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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 685 records · Page 38
All sourcesNASA NTRSDOE OSTI
NASA NTRS1972

Composite overwrapped metallic tanks

Work is reported for fabricating and testing the fiberglass overwrapped titanium pressure vessel for cryogenic service. Difficulties encountered in the tank liner fabrication phase involved explosive forming, vacuum annealing, chemical milling and electron beam welding. While each of these processes and the nondestructive test methods employed are normally considered to be individually reliable, the combination of poor material together with fabrication and development reversals prevented the full achievement of the desired end results. Eight tanks plus a prototype and tool proofing article were produced. Six of the vessels failed during the hydrostatic sizing operation. One of the remaining tanks was hydrostatically pressurized to burst and the other was pressurized repeatedly at 75 F from 100 psi to the operating pressure until failure occurred. As a result, it is not possible to draw firm conclusions as to the true value of the design concept due to the problems encountered in the program.

Caudill, C. L.↗
NASA NTRS1982

Ampoule sealing apparatus and process

An apparatus and process for sealing fused quartz ampoules housing a semiconductor growth charge under vacuum is described. An elongated fused quartz ampoule having an enlarged diameter open end and a reduced diameter closed end is vertically retained in a vacuum assembly. A semiconductor charge is disposed within the reduced diameter portion of the ampoule. A quartz plug of substantially the same diameter as the reduced diameter portion is suspended within the open and of the ampoule via a rotary vacuum feed. After evacuation of the ampoule a plug is lowered into the reduced diameter area and sealed therein while maintaining the vacuum on the ampoule. The charged ampoule area is then separated from the remaining structure by breaking along the scored line.

Debnam, W. J., Jr.↗
NASA NTRS1989

Encapsulated diffusion of sulphur into InP

This talk outlines a simple process for the fabrication of n(+)-p solar cells in indium phosphide. Large area cells (greater than 0.25 sq cm) have been made by this process, with a photovoltaic conversion efficiency of 15.21 percent under AM0 conditions of illumination. An ideality factor of 1.1 and a saturation current density of 8 x 10 to the minus 15th power A/sq cm have been observed for these cells. The technique for cell fabrication involves the diffusion of sulfur into InP by an open tube process, and gives highly reproducible results from run to run. A vacuum-deposited layer of gallium sulphide (Ga2S3) was used as the source for sulfur diffusion, with a chemically vapor deposited SiO2 cap layer to prevent decomposition of the InP surface during heat treatment. Diffusions were carried out in a flowing nitrogen ambient at 585 to 708 C, and characterized by their surface carrier concentration and the diffusion constant. The diffusion profile for sulfur in InP is estimated to be of the complementary error function type. The activation energy of the diffusion was estimated to be 1.94 eV. The technique described here is ideally suited for the fabrication of shallow n(+)-p junctions in InP, and has been used for space-borne solar cells.

Parat, K. K.↗
NASA NTRS1996

Brazing Dissimilar Metals

Brazing effective technique for joining ordinary structural metals to brittle, low-thermal-expansion refractory metals. Specifically, brazing process established for joining copper or nickel flanges to ends of vacuum-plasma-sprayed tungsten tubes and for joining stainless-steel flanges to ends of tubes made of alloy of molybdenum with 40 percent of rhenium.

Krotz, Phillip D.↗
NASA NTRS1996

Pendant-Drop Surface-Tension Measurement On Molten Metal

Method of measuring surface tension of molten metal based on pendant-drop method implemented in quasi-containerless manner and augmented with digital processing of image data. Electrons bombard lower end of sample rod in vacuum, generating hanging drop of molten metal. Surface tension of drop computed from its shape. Technique minimizes effects of contamination.

