Results for “Process Development and Demonstration” — Page 43

NASA NTRS2018

Engineering Trade-off Considerations Regarding Design-for-Security, Design-for-Verification, and Design-for-Test

The United States government has identified that application specific integrated circuit (ASIC) and field programmable gate array (FPGA) hardware are at risk from a variety of adversary attacks. This finding affects system security and trust. Consequently, processes are being developed for system mitigation and countermeasure application. The scope of this tutorial pertains to potential vulnerabilities and countermeasures within the ASIC/FPGA design cycle. The presentation demonstrates how design practices can affect the risk for the adversary to: change circuitry, steal intellectual property, and listen to data operations. An important portion of the design cycle is assuring the design is working as specified or as expected. This is accomplished by exhaustive testing of the target design. Alternatively, it has been shown that well established schemes for test coverage enhancement (design-for-verification (DFV) and design-for-test (DFT)) can create conduits for adversary accessibility. As a result, it is essential to perform a trade between robust test coverage versus reliable design implementation. The goal of this tutorial is to explain the evolution of design practices; review adversary accessibility points due to DFV and DFT circuitry insertion (back door circuitry); and to describe common engineering trade-off considerations for test versus adversary threats.

Design for reliability (DFR)↗

NASA NTRSDate not supplied

A Review Towards the Design Optimization of High Performance Additively Manufactured Rotating Detonation Rocket Engine Injectors

Rotating Detonation Rocket Engines (RDRE) have been marketed primarily for their higher specific impulse potential over constant pressure (CP) liquid rocket engines. However, several other performance advantages exist with RDREs over CP engines such as heat transfer advantages for gas expander cycle, increased completeness of combustion at low chamber L*, compact engine design, reduced coolant channel pressure drop potential, and improved injector C* performance. NASA has paved the way for liquid engine system performance enhancement since the Apollo program and continues to do so with metal additive manufacturing (AM), super-alloy materials, and advanced propulsion concepts. A team of propulsion development engineers at NASA are in the process of developing high-performance 7K lbf class RDRE hardware for their potential use in lander, upper stage, and even launch vehicle applications. Clear advantages have been demonstrated with AM including program cost and schedule reductions of up to 50%. It is well known that injector performance is integrally linked to the global performance of a combustion device. This is especially the case for RDREs since detonation stability is heavily dependent on the mixedness of propellants. A major program goal is to rapidly produce ultra-high-performance AM injectors. This paper reviews the available literature on liquid rocket injector design optimization as well as the experimental work conducted to date on injectors tested in RDREs. Major lessons learned are document and suggestions given towards the design of high-performance liquid RDRE injectors. In addition, the integration of metal AM into the design of liquid RDRE injector schemes is discussed. Finally, several candidate AM RDRE injector elements were produced to obtain their diodicity and cold flow characteristics.

rotating detonation engine↗

NASA NTRSDate not supplied

A Review Towards the Design Optimization of High-Performance Additively Manufactured Rotating Detonation Rocket Engine Injectors

Rotating Detonation Rocket Engines (RDRE) have been marketed primarily for their higher specific impulse potential over constant pressure (CP) liquid rocket engines. However, several other performance advantages exist such as heat transfer advantages for gas expander cycle, increased completeness of combustion at low chamber L*, compact engine design, reduced coolant channel pressure drop potential, and improved injector C* performance. NASA has paved the way for liquid engine system performance enhancement since the Apollo program and continues to do so with metal additive manufacturing (AM), new advanced materials, and advanced propulsion concepts. A team of propulsion development engineers at NASA are in the process of developing high-performance 7K lbf class RDRE hardware for their potential use in lander, upper stage, and even launch vehicle applications. Clear advantages have been demonstrated with AM including program cost and schedule reductions of up to 50%. It is well known that injector performance is integrally linked to the global performance of a combustion device. This is especially the case for RDREs since detonation stability is heavily dependent on the mixedness of propellants. A major goal of this work is to identify what has been done in the open experimental literature and what injectors design features are conducive to high performance in the detonation cycle. This paper reviews the available literature and reports the primary gaps in the knowledge base needed by the pressure gain combustion (PGC) community. Major conclusions are documented, and suggestions given towards the design of high-performance liquid RDRE injectors. In addition, the integration of metal AM into the design of liquid RDRE injector schemes is included.

