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At least 739 records · Page 41
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

Engineering Polymers as Structural Materials in Spacecraft Water Systems

The novel application of structural materials, surface treatments, and barrier coatings is desired to mitigate the rapid loss of ionic silver (Ag+) biocide observed with passive metal alloys, improve reliability, and reduce system mass. In this work, we provide an initial look at the potential replacement of these heritage alloys in spacecraft water systems with high-performance thermoplastic engineering polymers, including PEEK, PEI, and PVDF. Such materials have found increasing use as structural materials in a broad array of performance-critical applications, including in the aerospace, medical implant, and chemical processing fields. We selected a number of promising materials for investigation, compiled mechanical behavior data, and conducted theoretical performance analyses. We also identified and began to address numerous material suitability concerns as well as design requirements for pressurized components in human-rated spacecraft hardware. These include material flammability, offgassing, leaching, chemical resistance, radiation tolerance, prevention of fracture/yielding, and others. We find that there is significant potential for use of engineering polymers in spacecraft water systems, and suggest some directions for future research.

Lance Dean Delzeit↗
NASA NTRSDate not supplied

Concept Design a 1.4 MW Inverter for Rotor Loss Minimization in a Partially Superconducting Motor

Partially superconducting machines with cryocooler-cooled rotors are a potential near term technology that can achieve the motor performance needed by future fixed wing electric aircraft. For this type of machine, minimizing cryogenic heat load is one of the keys for enabling high machine performance. Rotor eddy current loss is often the most difficult cryogenic heat load to mitigate due to current ripple from the motor drive. This paper presents the concept design for a 20 kW/kg, 99.5 percent efficient motor drive that has sufficiently low current ripple to enable high performance partially superconducting machines by minimizing eddy current loss in the rotor. The motor drive concept design uses a resonant, interleaved, and multilevel topology to achieve these high-performance metrics with little current ripple. Rotor magnetic loss analysis using NASA’s 1.4 MW High Efficiency Megawatt Motor (HEMM) is used in the design process to down select the motor drive topology and show that the final design generates less than 5 W of magnetic loss in the rotor.

Concept design↗
NASA NTRSDate not supplied

Concept Design of a 1.4 MW Drive for Rotor Loss Minimization in a Partially Superconducting Motor

Partially superconducting machines with cryocooler-cooled rotors are a potential near-term technology that can achieve the motor performance needed by future fixed wing electric aircraft. For this type of machine, minimizing cryogenic heat load is one of the keys for enabling high machine performance. Rotor eddy current loss is often the most difficult cryogenic heat load to mitigate due to current ripple from the motor drive. This paper presents the concept design for a 20 kW/kg, 99.5% efficient motor drive that has sufficiently low current ripple to enable high performance partially superconducting machines by minimizing eddy current loss in the rotor. The motor drive concept design uses a resonant, interleaved, and multilevel topology to achieve these high-performance metrics with little current ripple. Rotor magnetic loss analysis using NASA’s 1.4 MW High Efficiency Megawatt Motor (HEMM) is used in the design process to down select the motor drive topology and show that the final design generates less than 5 W of magnetic loss in the rotor.

Cryogenic↗
NASA NTRS2022

Metal Additive Manufacturing for Spaceflight

NASA has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the 2000’s. Several efforts have focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, hot-fire testing, and infusion into development and flight applications. This presentation will discuss some of the various AM processes, components, testing and development efforts for spaceflight applications at NASA used on launch vehicles and propulsion systems. - AM process comparisons and selection for spaceflight applications. - Novel alloy development, characterization, and maturation for extreme environments. - Infusion and maturation of AM components into development and flight applications.