Man, Kin Fung↗
NASA NTRS2000

Nutritional Evaluation of NASA's Rodent Food Bar Diet

Tests are being conducted on NASA's rodent Food Bar in preparation for long-term use as the rat and mouse diet aboard the International Space Station. Nutritional analyses are performed after the bars are manufactured and then repeated periodically to determine nutritional stability. The primary factors analyzed are protein, ash, fat, fiber, moisture, amino acids, fatty acids, and minerals. Nutrient levels are compared to values published in the National Research Council's dietary requirements for rodents, and also to those contained in several commonly used commercial rodent lab diets. The Food Bar is manufactured from a powdered diet to which moisture is added as it is processed through an extruder. The bars are dipped into potassium sorbate, vacuum-sealed, and irradiated. In order to determine nutrient changes during extrusion and irradiation, the powdered diet, the non-irradiated bars, and the irradiated bars are all analyzed. We have observed lower values for some nutrients (iodine, vitamin K, and iron) in the Food Bars compared with NRC requirements. Many nutrients in the Food Bars are contained at a higher level than levels in the NRC requirements. An additional factor we are investigating is the 26% moisture level in the Food Bars, which drops to about 15% within a week, compared to a stable 10% moisture in many standard lab chow diets. In addition to the nutritional analyses, the food bar is being fed to several strains of rats and mice, and feeding study and necropsy results are being observed (Barrett et al, unpublished data). Information from the nutritional analyses and from the rodent studies will enable us to recommend the formulation that will most adequately meet the rodent Food Bar requirements for long-term use aboard the Space Station.

Barrett, Joyce E.↗
NASA NTRS2006

Distillation Kinetics of Solid Mixtures of Hydrogen Peroxide and Water and the Isolation of Pure Hydrogen Peroxide in Ultrahigh Vacuum

We present results of the growth of thin films of crystalline H2O2 and H2O2.2H2O (dihydrate) in ultrahigh vacuum by distilling an aqueous solution of hydrogen peroxide. We traced the process using infrared reflectance spectroscopy, mass loss on a quartz crystal microbalance, and in a few cases ultraviolet-visible reflectance. We find that the different crystalline phases-water, dihydrate, and hydrogen peroxide-have very different sublimation rates, making distillation efficient to isolate the less volatile component, crystalline H2O2.

Teolis, B. D.↗
NASA NTRS2017

LOX/Methane In-Space Propulsion Systems Technology Status and Gaps

Human exploration architecture studies have identified liquid oxygen (LOX)Methane (LCH4) as a strong candidate for both interplanetary and descent ascent propulsion solutions. Significant research efforts into methane propulsion have been conducted for over 50 years, ranging from fundamental combustion mixing efforts to rocket chamber and system level demonstrations. Over the past 15 years NASA and its partners have built upon these early activities that have demonstrated practical components and sub-systems needed to field future methane space transportation elements. These advanced development efforts have formed a foundation of LOXLCH4 propulsion knowledge that has significantly reduced the development risks of future methane based space transportation elements for human exploration beyond earth orbit. As a bipropellant propulsion system, LOXLCH4 has some favorable characteristics for long life and reusability, which are critical to lunar and Mars missions. Non-toxic, non-corrosive, self-venting, and simple to purge. No extensive decontamination process required as with toxic propellants. High vapor pressure provides for excellent vacuum ignition characteristics. Performance is better than current earth storable propellants for human scale spacecraft. Provides the capability for future Mars exploration missions to use propellants that are produced in-situ on Mars Liquid Methane is thermally similar to O2 as a cryogenic propellant, 90,111 K (LO2, LCH4 respectively) instead of the 23 K of LH2. Allows for common components and thus providing cost savings as compared to liquid hydrogen (LH2). Due to liquid methane having a 6x higher density than hydrogen, it can be stored in much smaller volumes. Cryogenic storage aspect of these propellants needs to be addressed. Passive techniques using shielding and orientations to deep space Refrigeration may be required to maintain both oxygen and methane in liquid forms

Propulsion systems↗
NASA NTRS2018

High Power Advanced Solar Electric Propulsion Development Under NASA's NextSTEP Project

Human missions to Mars will require next generation solar electric propulsion (SEP) systems that can operate at power levels of 300 kW or higher to efficiently transport crew and cargo. In the mid-2020s, NASA is planning to launch the Deep Space Gateway (DSG), which is a crew-tended habitat that will be placed in orbit around the Moon. NASA is developing 12.5 kW Hall thrusters for the DSG. In the late 2020s, the DSG will be followed by a second vehicle, called the Deep Space Transport (DST), which will simulate a crewed Mars mission in cislunar space. In parallel with the 12.5 kW thrusters for the DSG, NASA is initiating development of 100 kW thrusters for potential demonstration on the DST. In 2016, NASA issued a Next Space Technologies for Exploration Partnerships (NextSTEP) Broad Agency Announcement to solicit proposals for development of high-power electric thrusters. The partnerships require at least 50 percent cost sharing by the companies. Three companies were selected for development activities lasting up to three years: Ad Astra, Aerojet Rocketdyne, and MSNW. Ad Astra is developing a Variable Specific Impulse Magnetoplasma Rocket (VASIMR), Aerojet Rocketdyne is developing a Nested Hall Thruster (NHT), and MSNW is developing an Electrodeless Lorentz Force (ELF) plasma thruster. The primary goal of these activities is to operate the thrusters at 100 kW for 100 continuous hours in a vacuum chamber. In addition to the thrusters, the companies are developing Power Processing Units (PPUs), propellant feed systems, and thermal management systems. This presentation will describe the three activities, the progress they have made in achieving the primary testing goal, the technical challenges they have encountered, and discuss the importance of extensibility.

