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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 703 records · Page 39

All sources NASA NTRS DOE OSTI

NASA NTRS1989

Microencapsulated Phase-Change Materials For Storage Of Heat

Report describes research on engineering issues related to storage and transport of heat in slurries containing phase-change materials in microscopic capsules. Specific goal of project to develop lightweight, compact, heat-management systems used safely in inhabited areas of spacecraft. Further development of obvious potential of technology expected to lead to commercialization and use in aircraft, electronic equipment, machinery, industrial processes, and other sytems in which requirements for management of heat compete with severe restrictions on weight or volume.

Colvin, David P.↗

NASA NTRS2001

Detection of Micro-Leaks Through Complex Geometries Under Mechanical Load and at Cryogenic Temperature

Polymer Matrix Composite (PMC) hydrogen tanks have been proposed as an enabling technology for reducing the weight of Single-Stage-to-Orbit reusable launch vehicles where structural mass has a large impact on vehicle performance. A key development issue of these lightweight structures is the leakage of hydrogen through the composite material. The rate of hydrogen leakage can be a function of the material used, method of 6 fabrication used to manufacture the tank, mechanical load the tank must react, internal damage-state of the material, and the temperatures at which the tank must operate. A method for measuring leakage through a geometrically complex structure at cryogenic temperature and under mechanical load was developed, calibrated and used to measure hydrogen leakage through complex X-33 liquid-hydrogen tank structure sections.

Rivers, H. Kevin↗

NASA NTRS2005

Portable Electron-Beam Free-Form Fabrication System

A portable electron-beam free-form fabrication (EB F3) system, now undergoing development, is intended to afford a capability for manufacturing metal parts in nearly net sizes and shapes. Although the development effort is oriented toward the eventual use of systems like this one to supply spare metal parts aboard spacecraft in flight, the basic system design could also be adapted to terrestrial applications in which there are requirements to supply spare parts on demand at locations remote from warehouses and conventional manufacturing facilities. Prior systems that have been considered for satisfying the same requirements (including prior free-form fabrication systems) are not easily portable because of their bulk and massive size. The mechanical properties of the components that such systems produce are often inferior to the mechanical properties of the corresponding original, conventionally fabricated components. In addition, the prior systems are not efficient in the utilization of energy and of feedstock. In contrast, the present developmental system is designed to be sufficiently compact and lightweight to be easily portable, to utilize both energy and material more efficiently, and to produce components that have mechanical properties approximating those of the corresponding original components. The developmental EB F3 system will include a vacuum chamber and associated vacuum pumps, an electron-beam gun and an associated power supply, a multiaxis positioning subsystem, a precise wire feeder, and an instrumentation system for monitoring and control. The electron-beam gun, positioning subsystem, and wire feeder will be located inside the vacuum chamber (see figure). The electron beam gun and the wire feeder will be mounted in fixed positions inside the domed upper portion of the vacuum chamber. The positioning subsystem and ports for the vacuum pumps will be located on a base that could be dropped down to provide full access to the interior of the chamber when not under vacuum. During operation, wire will be fed to a fixed location, entering the melted pool created by the electron beam. Heated by the electron beam, the wire will melt and fuse to either the substrate or with the previously deposited metal wire fused on top of the positioning table. Based on a computer aided design (CAD) model and controlled by a computer, the positioning subsystem

Watson, J. Kevin↗

NASA NTRS2013

Ultra-Low Heat-Leak, High-Temperature Superconducting Current Leads for Space Applications

NASA Goddard Space Flight Center has a need for current leads used in an adiabatic demagnetization refrigerator (ADR) for space applications. These leads must comply with stringent requirements such as a heat leak of approximately 100 W or less while conducting up to 10 A of electric current, from more than 90 K down to 10 K. Additionally, a length constraint of < 300 mm length and < 50 mm diameter is to be maintained. The need for these current leads was addressed by developing a superconducting hybrid lead. This hybrid lead comprises two different high-temperature superconducting (HTS) conductors bonded together at a thermally and electrically determined optimum point along the length of the current lead. By taking advantage of material properties of each conductor type, employing advanced fabrication techniques, and taking advantage of novel insulation materials, the company was able to develop and fabricate the lightweight, low heat-leak leads currently to NASA's specs.