rotating detonation rocket engine↗

NASA NTRSDate not supplied

AIST Technology Perspectives for ESO Mission Processing and Open-sourced Science

NASA is formulating the Earth System Observatory (ESO), a set of Earth-focused missions to provide key information to guide efforts related to monitoring climate change, mitigating disasters, fighting forest fires, and improving real-time agricultural processes. Within that framework, this presentation will introduce the Advanced Collaborative Frameworks (ACF) concepts that have been developed as part of the Advanced Information Systems Technology (AIST) Program, demonstrating the capability for facilitating open-sourced science and with a strong transition/infusion potential.

Jacqueline Le Moigne↗

NASA NTRS2011

Model-Based Systems Engineering for Capturing Mission Architecture System Processes with an Application Case Study - Orion Flight Test 1

Model-based Systems Engineering (MBSE) is an emerging methodology that can be leveraged to enhance many system development processes. MBSE allows for the centralization of an architecture description that would otherwise be stored in various locations and formats, thus simplifying communication among the project stakeholders, inducing commonality in representation, and expediting report generation. This paper outlines the MBSE approach taken to capture the processes of two different, but related, architectures by employing the Systems Modeling Language (SysML) as a standard for architecture description and the modeling tool MagicDraw. The overarching goal of this study was to demonstrate the effectiveness of MBSE as a means of capturing and designing a mission systems architecture. The first portion of the project focused on capturing the necessary system engineering activities that occur when designing, developing, and deploying a mission systems architecture for a space mission. The second part applies activities from the first to an application problem - the system engineering of the Orion Flight Test 1 (OFT-1) End-to-End Information System (EEIS). By modeling the activities required to create a space mission architecture and then implementing those activities in an application problem, the utility of MBSE as an approach to systems engineering can be demonstrated.

Orion Flight Test 1 (OFT-1)↗

NASA NTRS2004

High Temperature VARTM with LaRC Polyimides

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 potential to reduce the manufacturing cost of composite structures. In VARTM, the fibrous preform is infiltrated on a rigid tool surface contained beneath a flexible vacuum bag. Both resin injection and fiber compaction are achieved under pressures of 101.3 KPa or less. Recent studies have demonstrated the feasibility of the VARTM process for fabrication of void free structures utilizing epoxy resin systems with fiber volume fractions approaching 60%. In this work, the VARTM process has been extended to the fabrication of composite panels from polyimide systems developed at the Langley Research Center. This work has focused on processing LARC(trademark) PETI-8 (Langley Research Center Phenylethynyl Terminated Imide- 8), an aromatic polyimide based on 3,3',4,4' -biphenyltetracarboxylic dianhydride, a 50:50 molar ratio of 3,4'-oxydianiline and 1,3-bis(3-aminophenoxy)benzene, with 4-phenylethynylphthalic anhydride as the endcapping agent. Various molecular weight versions were investigated to determine their feasibility of being processed by VARTM at elevated temperatures. An injection temperature of approximately 280 C was required to achieve the necessary viscosity (<5 Poise) for flow at VARTM pressures. Laminate quality and initial mechanical properties are presented for LARC(trademark) PETI-8 and 6k IM7 uniweave fabric.

