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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 73 records · Page 4

On development of an inexpensive, lightweight thermal micrometeroid garment for space suits

A lightweight and inexpensive coverlayer developed for space suits is described. Material selection, procurement, and testing, pattern design, and prototype fabrication are discussed. By using the minimum required cross section necessary for earth orbital mission, by utilizing the lightest weight materials possible, and by decreasing the use of weight costly taping a lightweight and economical thermal micrometeroid garment was developed. Simplification of manufacturing techniques and use of off-the-shelf materials helped to reduce costs.

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Feasibility study of a 200 watt per kilogram lightweight solar array system

Progress in an investigation of the feasibility of designing a lightweight solar array with a power-to-weight ratio of 200 watts per kilogram is described. This solar array will produce 10,000 watts of electrical power at 1 A.U. at its beginning of life (BOL), and degrade less than 20% over a three year period in interplanetary flight. A review of existing lightweight solar array system concepts is presented along with discussion pertaining to their applicable technology as it relates to a 200 watt/kilogram array. Also presented is a discussion of the candidate development solar cells being considered, and various deployable boom concepts under investigation.

Stanhouse, R.

Lightweight fuel cell powerplant for Tug

The design and characteristics of a lightweight powerplant based on advanced cell technology to meet the requirements of the Space Tug are described. The powerplant can be operated off low-pressure hydrogen and oxygen rocket propellant tanks and avoid the need for a dedicated reactant supply. Product water can be condensed or not, depending on vehicle or payload requirements. The heart of the unit, the fuel cell power section, consist of lightweight, series-connected, alkaline cells, while the power section contains accessory components for reactant conditioning, distribution, and venting, coolant circulation, passive product water removal and electric control. The proposed design offers at least a 50 per cent saving in powerplant weight, so that the total estimated powerplant dry weight including structure, tubing, wiring, interface connectors, and interface heat exchanger is 48 lb.

Handley, L. M.

Design, fabrication, and structural testing of a lightweight shadow shield for deep-space application

Two full-scale, lightweight, double-sheeted shadow shields were developed as the primary element of a deep-space thermal protection system for liquid-hydrogen propellant tankage. The thermal and mechanical considerations used in s, the method of fabrication, and the environmental testing results on a prototype shield are discussed. Testing consisted of a transient cooldown period, a prolonged cold soak, and a transient warmup. The mechanical and thermal analyses used in the shield design are sufficient to produce a lightweight rugged shadow shield assembly that is structurally adequate for its intended application.

Miao, D.

A lightweight solar array study

A sample module was assembled to model a portion of a flexible extendable solar array, a type that promises to become the next generation of solar array design. The resulting study of this module is intended to provide technical support to the array designer for lightweight component selection, specifications, and tests. Selected from available lightweight components were 127-micron-thick wrap-around contacted solar cells, 34- micron-thick sputtered glass covers, and as a substrate a 13-micron-thick polyimide film clad with a copper printed circuit. Each component displayed weaknesses. The thin solar cells had excessive breakage losses. Sputtered glass cover adhesion was poor, and the covered cell was weaker than the cell uncovered. Thermal stresses caused some cell delamination from the model solar array substrate.

Josephs, R. H.

Lightweight Space Tug body structure

Lightweight honeycomb sandwich construction using a wide variety of metal and fibrous composite faceskins was used in the design of a typical Space Tug skirt structure. Relatively low magnitude combined loading of axial compression and torsion resulted in designs using ultrathin faceskins, lightweight honeycomb cores, and thin faceskin/core adhesive bond layers. Two of the designs with metal faceskins (aluminum and titanium) and four with fibrous composite faceskins (using combinations of fiberglass, boron, and graphite) were evaluated through the fabrication and structural test of a series of small development panels. The two most promising concepts with aluminum and graphite/epoxy faceskins, were further evaluated through the fabrication and structural test of larger compression and shear panels. All panels tested exceeded design ultimate load levels, thereby, verifying the structural integrity of the selected designs. Projected skirt structural weights for the graphite/epoxy and aluminum concepts fall within original weight guidelines established for the Space Tug vehicle.