Rey, Christopher M.↗

NASA NTRS2014

Applying a Stiffened Stitched Concept to Shear-Loaded Structure

NASA and The Boeing Company have worked to develop new low-cost, lightweight composite structures for aircraft. A stitched carbon-epoxy material system was developed to reduce the weight and cost of transport aircraft structure, first in the NASA Advanced Composites Technology (ACT) Program in the 1990's and now in the Environmentally Responsible Aviation (ERA) Project. By stitching through the thickness of a dry carbon fiber material prior to cure, the need for mechanical fasteners is almost eliminated. Stitching also provides the benefit of reducing or eliminating delaminations, including those between stiffener flanges and skin. The stitched panel concept used in the ACT program used simple blade-stiffeners as stringers, caps, and clips. Today, the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept is being developed for application to advanced vehicle configurations. PRSEUS provides additional weight savings through the use of a stiffener with a thin web and a unidirectional carbon rod at the top of the web which provides structurally efficient stiffening. Comparisons between stitched and unstitched structure and between blade-stiffened and rod-stiffened structure are presented focusing on a panel loaded in shear. Shear loading is representative of spar loading in wing structures.

Jegley, Dawn C.↗

NASA NTRS2016

Compact, Lightweight, Ceramic Matrix Composite (CMC) Based Acoustic Liners for Reducing Subsonic Jet Aircraft Engine Noise

Recent developments have reduced fan and jet noise contributions to overall subsonic aircraft jet-engine noise. Now, aircraft designers are turning their attention toward reducing engine core noise. The NASA Glenn Research Center and NASA Langley Research Center have teamed to investigate the development of a compact, lightweight acoustic liner based on oxide/oxide ceramic matrix composite (CMC) materials. The NASA team has built upon an existing oxide/oxide CMC sandwich structure concept that provides monotonal noise reduction. Oxide/oxide composites have good high temperature strength and oxidation resistance, which could allow them to perform as core liners at temperatures up to 1000C (1832F), and even higher depending on the selection of the composite constituents. NASA has initiated the evaluation of CMC-based liners that use cells of different lengths (variable-depth channels) or effective lengths to achieve broadband noise reduction. Reducing the overall liner thickness is also a major goal, to minimize the volume occupied by the liner. As a first step toward demonstrating the feasibility of our concepts, an oxide/oxide CMC acoustic testing article with different channel lengths was tested. Our approach, summary of test results, current status, and goals for the future are reported.

testing↗

NASA NTRS2018

Composite Technology for Exploration (CTE)

The CTE project is developing and demonstrating weight-saving, performance-enhancing composite bonded joint technology by incorporating materials characterization studies into the design, manufacturing, and testing of lightweight composite bonded joint concepts for SLS-scale applications. The project is advancing current high-fidelity analysis tools and standards for improvements in the prediction of failure and residual strength of bonded joints.

Composite Technology↗

NASA NTRSDate not supplied

ACS3 - Flight Dynamics for A Solar Sail Technology Demonstration Mission

The NASA's Advanced Composite Solar Sail System (ACS3) mission consist of a spacecraft that will deploy an 80 m 2 solar sail in a 1000 km sun-synchronous orbit. The main objective of the mission is to demonstrate that the solar wind can impulse the spacecraft to change the semimajor-axis and obtain a different orbit altitude. The sail will be composed of a combination of composite materials with distinct properties, and it will be deployed with lightweight booms from a 12U CubeSat bus, developed by Nanoavionics. The spacecraft will be launched aboard an Electron launch vehicle from Rocket LAB Launch Complex in New Zealand no earlier than July 2023. This paper covers the orbital mechanics and navigation developments to support the mission, from the solar sail trajectory model to the actual flight dynamics system to provide the orbit determination analysis prior to flight. First, we introduce a description of our high-fidelity propagation that accounts for the solar radiation pressure to produce predictive ephemeris of the solar sail performance with several spacecraft attitude modes. As part of our results, we present plots of the expected altitudes achieved by the spacecraft once the solar sail is deployed under various assumptions of the solar weather. In addition to that, we present a full description of our orbit determination process which relies in GPS state vectors to accurately estimate the position and velocity uncertainties at a frequent cadence during the mission. The outcome of this process will be critical to achieving the objective of determining effective altitude change produced by the solar sail.