Moore, Chris↗
NASA NTRS2024

Effect of the Liquid-Vacuum Transition on the Relative Abundances of Amino and Fatty Acids Sought as Biosignatures on Icy Ocean Worlds

Interpreting measurements by robotic missions searching for signs of life in material erupted by cryovolcanic ocean worlds (e.g., Enceladus, Europa, Ceres) requires linking the composition of this material to that of its subsurface liquid source. Irrespective of the properties of –and processes along– the path of ejection, material erupted on airless worlds undergoes a transition from liquid to vacuum. Here, we investigate experimentally the effect of a direct transition from liquid to vacuum environments on the relative abundances of amino and carboxylic (fatty) acids, a metric used to distinguish between biological and abiotic sources for these compounds. Amino acids were dissolved in parent solutions prepared with 1 wt.% NaCl and pH 9–10 to match properties inferred from Enceladus plume grains. Compositional analysis of the dry solids resulting from the injection of this solution into vacuum indicates a < 50% change in amino acid abundances relative to glycine. Injection of two fatty acids, phenylacetic acid (soluble and undersaturated in the parent solution) and palmitic acid (insoluble and supersaturated) resulted in a change of less than a factor of 7 in their relative abundances. At this bulk scale (all grains aggregated together), proportions of amino and fatty acids were sufficiently conserved to allow distinction between end-member example biological and abiotic sources. We did not find strong correlations between the relative enrichment or depletion of amino or fatty acids with molecular properties such as molecular mass, hydrophobicity, functionality, or charge, other than high under-or supersaturation. Most of the organic residue was deposited along the experimental injection path, which suggests that cryovolcanic conduit walls on icy ocean worlds may be enriched in organic material relative to material having undergone the liquid-vacuum transition.

Amino acids↗
DOE OSTI2020

DFT-Based Calculation of Dissolution Activation Energy and Kinetics of Ni–Cr Alloys

A density functional theory investigation of the process of dissolution of Ni and Cr adatoms from model Ni–Cr(111) alloy surfaces is presented, both in vacuum and with explicit water molecules. The goal is to understand how the electronic structures solved using DFT can provide insights as to changes in valence, energy and coordination of the adatoms in the process of dissolving from the alloy surface. It is found that nearby Cr solute atoms increase the dissolution activation energy of Ni. Cr adatoms have a similar dissolution activation energy as Ni adatoms, except for one particular surface configuration that has a much smaller dissolution activation energy, which might promote selective dissolution of Cr in Ni–Cr alloys. To interpret the first-principles modeling results for the potential energy trajectory along the dissolution reaction coordinate, we provide a thermodynamic breakdown of the various terms that contribute to the dissolution activation and total reaction energy. The role of addition of Cr is explored on the dissolution kinetics of a Ni–Cr alloys of varying composition by constructing a model for the corrosion current density with DFT-based activation energies. Lastly, dissolution resistance index is proposed as a quantifiable descriptor of the dissolution resistance of corrosion resistant alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Correlating Surface Processing of Nb Superconducting RF Cavities with the Evolution of Surface Electronic States

Superconducting-radio frequency (RF) cavities provide an efficient way to accelerate particle beams with extremely high acceleration gradients while generating very small power dissipation. The few nanometers of the surface play a critical role in defining the RF performance of superconducting Nb based cavities. Over the past two decades, several pioneering surface treatment and processing methods have emerged, enabling remarkable improvements in superconducting cavity performance by simultaneously achieving high quality factors with increasing maximum acceleration gradients. These processing approaches include chemical polishing, distinct multi-step thermal treatments under ultra-high vacuum (UHV) conditions over low to high temperature regimes, as well as high-temperature treatments under controlled nitrogen atmospheres. Beyond their macroscopic impact on RF performance, these methods produce distinct surface oxide configurations characterized by different valence states, oxide thicknesses, chemical uniformity, and oxygen concentration profiles extending into the near-surface bulk of niobium. In this work, we are trying to understand how the surface-processing methods and the resulting oxide/oxygen profiles affect the electronic structure of surface and the mechanism of superconductivity. Using a combination of X-ray photoemission and X-ray absorption spectroscopies, we investigate how the valence-band structure and the electronic density of states (DoS) near the Fermi level evolve under different surface treatments. By employing tunable photon energies across multiple elemental absorption edges, we use resonant photoemission to disentangle and identify the elemental contributions to specific valence-band features. Our observations show that different surface-processing methods lead to distinct temperature evolutions of the DoS and valence-band states near the Fermi level. Our results suggest variations in different Nb-O orbital hybridizations in distinct processes and point towards the possibility of different underlying mechanisms of superconductivity governed by surface chemistry and oxide configuration. We also correlate these distinct superconducting mechanisms with RF cavity performance, specifically focusing on measured surface resistance, the nature of the Q-slope, and quench fields observed in superconducting RF measurements. These results will enable us to identify the potential limiting factors and relevant controllable parameters that can be further optimized to improve the performance of superconducting RF cavities.

