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At least 739 records · Page 41

Estimation of the Thermal-Fluids and Thermal-Structural Performance of Helium-Cooled Modular Finger-Type Divertors

Over the past decade, our group has investigated the thermal-fluid performance of the helium-cooled modular divertor with multiple jets (HEMJ) and a simplified “flat” design of the HEMJ for long-pulse magnetic fusion energy (MFE) reactors. Experimental studies were performed in a helium (He) loop at the prototypical pressure of 10 MPa, nearly prototypical He temperatures and incident heat fluxes using test sections made from stainless steel and tungsten alloys. Correlations for average Nusselt numbers and pressure loss coefficients were developed from the data and are used to validate computational fluid dynamics (CFD) models. Here, this work presents updated thermal-fluids performance curves based on these correlations that estimate the maximum heat flux that can be accommodated by the plasma-facing surface and coolant pumping power requirements at prototypical operating conditions. Thermal-structural performance curves developed from ITER structural design criteria are introduced, which include protection against ductile and non-ductile failure, ratcheting fatigue, and creep fatigue. The performance design curves for these finger-type divertors demonstrate that the “flat” design, with a significantly less complicated geometry than the HEMJ, has thermal-fluid and thermal-structural performance comparable to the original HEMJ concept, and may be superior in terms of non-ductile failure criteria.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Embedding ceramic components in metal structures with hybrid directed energy deposition

The combined benefit of both additive and subtractive manufacturing within the same gantry system enables hybrid directed energy deposition to create complex geometries with smooth surface finish and superior dimensional accuracy. Moreover, with layer-by-layer access to the structure during both the addition and subtraction of material, the insertion of components is now possible, assuming the components can survive the high temperatures associated with the subsequent metal deposition. Ceramic inserts are of interest for a variety of reasons including (1) to create complex interwoven ductile/brittle composites for ballistics or high-temperature applications or (2) to integrate high-temperature strain or temperature sensors protected within ceramic substrate subsumed into a larger metal structure. Here, in this work, stainless steel substrates were machined to create an internal cavity for the insertion of a ceramic component. During the investigation of several different over-the-ceramic deposition strategies, components were inserted, and different process sequences were allowed to continue to envelop the inserted ceramic with varying success. Unmelted powder was used to serve both as a thermal buffer and to provide a flush surface upon which the laser cladding could continue. Subsequent depositions were attempted with both dry and wet powder (addition of machining coolant to wet). The wet powder has previously been demonstrated to not significantly impact the mechanical properties of a final structure and provided a thermal barrier to protect the ceramic piece from the extreme temperatures of the final metal deposition. The wetting of the powder provided stability and minimized displacement caused by the powder flow from the laser cladding head. Finally, the use of an oblique angle for laser cladding allowed for the redirection of some fraction of the introduced thermal energy away from the ceramic component and, consequently, improved the survival of the ceramic inserts. With this combination of techniques, ceramic inserts survived full embedding within a 3D-printed stainless steel structure.