Cano, Roberto J.↗

NASA NTRS2006

Delta-Doped High Purity Silicon UV-NIR CCDs with High QE and Low Dark Current

Delta doping process was developed on p-channel CCDs for MIDEX-Orion and JDEM/SNAP and was applied to large format (2k x4k) CCDs. Delta doping is applied to fully-fabricated CCDs (complete with Al metallization). High QE and low dark current is demonstrated with delta doped p-channel CCDs. In-house AR coating is demonstrated. Advantages include: Delta doping enables high QE and stability across the entire spectral range attainable with silicon. Delta doping is a low temperature process and is compatible with fully-fabricated detector arrays. Same base device for Orion two channels. High radiation tolerance and no thinning requirements of high purity p-channel. CCDs are additional advantages.

Orion↗

NASA NTRS1975

Some recent developments in predicting unsteady loadings caused by control surface motions

Solution instabilities are identified within the procedures used to predict unsteady loadings due to motions of swept hingeline control surfaces. A preferred solution process that demonstrates the need of calculating smooth residual downwash distributions is described. Numerical results displaying erratic solution behavior when use is made of various forms of pressure expressions currently employed in control surface analyses are presented. A new expression of the asymptotic pressure function is derived, which exactly satisfies the change in boundary conditions around the boundary of the control surface. Results of applying the new pressure function are presented and indicate that stable converged solutions may be achieved for predicting the unsteady loadings caused by motions of swept hingeline control surfaces.

Rowe, W. S.↗

NASA NTRS1976

Development of autoclave moldable addition-type polyimides

Chemistry and processing modifications of the poly(Diels Alder) polyimide (PDA) resin were performed to obtain structural composites suitable for 589 K (600 F) service. This work demonstrated that the PDA resin formulation is suitable for service at 589 K (600 F) for up to 125 hours when used in combination with Hercules HTS graphite fiber. Sandwich panels were autoclave molded using PDA/HTS skins and polyimide/glass honeycomb core. Excellent adhesion between honeycomb core and the facing skins was demonstrated. Fabrication ease was demonstrated by autoclave molding three-quarter scale YF-12 wing panels.

Vaughan, R. W.↗

NASA NTRS2020

Miniaturized Laser Absorption Spectrometer for Combustion Calorimetry and Process Monitoring

A miniaturized tunable laser absorption spectrometer capable of measuring gas-phase concentrations of CO, CO2, and O2 has been developed for operation in spacecraft environments. As part of the Spacecraft Fire Safety Demonstration (Saffire) project, we previously demonstrated the Combustion Product Monitor (CPM) instrument to characterize pyrolysis of relevant test materials in low gravity aboard a transfer vehicle returning from low Earth orbit. Here, we adapted the CPM instrument design to achieve detection of CO, CO2, and O2 with improved minimum detection limits and dynamic range as well as reduced instrument size and power. The instrument can be operated in either an open or sealed configureation, allowing for ambient gas composition measuremnts or in-line monitoring of gas streams. By accurately monitoring CO, CO2, and O2 with broad pressure/temperature calibration and response time on the order of 1 s, the instrument can be used to characterize the dynamics of combustion reactions in a variety of environments.

Briggs, Ryan M.↗

NASA NTRS1977

Zero-G processing of magnets. Experiment MA-070

The magnetic compounds under study, manganese-bismuth (MnBi) copper-cobalt-cerium (Cu,Co)5Ce, are representative of magnetic alloy systems that have the potential for the development of high coercive strength and a high energy product. The samples of 50 at. % bismuth and 50 at. % manganese solidified in the low-g environment demonstrated a substantial improvement in the macroscopic chemical homogeneity. The bismuth/manganese-bismuth directionally solidified eutectic flight samples exhibited marked superior magnetic properties. Intrinsic coercive strengths in excess of 185 Koe have been measured in the low-g processed samples at 77 K. The average value of inductance was improved by 76 percent, and the energy product was improved by 57 percent. Additional results indicate that, in the near-absence of the gravitational body force, contained fluids will assume a lowest energy configuration that differs significantly from that found terrestrially.