Additive manufacturing↗
NASA NTRSDate not supplied

Joining and Integration of Silicon Carbide-Based Ceramic Materials for Aerospace Applications: An Overview

In order to fully utilize silicon carbide-based ceramics and ceramic matrix composites (CMCs) for aerospace and ground based applications, advanced joining and integration technologies are critically needed for achieving large, complex shaped, and integrated components. Careful material selection of joining inter-layers needs to consider chemical and thermal compatibilities with the parent materials that are being joined. Also, optimization needs to be conducted to select the proper processing conditions for achieving robust joints that are well adhered, strong, uniform, crack free, and have minimal residual stresses. NASA GRC developed pressureless and pressure aided approaches for joining ceramics and CMCs include brazing, diffusion bonding, refractory eutectic phase joining, and Single-step Elevated Temperature (SET) Joining. For joining ceramics and CMCs to metals, several brazes have been utilized. Brazing approaches for joining ceramics and metals have also included tailored brazes with multiple interlayers and particle additions. An overview of the joining approaches will be provided. In addition, processing-microstructure-property relationships will be discussed.

Silicon carbide↗
NASA NTRS2018

Marginal protein stability drives subcellular proteome isoelectric point

There exists a positive correlation between the pH of subcellular compartments and the median isoelectric point (pI) for the associated proteomes. Proteins in the human lysosome—a highly acidic compartment in the cell—have a median pI of ∼6.5, whereas proteins in the more basic mitochondria have a median pI of ∼8.0. Proposed mechanisms reflect potential adaptations to pH. For example, enzyme active site general acid/base residue pKs are likely evolved to match environmental pH. However, such effects would be limited to a few residues on specific proteins, and might not affect the proteome at large. A protein model that considers residue burial upon folding recapitulates the correlation between proteome pI and environmental pH. This correlation can be fully described by a neutral evolution process; no functional selection is included in the model. Proteins in acidic environments incur a lower energetic penalty for burying acidic residues than basic residues, resulting in a net accumulation of acidic residues in the protein core. The inverse is true under alkaline conditions. The pI distributions of subcellular proteomes are likely not a direct result of functional adaptations to pH, but a molecular spandrel stemming from marginal stability.

Kaiser Loell↗
NASA NTRS2022

Radial Loading of Hydrodynamic Bearings Due to Magnetic Variation

Anomalies during integration of a small-scale hydrodynamic pump motor prompted an investigation into all sources of radial loading on the bearings, and revealed that overall loads were insufficiently characterized. Experimental measurements demonstrated that magnetic forces in the pump motor contributed to significant amounts of radial loading on the bearings, potentially causing wear over long periods of operation and premature failures. The magnitude of these magnetic forces was determined for the rotor and stator separately, as well as for the rotor-stator assembly by designing various experimental setups able to recreate the pump motor without hydrodynamic bearings. Characterization of these magnetic forces led to changes in manufacturing processes and enabled selective choices of components, improving the pump motor hardware in order to meet NASA’s Europa Clipper project requirements.

Underhill, Micheal↗
NASA NTRS2016

Selection of a Brine Processor Technology for NASA Manned Missions

The current ISS Water Recovery System (WRS) reclaims water from crew urine, humidity condensate, and Sabatier product water. Urine is initially processed by the Urine Processor Assembly (UPA) which recovers 75% of the urine as distillate. The remainder of the water is present in the waste brine which is currently disposed of as trash on ISS. For future missions this additional water must be reclaimed due to the significant resupply penalty for missions beyond Low Earth Orbit (LEO). NASA has pursued various technology development programs for a brine processor in the past several years. This effort has culminated in a technology down-select to identify the optimum technology for future manned missions. The technology selection is based on various criteria, including mass, power, reliability, maintainability, and safety. Beginning in 2016 the selected technology will be transitioned to a flight hardware program for demonstration on ISS. This paper summarizes the technology selection process, the competing technologies, and the rationale for the technology selected for future manned missions.