Solar Sail↗

NASA NTRSDate not supplied

ACS3: Flight Dynamics

The NASA's Advanced Composite Solar Sail System (ACS3) mission consist of a spacecraft that will deploy an 80 m2 solar sail in Low Earth Orbit (LEO). The main objective of the mission is to demonstrate that the solar wind can impulse the spacecraft to change the semimajor-axis and obtain a different orbit altitude. The sail will be composed of a combination of composite materials with distinct properties, and it will be deployed with lightweight booms from a 12U CubeSat bus, developed by Nanoavionics. The spacecraft will be launched aboard an Electron launch vehicle from Rocket LAB Launch Complex in New Zealand. This paper covers the orbital mechanics and navigation developments to support the mission, from the solar sail trajectory model to the actual flight dynamics system to provide the orbit determination analysis prior to flight. First, we introduce a description of our high-fidelity propagation that accounts for the solar radiation pressure to produce predictive ephemeris of the solar sail performance with several spacecraft attitude modes. As part of our results, we present plots of the expected altitudes achieved by the spacecraft once the solar sail is deployed under various assumptions of the solar weather. In addition to that, we present a full description of our orbit determination process which relies in GPS state vectors to accurately estimate the position and velocity uncertainties at a frequent cadence during the mission. The outcome of this process will be critical to achieving the objective of determining effective altitude change produced by the solar sail.

Solar sail↗

NASA NTRS2012

Materials, Structures and Manufacturing: An Integrated Approach to Develop Expandable Structures

Membrane dominated space structures are lightweight and package efficiently for launch; however, they must be expanded (deployed) in-orbit to achieve the desired geometry. These expandable structural systems include solar sails, solar power arrays, antennas, and numerous other large aperture devices that are used to collect, reflect and/or transmit electromagnetic radiation. In this work, an integrated approach to development of thin-film damage tolerant membranes is explored using advanced manufacturing. Bio-inspired hierarchical structures were printed on films using additive manufacturing to achieve improved tear resistance and to facilitate membrane deployment. High precision, robust expandable structures can be realized using materials that are both space durable and processable using additive manufacturing. Test results show this initial work produced higher tear resistance than neat film of equivalent mass. Future research and development opportunities for expandable structural systems designed using an integrated approach to structural design, manufacturing, and materials selection are discussed.

Belvin, W. Keith↗

NASA NTRS2006

Characterization of Space Shuttle Thermal Protection System (TPS) Materials for Return-to-Flight following the Shuttle Columbia Accident Investigation