36 MATERIALS SCIENCE↗

Recent Advancements in Modeling and Simulation of Entry Systems at NASA

This paper describes recent development of modeling and simulation technologies for entry systems in support of NASA’s exploration missions. Mission-tailored research and development in modeling of entry systems occurs across the Agency (e.g., within the Orion and Mars 2020 Programs), however the aim of this paper is to discuss the broad, cross-mission research conducted by NASA’s Entry Systems Modeling (ESM) Project, which serves as the Agency’s only concerted effort toward advancing entry systems across a range of technical disciplines. Technology development in ESM is organized and prioritized from a system-level perspective, resulting in four broad technical areas of investment: (1) Predictive material modeling, (2) Shock layer kinetics and radiation, (3) Computational and experimental aerosciences, and (4) Guidance, navigation, and control. Investments in thermal protection material modeling are geared toward high-fidelity, predictive models capable of handling complex structures, with an eye toward optimizing design performance and quantifying thermal protection system reliability. New computational tools have been developed to characterize material properties and behavior at the microstructural level, and experimental techniques (molecular beam scattering, micro-computed tomography, among others) have been developed to measure material kinetics, morphology, and other parameters needed to inform and validate detailed simulations. Advancements have also been made in macrostructural simulation capability to enable 3-D system-scale calculations of material response with complex topological features, including differential recession of tile gaps. Research and development in the area of shock layer kinetics has focused on air and CO2-based atmospheres. Capacity and capability of the NASA Ames Electric Arc Shock Tube (EAST) have been expanded in recent years and analysis of resulting data has led to several improvements in kinetic models, while simultaneously reducing uncertainties associated with radiative heat transfer predictions. First-principles calculations of fundamental kinetic, thermodynamic, and transport data, along with state-specificmodels for non-equilibrium flow regimes, have also yielded new insights and have the potential to vastly improve model fidelity. Aerosciences is a very broad area of interest in entry systems, yet a number of important challenges are being addressed: Coupled fluid-structure simulations of parachute inflation and dynamics; Experimental and computational studies of vehicle dynamics; Multi-phase flow with dust particles to simulate entry environments at Mars during dust storms; Studies of roughness-induced heating augmentation relevant to tiled and woven thermal protection systems; and Advanced numerical methods to optimize computational analyses for desired accuracy versus cost. Guidance and control in the context of entry systems has focused on development of methods for multi-axis control (i.e. pitch and yaw, rather than bank angle alone) of spacecraft during entry and descent. With precision landing requirements driven by Mars human exploration goals, recent efforts have yielded 6-DOF models of multi-axis control with propulsive descent of both inflatable and rigid ellipsled-like architectures. Results for both configurations have demonstrated the ability to land within the 50-meter precision requirement demanded by Mars human exploration missions, while also reducing propellant requirements by enabling more efficient control through entry and descent. Ongoing research in GN&C is developing mechanical specifications for the systems and establishing engineering feasibility.

aerothermodynamics↗

Recent Advancements in Modeling and Simulation of Entry Systems at NASA

This paper describes recent development of modeling and simulation technologies for entry systems in support of NASA's exploration missions. Mission-tailored research and development in modeling of entry systems occurs across the Agency (e.g., within the Orion and Mars 2020 Programs), however the aim of this paper is to discuss the broad, cross-mission research conducted by NASA's Entry Systems Modeling (ESM) Project, which serves as the Agency's only concerted effort toward advancing entry systems across a range of technical disciplines. Technology development in ESM is organized and prioritized from a system-level perspective, resulting in four broad technical areas of investment: (1) Predictive material modeling, (2) Shock layer kinetics and radiation, (3) Computational and experimental aerosciences, and (4) Guidance, navigation, and control. Investments in thermal protection material modeling are geared toward high-fidelity, predictive models capable of handling complex structures, with an eye toward optimizing design performance and quantifying thermal protection system reliability. New computational tools have been developed to characterize material properties and behavior at the microstructural level, and experimental techniques (molecular beam scattering, micro-computed tomography, among others) have been developed to measure material kinetics, morphology, and other parameters needed to inform and validate detailed simulations. Advancements have also been made in macrostructural simulation capability to enable 3-D system-scale calculations of material response with complex topological features, including differential recession of tile gaps. Research and development in the area of shock layer kinetics has focused on air and CO2-based atmospheres. Capacity and capability of the NASA Ames Electric Arc Shock Tube (EAST) have been expanded in recent years and analysis of resulting data has led to several improvements in kinetic models, while simultaneously reducing uncertainties associated with radiative heat transfer predictions. First-principles calculations of fundamental kinetic, thermodynamic, and transport data, along with state-specific models for non-equilibrium flow regimes, have also yielded new insights and have the potential to vastly improve model fidelity. Aerosciences is a very broad area of interest in entry systems, yet a number of important challenges are being addressed: Coupled fluid-structure simulations of parachute inflation and dynamics; Experimental and computational studies of vehicle dynamics; Multi-phase flow with dust particles to simulate entry environments at Mars during dust storms; Studies of roughness-induced heating augmentation relevant to tiled and woven thermal protection systems; and Advanced numerical methods to optimize computational analyses for desired accuracy versus cost. Guidance and control in the context of entry systems has focused on development of methods for multi-axis control (i.e. pitch and yaw, rather than bank angle alone) of spacecraft during entry and descent. With precision landing requirements driven by Mars human exploration goals, recent efforts have yielded 6-DOF models of multi-axis control with propulsive descent of both inflatable and rigid ellipsled-like architectures.