Larson, D. J., Jr.↗

NASA NTRSDate not supplied

Integral Channel Nozzles and Heat Exchangers using Additive Manufacturing Directed Energy Deposition NASA HR-1 Alloy

Heat exchangers for use in propulsion applications are very critical components because they must be efficient, compact and light and often operate with working fluids at extreme temperatures or pressures or both. Various components and systems use heat exchangers such as combustion chambers of gas turbines and internal combustion engines, fuel cells (air supply and thermal management), electric batteries (thermal management), evaporators and recuperators of waste-heat-to-power systems, and rocket engines. Even if the results are more generally applicable, the heat exchangers applications to which this study is more closely related are regeneratively cooled rocket nozzles and chambers, and repressurization systems for the launch vehicles. These components are often thin-walled and contain pressurized fluids, like propellants at cryogenic or elevated temperatures. Given that the environments that these propulsion components must endure are challenging, the manufacturing to meet these specifications often require long lead times due to specialty processes and unique tooling associated with the combined thin-wall integral channel and large-scale structures. Additive manufacturing (AM) offers programmatic advantages for reduction in processing time and cost in addition to various technical advantages, including the possibility to achieve enhanced hardware complexity targeted to superior performance, part consolidation, and the capability of processing of novel alloys. While AM is already being utilized for heat exchanger components in propulsion applications, almost all these AM components are made by means of Laser Powder Bed Fusion (L-PBF). L-PBF allows for fine features but is rather limited with respect to the overall size of the components that can be manufactured. Recent developments are maturing the Laser Powder Directed Energy Deposition (LP-DED) process which may be used, for example, to make integral channel thin-wall regeneratively-cooled rocket nozzles with diameters greater than 1 m. This paper highlights some integral channel heat exchanger demonstrator hardware applications of LP-DED, as well as the characterization of this process in combination with the use of the NASA HR-1 alloy. To properly utilize LP-DED for heat exchanger manufacturing, various aspects are being characterized such as geometry limitations, measurement of surface texture and geometric angled surfaces, surface enhancements for internal channels, and material evaluation. NASA HR-1 (FeNi-Cr) is a high strength hydrogen resistant superalloy developed for use in aerospace applications, such as heat exchangers. Some aspects and considerations about the design of heat exchangers are summarized together with data relevant to LP-DED manufacturing in combination with the NASA HR-1 alloy. Microchannels were successful deposited down to 2.54 mm and 1 mm wall thickness, wall angles of 30°, both with high reproducibility. It was also found that the areal surface roughness is highly dependent on the size of the powder feedstock used for deposition. The characterization of these LP-DED features is critical for fluid flow and heat transfer predictions as it can be exploited to enhance heat transfer at the cost of increased pressure drop.

Additive Manufacturing↗

NASA NTRSDate not supplied

Integral Channel Nozzles and Heat Exchangers using Additive Manufacturing Directed Energy Deposition NASA HR-1 Alloy