During the Space Shuttle Columbia Accident Investigation, it was determined that a large chunk of polyurethane insulating foam (= 1.67 lbs) on the External Tank (ET) came loose during Columbia's ascent on 2-1-03. The foam piece struck some of the protective Reinforced Carbon-Carbon (RCC) panels on the leading edge of Columbia's left wing in the mid-wing area. This impact damaged Columbia to the extent that upon re-entry to Earth, superheGed air approaching 3,000 F caused the vehicle to break up, killing all seven astronauts on board. A paper after the Columbia Accident Investigation highlighted thermal analysis testing performed on External Tank TPS materials (1). These materials included BX-250 (now BX-265) rigid polyurethane foam and SLA-561 Super Lightweight Ablator (highly-filled silicone rubber). The large chunk of foam from Columbia originated fiom the left bipod ramp of the ET. The foam in this ramp area was hand-sprayed over the SLA material and various fittings, allowed to dry, and manually shaved into a ramp shape. In Return-to-Flight (RTF) efforts following Columbia, the decision was made to remove the foam in the bipod ramp areas. During RTF efforts, further thermal analysis testing was performed on BX-265 foam by DSC and DMA. Flat panels of foam about 2-in. thick were sprayed on ET tank material (aluminum alloys). The DSC testing showed that foam material very close to the metal substrate cured more slowly than bulk foam material. All of the foam used on the ET is considered fully cured about 21 days after it is sprayed. The RTF culminated in the successful launch of Space Shuttle Discovery on 7-26-05. Although the flight was a success, there was another serious incident of foam loss fiom the ET during Shuttle ascent. This time, a rather large chunk of BX-265 foam (= 0.9 lbs) came loose from the liquid hydrogen (LH2) PAL ramp, although the foam did not strike the Shuttle Orbiter containing the crew. DMA testing was performed on foam samples taken fiom a simulated PAL ramp panel. It was found that the smooth rind on the foam facing the cable tray did significantly affect the properties of foam at the PAL ramp surface. The smooth rind increased the storage modulus E' of the foam as much as 20- 40% over a temperature range of -145 to 95 C. Because of foam loss fiom the PAL ramp, future Shuttle flights were grounded indefinitely to allow further testing to better understand foam properties. The decision was also made to remove foam from the LH2 PAL, ramp. Other RTF efforts prior to the launch of Discovery included

Wingard, Doug↗

NASA NTRS2023

Mitigating Space Radiation Using Magnesium(-Lithium) and Boron Carbide Composites

The health effects of galactic cosmic radiation are a serious impediment to crewed exploration of the solar system. OLTARIS, an interface for the 3DHZETRN deterministic radiation transport code, was used to assess the response of aerospace materials to this constant radiation exposure. Traditional aerospace structural materials like aluminum can, after a certain mass, increase the health effects of such radiation. However, materials with lower atomic mass may mitigate this build-up in secondary radiation with increasing areal density. As such, lower atomic mass structural alloys of magnesium and magnesium–lithium are promising candidates. These alloys may reduce the mass of structures when substituted for aluminum alloys. Reinforcement with boron carbide could further reduce atomic mass while also improving the mechanical properties of such lightweight alloys. This study found that the lower atomic mass of these materials increased nuclear fragmentation upon cosmic radiation interactions, leading to a softening of the secondary (neutron) radiation spectra. This softened spectra reduced the effective dose equivalent, a measure of health effects, for magnesium(-lithium) alloys and their boron carbide-reinforced composites when compared to aluminum.

Galactic cosmic radiation↗

NASA NTRS1993

Optical Spectroscopy of New Materials

Composites are currently used for a rapidly expanding number of applications including aircraft structures, rocket nozzles, thermal protection of spacecraft, high performance ablative surfaces, sports equipment including skis, tennis rackets and bicycles, lightweight automobile components, cutting tools, and optical-grade mirrors. Composites are formed from two or more insoluble materials to produce a material with superior properties to either component. Composites range from dispersion-hardened alloys to advanced fiber-reinforced composites. UV/VIS and FTIR spectroscopy currently is used to evaluate the bonding between the matrix and the fibers, monitor the curing process of a polymer, measure surface contamination, characterize the interphase material, monitor anion transport in polymer phases, characterize the void formation (voids must be minimized because, like cracks in a bulk material, they lead to failure), characterize the surface of the fiber component, and measure the overall optical properties for energy balances.