Tripathi, Malvika [Fermilab] (ORCID:00000001989251↗
NASA NTRS2008

Vacuum Packaging of MEMS With Multiple Internal Seal Rings

A proposed method of design and fabrication of vacuum-packaged microelectromechanical systems (MEMS) and of individual microelectromechanical devices involves the use of multiple internal seal rings (MISRs) in conjunction with vias (through holes plated with metal for electrical contacts). The proposed method is compatible with mass production in a wafer-level fabrication process, in which the dozens of MEMS or individual microelectromechanical devices on a typical wafer are simultaneously vacuum packaged by bonding a capping wafer before the devices are singulated (cut apart by use of a dicing saw). In addition to being compatible with mass production, the proposed method would eliminate the need for some complex and expensive production steps and would yield more reliable vacuum seals. Conventionally, each MEMS or individual microelectromechanical device is fabricated as one of many identical units on a device wafer. Vacuum packaging is accomplished by bonding the device wafer to a capping wafer with metal seal rings (one ring surrounding each unit) that have been formed on the capping wafer. The electrical leads of each unit are laid out on what would otherwise be a flat surface of the device wafer, against which the seal ring is to be pressed for sealing. The resulting pattern of metal lines and their insulating oxide coverings presents a very rough and uneven surface, upon which it is difficult to pattern the sealing metal. Consequently, the seal is prone to leakage unless additional costly and complex planarization steps are performed before patterning the seal ring and bonding the wafers.

Hayworth, Ken↗
NASA NTRS2001

Cryogenic Treatment of Al-Li Alloys for Improved Weldability, Repairability, and Reduction of Residual Stresses

Service performance has shown that cryogenic treatment of some metals provides improved strength, fatigue life, and wear resistance to the processed material. Effects such as these were initially discovered by NASA engineers while evaluating spacecraft that had returned from the cold vacuum of space. Factors such as high cost, poor repairability, and poor machinability are currently prohibitive for wide range use of some aerospace aluminum alloys. Application of a cryogenic treatment process to these alloys is expected provide improvements in weldability and weld properties coupled with a reduction in repairs resulting in a significant reduction in the cost to manufacture and life cycle cost of aerospace hardware. The primary purpose of this effort was to evaluate the effects of deep cryogenic treatment of some aluminum alloy plate products, welds, and weld repairs, and optimize a process for the treatment of these materials. The optimized process is being evaluated for improvements in properties of plate and welds, improvements in weldability and repairability of treated materials, and as an alternative technique for the reduction of residual stresses in repaired welds. This paper will present the results of testing and evaluation conducted in this effort. These results will include assessments of changes in strength, toughness, stress corrosion susceptability, weldability, repairability, and reduction in residual stresses of repaired welds.

Malone, Tina W.↗
NASA NTRS1992

Metals production

Existing procedures for design of electrochemical plants can be used for design of lunar processes taking into consideration the differences in environmental conditions. These differences include: 1/6 Earth gravity, high vacuum, solar electrical and heat source, space radiation heat sink, long days and nights, and different availability and economics of materials, energy, and labor. Techniques have already been developed for operation of relatively small scale hydrogen-oxygen fuel cell systems used in the U.S. lunar landing program. Design and operation of lunar aqueous electrolytic process plants appears to be within the state-of-the-art. Finding or developing compatible materials for construction and designing of fused-magma metal winning cells will present a real engineering challenge.