Heat exchangers for use in propulsion applications are very critical components because they must be efficient, compact and light and often operate with working fluids at extreme temperatures or pressures or both. Various components and systems use heat exchangers such as combustion chambers of gas turbines and internal combustion engines, fuel cells (air supply and thermal management), electric batteries (thermal management), evaporators and recuperators of waste-heat-to-power systems, and rocket engines. Even if the results are more generally applicable, the heat exchangers applications to which this study is more closely related are regeneratively cooled rocket nozzles and chambers, and repressurization systems for the launch vehicles. These components are often thin-walled and contain pressurized fluids, like propellants at cryogenic or elevated temperatures. Given that the environments that these propulsion components must endure are challenging, the manufacturing to meet these specifications often require long lead times due to specialty processes and unique tooling associated with the combined thin-wall integral channel and large-scale structures. Additive manufacturing (AM) offers programmatic advantages for reduction in processing time and cost in addition to various technical advantages, including the possibility to achieve enhanced hardware complexity targeted to superior performance, part consolidation, and the capability of processing of novel alloys. While AM is already being utilized for heat exchanger components in propulsion applications, almost all these AM components are made by means of Laser Powder Bed Fusion (L-PBF). L-PBF allows for fine features but is rather limited with respect to the overall size of the components that can be manufactured. Recent developments are maturing the Laser Powder Directed Energy Deposition (LP-DED) process which may be used, for example, to make integral channel thin-wall regeneratively-cooled rocket nozzles with diameters greater than 1 m. This paper highlights some integral channel heat exchanger demonstrator hardware applications of LP-DED, as well as the characterization of this process in combination with the use of the NASA HR-1 alloy. To properly utilize LP-DED for heat exchanger manufacturing, various aspects are being characterized such as geometry limitations, measurement of surface texture and geometric angled surfaces, surface enhancements for internal channels, and material evaluation. NASA HR-1 (FeNi-Cr) is a high strength hydrogen resistant superalloy developed for use in aerospace applications, such as heat exchangers. Some aspects and considerations about the design of heat exchangers are summarized together with data relevant to LP-DED manufacturing in combination with the NASA HR-1 alloy. Microchannels were successful deposited down to 2.54 mm and 1 mm wall thickness, wall angles of 30°, both with high reproducibility. It was also found that the areal surface roughness is highly dependent on the size of the powder feedstock used for deposition. The characterization of these LP-DED features is critical for fluid flow and heat transfer predictions as it can be exploited to enhance heat transfer at the cost of increased pressure drop.

additive manufacturing↗

NASA NTRS1998

Vacuum Plasma Spray (VPS) Forming of Solar Thermal Propulsion Components Using Refractory Metals

The Thermal Spray Laboratory at NASA's Marshall Space Flight Center has developed and demonstrated a fabrication technique using Vacuum Plasma Spray (VPS) to form structural components from a tungsten/rhenium alloy. The components were assembled into an absorption cavity for a fully-functioning, ground test unit of a solar thermal propulsion engine. The VPS process deposits refractory metal onto a graphite mandrel of the desired shape. The mandrel acts as a male mold, forming the required contour and dimensions of the inside surface of the deposit. Tungsten and tungsten/25% rhenium were used in the development and production of several absorber cavity components. These materials were selected for their high temperature (less than 2500 C) strength. Each absorber cavity comprises 3 coaxial shells with two, double-helical flow passages through which the propellant gas flows. This paper describes the processing techniques, design considerations, and process development associated with forming these engine components.

Zimmerman, Frank↗

NASA NTRSDate not supplied

Printed Electrochemical Sensor for Quantifying Bone Density Loss in Microgravity

Printed electrochemical biosensors have been developed for astronaut point-of-care testing. Our fabrication approach is complimentary with in-space manufacturing for an on-demand and hands-free fabrication process. These sensors are developed using a combination of thin film materials printing and 3D printing and are comprised of carbon nanotube, gold nanoparticle, silver nanoparticle and dielectric inks to make traditional electrochemical sensor devices. Initial prototyped printed electrochemical sensors demonstrate good electrochemical performance while also displaying low batch to batch variability. Here we report the development of a printed sensor to monitor bone turnover. The absence of load bearing forces experienced in microgravity causes a reduction of overall bone mass and results in the development of space osteopenia/osteoporosis.(1,2) Our approach to identify space osteopenia/osteoporosis is to monitor the change in bone mass indirectly through an excreted biomarker of bone remodeling, amino-terminal collagen crosslinks (NTX). Antibodies specific to NTX are added to the sensor’s electrode ink and applied during the manufacturing process. NTX is measured from a urine sample by changes in voltammetry and electrochemical impedance as it binds to the antibody modified electrode surface. The measurement is rapid, quantitative and requires only small handheld electronics to perform the measurement. By this process, ground and flight physicians will receive frequent and real-time insight into the development of space osteopenia/osteoporosis to guide appropriate countermeasures. REFERENCES [1] Nabavi, N. et al (2011) Bone 49, 965-974. [2] Tamma, R. et al (2009) FASEB J 23, 2549-2554.

