were performed to develop and verify the design. The basic design considerations for fatigue-resistant structure are illustrated in terms of material selection, design loads spectra, methods for accurate stress and fatigue damage analysis, and proven concepts for efficient detail design.

Stone, M. E.↗

NASA NTRS2019

Myco-Architecture off Planet: Growing Surface Structures at Destination

Our work focused on filling major select key technical knowledge gaps, and technical aspects to be addressed in a Phase II proposal were identified such as the secretion of glues or plastics by the fungi or bacteria to form biocomposites. Specifically, we raised the technical TRL by assessing the growth of in-house mycelial-producing strains on potential food substrates and analyzed the advantages and disadvantages to their use off planet. Growth of the mycelia on sawdust and powdered nutrients including dried, powdered algae, was used as a baseline. We measured growth as a function of temperature, tested the relevant material properties of the mycelia products produced, and measured the mass of input and output volume for production per volume of material. Mycotecture was produced in a bag simulating the proposed mission implementation. Post-production such as heat treatment (as is done with terrestrial mycotecture)was assessed.The material properties of the dried, frozen and baked mycelial outputs included density, strength,thermal insulation and flame retardation. Tensile/compression testing on biocomposite material specimens was performed to obtain three-dimensional elastic constants, as well as to examine deformation and fracture behavior. These mechanical tests were performed on both dormant and activated samples to understand the evolution of the structural material. In addition, experimental data obtained from the mechanical testing was used to build a failure prediction model that accounts for material anisotropy. This aided in future structural design through a quantitative understanding of the mechanical limits of the material. To examine the texture, defects, fracture surfaces of the material, high-resolution microstructural imaging was utilized before and after the mechanical tests. This microstructural analysis informed us about the macro-structural behavior and influenced structural design. Thermal decomposition analysis was also performed tounderstand the thermal limits.

Biocomposites↗

NASA NTRS2015

Thermal Testing of the Heatshield for Extreme Entry Environment Technology (HEEET) TPS

The testing of a thermal protection system (TPS) in multiple arc jets and laser facilities is critical not only to determine the ability of a material to withstand the harsh aerothermal environments but is also required to collect relevant data that allows construction of a thermal response model of the TPS for flight design. The present talk provides an overview of recent arcjet testing of the HEEET material, one of the families of materials from the 3D Woven TPS program, being developed under NASAs Heatshield for Extreme Entry Environment Technology (HEEET) project.

Gasch, M,↗