Lager, J. R.

Development of long life lightweight nickel-cadmium cells and batteries

The paper describes the development of a high-specific energy Ni-Cd cell for a lightweight battery. After preliminary cycling tests on laboratory and commercial cells, a cell was produced that features electrochemically impregnated positive and negative electrodes, a single terminal, and increased amount of electrolyte. This cell weighed an average of 948 g and had a measured specific energy of over 50 Wh/kg at a C/2 discharge to 1.0 V. The epoxy graphite case capable of withstanding internal pressures in excess of 300 psig represents a 35% weight reduction from a lightweight 0.30 mm Ni-Cd case. A pack of these cells was cycled at 70% maximum depth of discharge beyond 10 simulated geosynchronous orbit-eclipse seasons, and high end-of-charge voltages were obtained. A prototype battery consisting of 14 such cells was fabricated and has a measured specific energy of 46 Wh/kg.

Ritterman, P. F.

Lightweight Face Mask

Lightweight face mask originally developed to protect epileptic patients during seizures could have many other medical and nonmedical applications such as muscular distrophy patients, football linesmen and riot-control police. Masks are extremely lightweight, the lightest of the configurations weighing only 136 grams.

Cason, W. E. I.

Lightweight solar array blanket tooling, laser welding and cover process technology

A two phase technology investigation was performed to demonstrate effective methods for integrating 50 micrometer thin solar cells into ultralightweight module designs. During the first phase, innovative tooling was developed which allows lightweight blankets to be fabricated in a manufacturing environment with acceptable yields. During the second phase, the tooling was improved and the feasibility of laser processing of lightweight arrays was confirmed. The development of the cell/interconnect registration tool and interconnect bonding by laser welding is described.

Dillard, P. A.

Making a Lightweight Battery Plaque

Plaque formed in porous plastic by electroless plating. Lightweight plaque prepared by electroless plating of porous plastic contains embedded wire or expanded metal grid. Plastic may or may not be filled with soluble pore former. If it contains soluble pore former, treated to remove soluble pore former and increase porosity. Porous plastic then clamped into rig that allows plating solutions to flow through plastic. Lightweight nickel plaque used as electrode substrate for alkaline batteries, chiefly Ni and Cd electrodes, and for use as electrolyte-reservoir plates for fuel cells.

Reid, M. A.

Development of lightweight, glass mirror segments for the Large Deployable Reflector

Accomplishments in the development of lightweight, honeycomb-core, sandwich mirror blanks made of borosilicate and high-silica glasses at the University of Arizona for the Large Deployable Reflector program are described. In this paper, work spanning the last 2 years is reported, highlighting a new mirror blank fabrication technique that permits the fabrication of the honeycomb core integrally with the front and back plates of the blank in a single furnace cycle. Two types of mirror blanks made by this method, an off-axis, aspheric segment and a smaller Vycor circular piece, are described. The fabrication of two off-axis, aspheric mirror segments is also described. Cryogenic test results are included on the test of a 38-cm diameter, lightweight, honeycomb core, sandwich mirror made of Pyrex.

Melugin, R. K.

Thermal stability of lightweight graphite glass sandwich reflectors for far infrared astronomy

Graphite fiber-reinforced glass matrix composites are being developed for a variety of structural applications requiring excellent thermomechanical stability. These materials are ideally suited for lightweight, high strength, thermally stable infrared mirrors because of their low density, low thermal expansion, high strength and stiffness, and their ability to be machined, replicated and figured using standard polishing techniques. These properties are particularly promising for applications such as a 3-meter balloon-borne far-infrared and submillimeter telescope mirror which must be both very lightweight and able to retain its figure accuracy when cycled between room temperature and its operating temperature of -50 C. This paper presents the results of a set of low temperature optical tests conducted to determine the figure stability of a 30-cm diameter, frit-bonded graphite/glass mirror in the +20 to -60 C temperature range using a 10.6 micron laser interferometer. The results indicate that the residual change in figure was less than 0.3 microns, rms.

Bluege, J. H.