in-space manufacturing↗

NASA NTRS2013

Advanced Signal Processing for High Temperatures Health Monitoring of Condensed Water Height in Steam Pipes

An advanced signal processing methodology is being developed to monitor the height of condensed water thru the wall of a steel pipe while operating at temperatures as high as 250deg. Using existing techniques, previous study indicated that, when the water height is low or there is disturbance in the environment, the predicted water height may not be accurate. In recent years, the use of the autocorrelation and envelope techniques in the signal processing has been demonstrated to be a very useful tool for practical applications. In this paper, various signal processing techniques including the auto correlation, Hilbert transform, and the Shannon Energy Envelope methods were studied and implemented to determine the water height in the steam pipe. The results have shown that the developed method provides a good capability for monitoring the height in the regular conditions. An alternative solution for shallow water or no water conditions based on a developed hybrid method based on Hilbert transform (HT) with a high pass filter and using the optimized windowing technique is suggested. Further development of the reported methods would provide a powerful tool for the identification of the disturbances of water height inside the pipe.

health monitoring↗

NASA NTRS1999

Development Unit Configuration and Current Status of the MIP/MTERC Experiment

The Mars In-Situ Propellant Production (ISPP) Precursor (MIP) experiment package is planned for inclusion on the Mars 2001 Lander. This experiment package consists of five experiments whose purpose is to demonstrate the performance of various ISPP processes in-situ on Mars. The demonstrated ability to produce propellant for Mars Return Vehicles (MRV) is considered to be a necessary precursor to any future manned mission to Mars. The Mars Thermal Environment/Radiator Characterization (MTERC) experiment is part of the MIP package and is intended to determine the Mars night sky temperature as well as to characterize the performance degradation of radiators caused by environmental exposure on Mars over time. Radiators are needed as part of the ISPP process to remove heat from the Mars Atmosphere Acquisition and Compression (MAAC) CO2 sorption compressor. MTERC will provide the data needed to optimize the design of radiators for ISPP and other processes. A MTERC Development Unit (DU) has been fabricated and tested at JPL. The MTERC DU consists of 1) a radiator subassembly, 2) a motor/cover subassembly, 3) a differential temperature control circuit and motor control electronics circuit board, and 4) a command and data handling electronics circuit board. This paper will describe the operational theory and the configuration of the MTERC DU and will discuss the current status of the MTERC experiment development including some selected results of performance testing that has been completed prior to the ISRU III meeting.

Juanero, K. J.↗

NASA NTRS1999

Development Unit Configuration and Current Status of the MIP/MTERC Experiment

The Mars In-Situ Propellant Production (ISPP) Precursor (MIP) experiment package is planned for inclusion on the Mars 2001 Lander. This experiment package consists of five experiments whose purpose is to demonstrate the performance of various ISPP processes in-situ on Mars. The demonstrated ability to produce propellant for Mars Return Vehicles (MRV) is considered to be a necessary precursor to any future manned mission to Mars. The Mars Thermal Environment/Radiator Characterization (MTERC) experiment is part of the MIP package and is intended to determine the Mars night sky temperature as well as to characterize the performance degradation of radiators caused by environmental exposure on Mars over time. Radiators are needed as part of the ISPP process to remove heat from the Mars Atmosphere Acquisition and Compression (MAAC) C02 sorption compressor. MTERC will provide the data needed to optimize the design of radiators for ISPP and other processes. A MTERC Development Unit (DU) has been fabricated and tested at JPL. The MTERC DU consists of: (1) a radiator subassembly, (2) a motor/cover subassembly, (3) a differential temperature control circuit and motor control electronics circuit board, and (4) a command and data handling electronics circuit board. This paper will describe the operational theory and the configuration of the MTERC DU and will discuss the current status of the MTERC experiment development including some selected results of performance testing that has been completed prior to the ISRU III meeting.

Juanero, K. J.↗