Beck, Theodore S.↗
NASA NTRS2010

Epoxy/Glass and Polyimide (LaRC(TradeMark) PETI-8)/Carbon Fiber Metal Laminates Made by the VARTM Process

Recent work at NASA Langley Research Center (LaRC) has concentrated on developing new polyimide resin systems for advanced aerospace applications that can be processed without the use of an autoclave. Polyimide composites are very attractive for applications that require a high strength to weight ratio and thermal stability. Vacuum assisted resin transfer molding (VARTM) has shown the potential to reduce the manufacturing cost of composite structures. Fiber metal laminates (FML) made via this process with aluminum, glass fabric, and epoxy resins have been previously fabricated at LaRC. In this work, the VARTM process has been refined for epoxy/glass FMLs and extended to the fabrication of FM Ls with titanium/carbon fabric layers and a polyimide system developed at NASA, LARC(TradeMark) PETI-8. Resin flow pathways were introduced into the titanium foils to aid the infiltration of the polyimide resin. Injection temperatures in the range of 250-280 C were required to achieve the necessary VARTM viscosities (<10 Poise). Laminate quality and initial mechanical properties will be presented.

Cano, Roberto J.↗
DOE OSTI2022

Slides for MS&T2022: Carbon-Carbon Composites from 3D Printed Preforms Graphitized by Electric Field Assisted Sintering

Formation of Carbon-Carbon (C-C) composite materials requires putting a carbon fiber preform through a cycle of densification, carbonization, and graphitization. This cycle is then repeated until the desired properties are achieved. The graphitization phase is particularly energy demanding as it involves heating the components to in excess of 2000°C. In traditional furnaces this is also quite time consuming as typical heating rates are low, and the actual heat treatment may be limited by component dimensions, as heat is conducted throughout the part primarily by thermal diffusion. Joule heating by means of Electric Field Assisted Sintering (EFAS) systems enables high heating rates and causes the part to be heated from the inside, which eliminates the thermal diffusion time constraint. In our process, C-C composites are formed by pyrolyzation of 3D-printed carbon fiber preforms, vacuum infiltration of naphthalene based mesophase pitch, and carbonization. The part is then graphitized in the EFAS system. By this method graphitization of the composite matrix was achieved in less than an hour. A part density of greater than 1.6g/cc (up to 1.9g/cc demonstrated) was achieved after only two rounds of infiltration and a single graphitization. Overall the process took less than a week which is significantly faster than traditional methods. Optical microscopy and XRD results are discussed to elucidate the internal porosity and characterize the degree of graphitization. Testing was performed showing the impact on fiber direction to electrical and thermal properties of the final part.

36 MATERIALS SCIENCE↗
NASA NTRS2013

Using Combustion Synthesis to Reinforce Berms and Other Regolith Structures

The Moonraker Excavator and other tools under development for use on the Moon, Mars, and asteroids will be employed to construct a number of civil engineering projects and to mine the soil. Mounds of loose soil will be subject to the local transport mechanisms plus artificial mechanisms such as blast effects from landers and erosion from surface vehicles. Some of these structures will require some permanence, with a minimum of maintenance and upkeep. Combustion Synthesis (CS) is a family of processes and techniques whereby chemistry is used to transform materials, often creating flame in a hard vacuum. CS can be used to stabilize civil engineering works such as berms, habitat shielding, ramps, pads, roadways, and the like. The method is to unroll thin sheets of CS fabric between layers of regolith and then fire the fabric, creating a continuous sheet of crusty material to be interposed among layers of loose regolith. The combination of low-energy processes, ISRU (in situ resource utilization) excavator, and CS fabrics, seems compelling as a general method for establishing structures of some permanence and utility, especially in the role of robotic missions as precursors to manned exploration and settlement. In robotic precursory missions, excavator/ mobility ensembles mine the Lunar surface, erect constructions of soil, and dispense sheets of CS fabrics that are covered with layers of soil, fired, and then again covered with layers of soil, iterating until the desired dimensions and forms are achieved. At the base of each berm, for example, is a shallow trench lined with CS fabric, fired and filled, mounded, and then covered and fired, iteratively to provide a footing against lateral shear. A larger trench is host to a habitat module, backfilled, covered with fabric, covered with soil, and fired. Covering the applied CS fabric with layers of soil before firing allows the resulting matrix to incorporate soil both above and below the fabric ply into the fused layer, developing a very irregular surface which, like sandpaper, can provide an anchor for loose soil. CS fabrics employ a coarse fiberglass weave that persists as reinforcement for the fired material. The fiberglass softens at a temperature that exceeds the combustion temperature by factors of two to three, and withstands the installation process. This type of structure should be more resistant to rocket blast effects from Lunar landers.

Rodriquez, Gary↗