Barnhardt, Michael D.↗

The case for a high-speed research airplane - Results from an in-house study

Results of a study aimed at determining the feasibility of developing a single versatile high-speed research airplane (HSRA) which will meet flight research needs of both Mach 3 to 5 JP-fueled military aircraft and of hydrogen-fueled aircraft, both military and civil, for speeds up to Mach 10. The proposed HSRA design concept is an air-launched, rocket-boosted research aircraft designed to accommodate a wide variety of large-scale propulsive and structural flight research experiments. The aircraft is a 60-foot-long discrete wing-body concept with high wings and a center-line vertical tail. Heat sink shields are proposed as an effective and versatile method of achieving low-cost, low-risk thermal protection of the all-aluminum primary structure.-

Kirkham, F. S.↗

The Shuttle tile story

The structural problems associated with the reusable thermal protection system (TPS) of the Space Shuttle Orbiter are assessed. The ceramic insulation was placed on the aluminum in the form of about 30,000 tiles over approximately 70% of the Orbiter's exterior. The tiles were bonded to felt pads, and then the tile-pad structure was attached to the aluminum skin. As Orbiter design progressed, it was discovered that the TPS would have to withstand loads greater than initially predicted. The group tensile strength was less than that of the individual components. This was the primary factor contributing to the delay of the first flight. Values are given for Orbiter isotherms during a normal flight as well as the corresponding TPS distribution. The complete TPS assemblage is shown schematically, noting the sequence of assembling the tile components into a testing specimen. It is noted that tensile loads are applied to the strain-isolation path at discrete regions along transverse fiber bundles, causing a 50% reduction in system tensile strength. Procedures for strengthening the interface between the insulation and strain-isolation path are discussed and flight-simulation tests are outlined.

Cooper, P. A.↗

Epoxy blanket protects milled part during explosive forming

Epoxy blanket protects chemically milled or machined sections of large, complex structural parts during explosive forming. The blanket uniformly covers all exposed surfaces and fills any voids to support and protect the entire part.

Source record↗

An enhanced Whipple Bumper system - Impact resistance of composite materials

For long-duration space flights where human occupation is expected, micrometeroid and debris shields are necessary to prevent puncture of the pressure vessels. Current 'Whipple Bumper' designs range from single thin sheets of aluminum to complicated structures of many energy absorbing layers. This paper details the results of an experimental program tao determine the increased protection afforded by intermediate bumpers made of composite material structures. Various configurations of honeycomb support structures sandwiched between layers of materials such as Kevlar, Spectra, aluminum, and others are inserted between the bumper and pressure shell. The areal densities of each new material structure are maintained constant so that the results compare directly with single-sheet aluminum intermediate bumpers.