White, Susan M.↗

NASA NTRS2000

Lightweight Lidar Telescopes for Space Applications

NASA is intent on exploiting the unique perspective of space-based remote optical instruments to observe and study large-scale environmental processes. Emphasis on smaller and more affordable missions continues to force the remote sensing instruments to find innovative ways to reduce the size, weight, and cost of the sensor package. This is a challenge because many of the proposed instruments incorporate a high quality meter-class telescope that can be a significant driver of total instrument costs. While various methods for telescope weight reduction have been achieved, many of the current approaches rely on exotic materials and specialized manufacturing techniques that limit availability or substantially increase costs. A competitive lightweight telescope technology that is especially well suited to space-based coherent Doppler wind lidar has been developed through a collaborative effort involving NASA Marshall Space Flight Center (MSFC) through the Global Hydrology and Climate Center (GHCC) and the University of Alabama in Huntsville (UAH) at the Center for Applied Optics (CAO). The new lightweight optics using metal alloy shells and surfaces (LOMASS) fabrication approach is suitable for high quality metal mirrors and meter-class telescopes. Compared to alternative materials and fabrication methods the new approach promises to reduce the areal density of a meter-class telescope to less than 15-kg/sq m; deliver a minimum VIO-RMS surface optical quality; while using commercial materials and equipment to lower procurement costs. The final optical figure and finish is put into the mirrors through conventional diamond turning and polishing techniques. This approach is especially advantageous for a coherent lidar instrument because the reduced telescope weight permits the rotation of the telescope to scan the beam without requiring heavy wedges or additional large mirrors. Ongoing investigations and preliminary results show promise for the LOMASS approach to be successful in demonstrating a novel alternative approach to fabricating lightweight mirrors with performance parameters comparable with the Space Readiness Coherent Lidar Experiment (SPARCLE). Development and process characterization is continuing with the design and fabrication of mirrors for a 25-cm telescope suitable for a lidar instrument.

Peters, Bruce R.↗

NASA NTRS1999

The Development of Lightweight Electronics Enclosures for Space Applications

This paper outlines the end to end effort to produce lightweight electronics enclosures for NASA GSFC electronics applications with the end goal of presenting an array of lightweight box options for a flight opportunity. Topics including the development of requirements, design of three different boxes, utilization of advanced materials and processes, and analysis and test will be discussed. Three different boxes were developed independently and in parallel. A lightweight machined Aluminum box, a cast Aluminum box and a composite box were designed, fabricated, and tested both mechanically and thermally. There were many challenges encountered in meeting the requirements with a non-metallic enclosure and the development of the composite box employed several innovative techniques.

Fenske, Matthew T.↗

NASA NTRS1999

The Development of Lightweight Electronics Enclosures for Space Applications

Fenske, Matthew T.↗

NASA NTRS2005

Advanced Ablative Insulators and Methods of Making Them

Advanced ablative (more specifically, charring) materials that provide temporary protection against high temperatures, and advanced methods of designing and manufacturing insulators based on these materials, are undergoing development. These materials and methods were conceived in an effort to replace the traditional thermal-protection systems (TPSs) of re-entry spacecraft with robust, lightweight, better-performing TPSs that can be designed and manufactured more rapidly and at lower cost. These materials and methods could also be used to make improved TPSs for general aerospace, military, and industrial applications.

Congdon, William M.↗

NASA NTRS1979

Computer design synthesis of a below knee-Syme prosthesis

A detailed design synthesis analysis of the BK Syme prosthesis is provided, to determine the socket's cutout orientation size and shape, cutout fillet shape, socket wall thickness distribution and the reinforced fiber distribution in the socket wall, for a minimally stressed structurally safe lightweight prosthesis. For analysis purposes, the most adverse socket loading is obtained at the push-off stage of gait; this loading is idealized as an axial in-plane loading on the bottom edge of the circular cylindrical socket shell whose top edge is considered fixed. Finite element stress analysis of the socket shell (with uniform and graded wall thickness) are performed for various orientations of the cutout and for various types of corner fillets. A lateral cutout with a streamline fillet is recommended. The wall material (i.e., thickness) distribution is determined so as to minimize the stresses, while ensuring that the wall material's stress limits are not exceeded. For such a maximally stressed lightweight socket shell, the panels in the neighborhood of the cutout are checked to ensure that they do not buckle under their acquired stresses. A fiber-reinforced laminated composite socket shell is also analyzed in order to recommend optimum variables in orientations and densities of reinforcing fibers.

Elangovan, P. T.↗