Carter, Donald L.↗
NASA NTRS2012

Overview of NASA's Microgravity Materials Science Program

The microgravity materials program was nearly eliminated in the middle of the aughts due to budget constraints. Hardware developments were eliminated. Some investigators with experiments that could be performed using ISS partner hardware received continued funding. Partnerships were established between US investigators and ESA science teams for several investigations. ESA conducted peer reviews on the proposals of various science teams as part of an ESA AO process. Assuming he or she was part of a science team that was selected by the ESA process, a US investigator would submit a proposal to NASA for grant funding to support their part of the science team effort. In a similar manner, a US materials investigator (Dr. Rohit Trivedi) is working as a part of a CNES selected science team. As funding began to increase another seven materials investigators were selected in 2010 through an NRA mechanism to perform research related to development of Materials Science Research Rack investigations. One of these has since been converted to a Glovebox investigation.

Downey, James Patton↗
NASA NTRS1975

On the variational equations for Householder transformations in feature selection

Results that suggest the possibility of using a sequential monotone process for solving the feature selection problem using Householder transformations are applied to the divergence separability criterion and an expression for the gradient of the divergence with respect to the generator of a single Householder transformation will be developed. This expression for the gradient is used in any number of differential correction schemes (iterators) that attempt to extremize the divergence. Data sets provided by the Earth Observations Division-JSC are used to demonstrate selecting the Householder transformations that generate the kxn matrix defining the best (in the sense of extremizing the divergence) k linear combinations of features. The tests allow initial comparisons to be made with results. In particular, this technique does not appear to require initial guesses for the iterator to be generated without replacement, exhaustive search, or other similar schemes.

Decell, H. P., Jr.↗
NASA NTRS1992

Army (MANTECH) Thrust Area Concept: Optics Thrust Area

With the shrinking of the U.S. Army's material needs and the compression of defense requirements, the Army Manufacturing Technology (MANTECH) Program has the opportunity to advance the manufacturing state-of-the-art and solve near term production problems of the U.S. industrial base. To exploit this opportunity, the Army restructured its MANTECH efforts in FY 90 based on a thrust area concept. Each of the ten current thrusts, directed by a thrust area manager, has a broad technical objective selected to improve specific manufacturing processes. The manager is charged with setting objectives, selecting tasks, monitoring execution, leveraging external resources, and establishing microfactories to promote technology transfer. The Optics Manufacturing Thrust is an example of the concept. It is currently directed at revitalizing the domestic precision optics manufacturing base, now characterized by high labor costs and 1940's technology, through introduction of revolutionary machines, new processes, and Computer Integrated Manufacturing (CIM) principles. Leveraging of MANTECH dollars with those of industry, academia, and state governments led to the establishment of the center for Optics Manufacturing and plans for regional centers. Recognition of the U.S. as a world leader in precision optics manufacturing and a dramatic reduction of both manufacturing time and cost should accrue from thrust area efforts.

Kopacz, Stanley P.↗
NASA NTRS1994

An examination of anticipated g-jitter on Space Station and its effects on materials processes

This study is concerned with the effects of g-jitter, the residual acceleration aboard spacecraft, on selected classes of materials processes. In particular, the anticipated acceleration environment aboard Space Station Freedom (SSF) and its potential effects are analyzed, but the topic is covered with a sufficient level of generality as to apply to other processes and to other vehicles as well. Some of the key findings of this study include: The present acceleration specifications for SSF are inadequate to assure a quality level low-g environment. The local g vector orientation is an extremely sensitive parameter for certain key processes, but can not be controlled to within the desired tolerance. Therefore, less emphasis should be placed upon achieving a tight control of SSF attitude, but more emphasis should be focused on reducing the overall level of the g-jitter magnitude. Melt-based crystal growth may not be successfully processed in the relatively noisy environment of a large inhabited space structure. Growth from vapor or from solution appears more favorable. A smaller space structure and/or a free flyer can provide better alternatives in terms of g-jitter considerations. A high priority (including budgetary) should be given to coordinated efforts among researchers, SSF designers, and equipment contractors, to develop practical experiment-specific sensitivity requirements. Combined focused numerical simulations and experiments with well-resolved acceleration measurements should be vigorously pursued for developing reliable experiment-specific sensitivity data. Appendices provide an extensive cross-referenced bibliography, a discussion of the merits offered by g-jitter analysis techniques, as well as definitions of relevant nondimensional quantities and a brief description of available accelerometry hardware.