Zwiener, J.↗

Elucidating Cathode Degradation Mechanisms in LiNi 0.8 Mn 0.1 Co 0.1 O 2 (NMC811)/Graphite Cells Under Fast Charge Rates Using Operando Synchrotron Characterization

Li-ion batteries capable of extreme fast charging (XFC) are in demand to facilitate widespread electric vehicle (EV) adoption. While the impact of fast charge on the negative electrode has been studied, degradation of state-of-the-art NMC811 under XFC conditions has not been studied in detail. Herein, cathode degradation is probed in NMC811/graphite batteries by analysis of structural and chemical changes for recovered samples previously cycled under XFC conditions and during typical cycling. NMC surface reconstruction, as determined by soft X-ray absorption, was not detected for recovered electrodes. Furthermore, bulk redox activity from X-ray absorption near edge structure measurements showed more change in the oxidation state of Ni and Co under the 1C charge rate compared to the 4C rate consistent with the electrochemistry. Increased unit cell volume contraction under the 1C rate as determined by operando X-ray diffraction suggests that higher charge rates may provide a protective effect on the cathode by reducing structural distortion due to less delithiation.

25 ENERGY STORAGE↗

Creep analysis capability for stiffened panel structures

A method of analysis developed for predicting permanent cyclic creep deflections in stiffened panel structures is presented. The resulting computer program (TPSC, for Thermal Protection System Creep) applies either the time hardening or strain hardening theories of creep accumulation, using iterative techniques to determine structural rotations, creep strains, and stresses as a function of time. Deflections are determined by numerical integration of structural rotations along the panel length. The analytical approach was developed for purposes of analyzing thin gage entry vehicle metallic thermal protection system panels subjected to cyclic bending loads at high temperatures. The method is applicable to any panel subjected to bending loads. Predicted panel creep deflections are compared with results from cyclic tests of subsize and full size corrugation and rib stiffened panels. Empirical equations used in the analysis were developed for each material based on correlation with tensile cyclic creep data.

Cramer, B. A.↗

Lightning protection technology for small general aviation composite material aircraft

An on going NASA (Small Business Innovative Research) SBIR Phase II design and development program will produce the first lightning protected, fiberglass, General Aviation aircraft that is available as a kit. The results obtained so far in development testing of typical components of the aircraft kit, such as the wing and fuselage panels indicate that the lightning protection design methodology and materials chosen are capable of protecting such small composite airframes from lightning puncture and structural damage associated with severe threat lightning strikes. The primary objective of the program has been to develop a lightening protection design for full scale test airframe and verify its adequacy with full scale laboratory testing, thus enabling production and sale of owner-built, lightning-protected, Stoddard-Hamilton Aircraft, Inc. Glasair II airplanes. A second objective has been to provide lightning protection design guidelines for the General Aviation industry, and to enable these airplanes to meet lightening protection requirements for certification of small airplanes. This paper describes the protection design approaches and development testing results obtained thus far in the program, together with design methodology which can achieve the design goals listed above. The presentation of this paper will also include results of some of the full scale verification tests, which will have been completed by the time of this conference.

Plumer, J. A.↗

Optimization of a Multifunctional Hot Structure Aeroshell for Mars Entry

Vehicle size and weight are driving cost factors in sending vehicles into space because the cost of launch is directly related to the payload mass being delivered. Vehicle size and weight have a larger impact on deep- space missions compared to sending a payload to low Earth orbit due to the extra fuel and supplies required to complete the longer duration mission. One area of study for possible vehicle volume or weight reduction is the thermal protection system (TPS) of a vehicle. Hot structures have been proposed as a TPS concept which can carry both primary structural loads and thermal loads. The use of hot structures on a Mars entry vehicle may be feasible and have potential volume and weight savings over the current state of the art ablative TPS technology. A preliminary trade study was performed on a mid lift-to-drag aeroshell Mars entry concept vehicle; comparing the weight and skin thickness of a vehicle using ablative TPS with a vehicle using hot structures. Independent thermal and structural analyses were performed to determine the minimum mass designs. The goal of this study was to determine if the use of hot structures was feasible and had potential for significant vehicle volume and weight savings over the current state of the art. This trade study found that use of a hot structures leads to a feasible alternative to ablative TPS technology, with potential 53% weight and 22% thickness (volume) saving benefits that could enable future missions.