On Motion Planning and Control of Multi-Link Lightweight Robotic Manipulators

A general gross and fine motion planning and control strategy is needed for lightweight robotic manipulator applications such as painting, welding, material handling, surface finishing, and spacecraft servicing. The control problem of lightweight manipulators is to perform fast, accurate, and robust motions despite the payload variations, structural flexibility, and other environmental disturbances. Performance of the rigid manipulator model based computed torque and decoupled joint control methods are determined and simulated for the counterpart flexible manipulators. A counterpart flexible manipulator is defined as a manipulator which has structural flexibility, in addition to having the same inertial, geometric, and actuation properties of a given rigid manipulator. An adaptive model following control (AMFC) algorithm is developed to improve the performance in speed, accuracy, and robustness. It is found that the AMFC improves the speed performance by a factor of two over the conventional non-adaptive control methods for given accuracy requirements while proving to be more robust with respect to payload variations. Yet there are clear limitations on the performance of AMFC alone as well, which are imposed by the arm flexibility. In the search to further improve speed performance while providing a desired accuracy and robustness, a combined control strategy is developed. Furthermore, the problem of switching from one control structure to another during the motion and implementation aspects of combined control are discussed.

Cetinkunt, Sabri

Rapid fabrication of lightweight ceramic mirrors via chemical vapor deposition

Lightweight Si/SiC mirrors of nominal diameter 7.5 cm have been fabricated via a scalable and rapid CVD process to demonstrate the CVD mirror fabrication technology. These mirrors consist of a faceplate of either Si or Si-coated SiC and a lightweight backstructure made of either Si or SiC. The mirrors were polished to a figure better than 1/5th of a wave at 0.6328 A and a finish of better than 10 A rms. A procedure for fabricating these mirrors is described. The CVD fabrication process is fast and has the potential to yield several mirrors in a few weeks time from a single reactor. The CVD mirror fabrication technology is quite general and can be extended to include mirrors of other ceramic materials such as TiB2 and B4C.

Goela, Jitendra S.

Characterization and cycle tests of lightweight nickel electrodes

Development of a high specific energy nickel electrode is the main goal of the lightweight nickel electrode program at NASA Lewis Research Center. The approach was to improve the nickel electrode by continuing combined in-house and contract efforts to develop a more efficient and lighter weight electrode for the nickel-hydrogen battery. High energy nickel electrodes suffer from having shorter lives than state-of-the-art electrode. However, these lightweight electrodes appear to be favorable for missions requiring moderate cycle lives and depth-of-discharge.

Britton, Doris L.

Electrochemical impregnation and cycle life of lightweight nickel electrodes for nickel-hydrogen cells

Development of a high specific energy nickel electrode is the main goal of the lightweight nickel electrode program at NASA-Lewis. The approach was to improve the nickel electrode by continuing combined in-house and contract efforts to develop a more efficient and lighter weight electrode for the nickel-hydrogen cell. Lightweight plaques are used as conductive supports for the nickel hydroxide active material. These plaques are commercial products that are fabricated into nickel electrodes by electrochemically impregnating them with active material. The electrodes are life cycle tested in a low Earth orbit regime at 40 and 80 percent depths-of-discharge.

Britton, Doris L.

Lightweight ceramic insulation and method

A process is disclosed for manufacturing a low density ceramic powder which can be formed to make a lightweight material for insulation or other construction. The ceramic product made from the process has a final density of less than 25 to about 1 percent of the theoretical weight of the ceramic powder. The ceramic product is lightweight and can be made to withstand high temperatures greater than 1400 C.

Green, David J.

High performance arrays for lightweight spacecraft

JPL is developing the solar arrays for NASA's ultralightweight spacecraft, the Lunar Get-Away Special (L-GAS), which requires 1 kWe after its slow passage through the Van Allen Belts. The solar array design developed for the mission extended recent NASA-developed photovoltain array technology to power levels well below those conventionally considered practical for deployable lightweight array technology. It has become feasible by these means to consider the design of lightweight spacecraft which require up to 3 kWe at the begining of their service life.

Stella, Paul M.