Nelson, Emily S.↗
NASA NTRS2006

Selective Plasma Deposition of Fluorocarbon Films on SAMs

A dry plasma process has been demonstrated to be useful for the selective modification of self-assembled monolayers (SAMs) of alkanethiolates. These SAMs are used, during the fabrication of semiconductor electronic devices, as etch masks on gold layers that are destined to be patterned and incorporated into the devices. The selective modification involves the formation of fluorocarbon films that render the SAMs more effective in protecting the masked areas of the gold against etching by a potassium iodide (KI) solution. This modification can be utilized, not only in the fabrication of single electronic devices but also in the fabrication of integrated circuits, microelectromechanical systems, and circuit boards. In the steps that precede the dry plasma process, a silicon mold in the desired pattern is fabricated by standard photolithographic techniques. A stamp is then made by casting polydimethylsiloxane (commonly known as silicone rubber) in the mold. The stamp is coated with an alkanethiol solution, then the stamp is pressed on the gold layer of a device to be fabricated in order to deposit the alkanethiol to form an alkanethiolate SAM in the desired pattern (see figure). Next, the workpiece is exposed to a radio-frequency plasma generated from a mixture of CF4 and H2 gases. After this plasma treatment, the SAM is found to be modified, while the exposed areas of gold remain unchanged. This dry plasma process offers the potential for forming masks superior to those formed in a prior wet etching process. Among the advantages over the wet etching process are greater selectivity, fewer pin holes in the masks, and less nonuniformity of the masks. The fluorocarbon films formed in this way may also be useful as intermediate layers for subsequent fabrication steps and as dielectric layers to be incorporated into finished products.

Crain, Mark M., III↗
NASA NTRS1992

Sensor-model prediction, monitoring and in-situ control of liquid RTM advanced fiber architecture composite processing

In-situ frequency dependent electromagnetic sensors (FDEMS) and the Loos resin transfer model have been used to select and control the processing properties of an epoxy resin during liquid pressure RTM impregnation and cure. Once correlated with viscosity and degree of cure the FDEMS sensor monitors and the RTM processing model predicts the reaction advancement of the resin, viscosity and the impregnation of the fabric. This provides a direct means for predicting, monitoring, and controlling the liquid RTM process in-situ in the mold throughout the fabrication process and the effects of time, temperature, vacuum and pressure. Most importantly, the FDEMS-sensor model system has been developed to make intelligent decisions, thereby automating the liquid RTM process and removing the need for operator direction.

Kranbuehl, D.↗
NASA NTRS1975

Materials and processes for space shuttle's engines

It is pointed out that over 50 different alloys are used in construction of the space shuttle main engines (SSME). Primary construction of the SSME is by welding or brazing of wrought and cast components. Welding processes involve both gas tungsten-arc welds and electron-beam welds. Electroforming has been developed as a process to fabricate and bond structural members for the SSME. Important aspects in the selection of materials and processes are related to weight saving considerations and the high-pressure hydrogen environment. Special problems and their solution in the case of various engine components are discussed, giving attention to the oxidizer preburner, the high pressure oxidizer turbopump, and the heat exchanger.

J. R. Lewis↗
NASA NTRS1992

Composite intermediate case manufacturing scale-up for advanced engines

This Manufacturing Technology for Propulsion Program developed a process to produce a composite intermediate case for advanced gas turbine engines. The method selected to manufacture this large, complex part uses hard tooling for surfaces in the airflow path and trapped rubber to force the composite against the mold. Subelements were manufactured and tested to verify the selected design, tools, and processes. The most significant subelement produced was a half-scale version of a composite intermediate case. The half-scale subelement maintained the geometry and key dimensions of the full-scale case, allowing relevant process development and structural verification testing to be performed on the subelement before manufacturing the first full-scale case.