Langston, Sarah L.↗

Techniques for aerothermal tests of large, flightweight thermal protection panels in a Mach 7 wind tunnel

Thermal performance and structural integrity are experimentally evaluated in the Langley 8-ft high temperature structures tunnel, which uses a combustion products test medium to provide realistic combinations of aerodynamic heating and loading. Recently developed techniques provide independent control of rate and magnitude of surface heating and differential pressure, protection against adverse acoustics buffeting during facility starting and stopping, programed radiant heating before exposing test panels to the high energy stream, and infrared radiometry for detailed surface temperatures. These techniques were verified repeatedly by return of useful data on metallic and nonmetallic panel concepts of reusable surface insulation.

Deveikis, W. D.↗

Versatile honeycomb matrix heat shield

A thermal protection system for atmospheric entry of a vehicle, the system including a honeycomb structure with selected cross sectional shapes that receives and holds thermally cured thermal protection (TP) blocks that have corresponding cross sectional shapes. Material composition for TP blocks in different locations can be varied to account for different atmospheric heating characteristics at the different locations. TP block side walls may be attached to all, or to less than all, the corresponding honeycomb structure side walls.

Zell, Peter T.↗

Long-Term Lunar Radiation Degradation Effects on Materials

The National Aeronautics and Space Administration (NASA) is focused on developing technologies for extending human presence beyond low Earth orbit. These technologies are to advance the state-of-the-art and provide for longer duration missions outside the protection of Earth's magnetosphere. One technology of great interest for large structures is advanced composite materials, due to their weight and cost savings, enhanced radiation protection for the crew, and potential for performance improvements when compared with existing metals. However, these materials have not been characterized for the interplanetary space environment, and particularly the effects of high energy radiation, which is known to cause damage to polymeric materials. Therefore, a study focusing on a lunar habitation element was undertaken to investigate the integrity of potential structural composite materials after exposure to a long-term lunar radiation environment. An overview of the study results are presented, along with a discussion of recommended future work.

Rojdev, Kristina↗

Fail-safe hydraulic shaker protection

Nine channel system controls acceleration and force on structure undergoing vibration stress testing. System has automatic and manually operative abort feature.

Woodbury, R. C.↗

Membrane lipids and the origin of life

The current state of knowledge regarding the development of biological systems is briefly reviewed. At a crucial stage concerning the evolution of such systems, the mechanisms leading to more complex structures must have evolved within the confines of a protected microenvironment, similar to those provided by the contemporary cell membranes. The major components found normally in biomembranes are phospholipids. The structure of the biomembrane is examined, and attention is given to questions concerning the availability of the structural components which are necessary in the formation of primitive lipid membranes. Two approaches regarding the study of protomembranes are discussed. The probability of obtaining ether lipids under prebiotic conditions is considered, taking into account the formation of cyclic and acyclic isoprenoids by the irradiation of isoprene with UV.

Oro, J.↗

Remote Optical Recession Measurement of Orion Thermal Protection System

For the Orion Multi-Purpose Crew Vehicle (MPCV) project, NASA is minimizing the use of onboard diagnostics, especially external sensors that penetrate the structure. Nonetheless, there is a desire to measure the Thermal Protection System (TPS) recession during reentry. One noninvasive technique currently under investigation is the insertion of indicator metals into the heatshield at varied depths and spatial locations. A remote (airborne) spectrometer detects the emissions from the ionized metal to reveal the time (thus depth) of the metal release. Innovative processing enables the emission features from trace amounts of the selected metals to be reliably detected against the complex and structured spectral background of the shock layer and ablated TPS material. The con-cept has been proven viable through ground testing at NASA HyMETS and AHF arc jet facilities using the Orion TPS material (Avcoat). This presentation highlights the parametric testing that was conducted to select the optimal indicator metals and to assess the accuracy of remote recession measurements using this technique. The CONOPS for integrating the technique into the Orion flight tests is also presented. This includes the onboard indicator metal "seeded plugs" and the offboard airborne sensor platform that would be deployed.

Scriven, Gordon↗