Ecklund, Rowena H.↗
NASA NTRS1992

Evolution of catalytic RNA in the laboratory

We are interested in the biochemistry of existing RNA enzymes and in the development of RNA enzymes with novel catalytic function. The focal point of our research program has been the design and operation of a laboratory system for the controlled evolution of catalytic RNA. This system serves as working model of RNA-based life and can be used to explore the catalytic potential of RNA. Evolution requires the integration of three chemical processes: amplification, mutation, and selection. Amplification results in additional copies of the genetic material. Mutation operates at the level of genotype to introduce variability, this variability in turn being expressed as a range of phenotypes. Selection operates at the level of phenotype to reduce variability by excluding those individuals that do not conform to the prevailing fitness criteria. These three processes must be linked so that only the selected individuals are amplified, subject to mutational error, to produce a progeny distribution of mutant individuals. We devised techniques for the amplification, mutation, and selection of catalytic RNA, all of which can be performed rapidly in vitro within a single reaction vessel. We integrated these techniques in such a way that they can be performed iteratively and routinely. This allowed us to conduct evolution experiments in response to artificially-imposed selection constraints. Our objective was to develop novel RNA enzymes by altering the selection constraints in a controlled manner. In this way we were able to expand the catalytic repertoire of RNA. Our long-range objective is to develop an RNA enzyme with RNA replicase activity. If such an enzyme had the ability to produce additional copies of itself, then RNA evolution would operate autonomously and the origin of life will have been realized in the laboratory.

Joyce, Gerald F.↗
NASA NTRS2001

The Role of Convection and Growth Competition in Phase Selection in Microgravity: Controlled Convection in the Containerless Processing of Steel Alloys

Containerless processing using electromagnetic levitation (EML) is a powerful technique in the investigation of reactive molten metal systems. On ground, the power required to overcome the weight of the sample is sufficient to cause significant heating and induce substantial melt convection. In microgravity, the heating and positioning fields may be decoupled and the field strength may be varied to achieve the desired level of convection within the limits set by the geometry of the levitation coil and the sample size. From high-speed digital images of the double recalescence behavior of Fe-Cr-Ni alloys in ground-based testing and in reduced-gravity aboard the NASA KC-135 parabolic aircraft, we have shown that phase selection can be predicted based on a growth competition model. An important parameter in this model is the delay time between primary nucleation and subsequent nucleation of the stable solid within the liquid/metastable solid array. This delay time is a strong function of composition and a weak function of the undercooling of the melt below the metastable liquidus. From the results obtained during the first Microgravity Sciences Laboratory (MSL-1) mission, we also know that convection may significantly influence the delay time, especially at low undercoolings. Currently, it is unclear what mechanism controls the formation of a heterogeneous site that allows nucleation of the austenitic phase on the pre-existing ferrite skeleton. By examining the behavior of the delay time under different convective conditions, we hypothesize that we can differentiate between several of these mechanisms to gain an understanding of how to control microstructural. evolution. We will anchor these predictions by examining samples quenched at different times following primary recalescence in microgravity. A second important parameter in the growth competition model is the identification of the growth rate of the stable phase into the semi-solid array that formed during primary recalescence. Current dendritic growth theory is inadequate in predicting solidification behavior under these conditions as metallographic analyses show that stable phase growth proceeds along the interface between the metastable solid and residual liquid. Since growth velocity is independent of the initial undercooling relative to the metastable liquidus, we hypothesize that purely thermal effects can be separated from other important growth model parameters by careful selection of the liquid composition in a ternary system.

Matson, D. M.↗