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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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Report contains sufficient information to assemble complete tested residential flat-plate solar heating system. Descriptive material provides design, performance, and hardware specifications for utilization by architectural engineers, and contractors in procurement, installation, operation, and maintenance of similar solar applications.
Material coupon tests were conducted to formulate design allowables for T300/5208 graphite/epoxy unidirectional tape and bidirectional fabric composites. This paper gives a description of the tests conducted, representative ply level and laminate test data, and results of the statistical analysis. The design allowables for tension and compression strength are given and include the effect of notches, impact damage, temperature extremes and moisture absorption.
The U.S. Advanced Launch System (ALS) effort has been established to reduce the cost of payload mass to orbit and increase launch reliability. One approach to reducing costs of primarily expendable launch vehicles is to recover and reuse the most costly elements (i.e., the main engines and the avionics hardware); this is the mission of the propulsion/avionics (P/A) module. This study was conducted to identify material and design options for P/A module structure. A critical structural element is the aeroshell which: (1) provides the reentry aerodynamic surface, (2) shields other subcomponents from reentry heating, and (3) absorbs touchdown loads. Two P/A module types are required for the ALS: one that flies a high-temperature return from orbit profile and another that flies a cooler suborbital profile. For system cost benefits, common structure is desired for both types. A design concept is developed for a honeycomb sandwich structure that can survive the suborbital-reentry heating rates and the return-from-orbit heating rates with an ablative thermal protection system. Thermal analyses show that structural temperatures from aerodynamic heating are within material capabilities. Stress analyses indicate the structural design can support the critical loads.
Block copolymers (BCPs) of an A-block-(B-random-C) architecture have been explored as materials for nanolithography because the composition and chemistry of the random block enables modification of thermodynamic and wetting properties to meet manufacturing criteria. Here, in this study, A-b-(B-r-C) BCPs created by an amidation reaction of polystyrene-block-poly(pentafluorophenyl methacrylate) (PS-b-PPFMA) with controlled amounts of Si add insight to previous conclusions about the dual contributions of BCP chemistry and reactive ion etch (RIE) gas chemistry on etch properties. We focus on two RIE etch characteristics: organosilicon etch resistance in H 2 /N 2 plasma etching and enhanced removal of non-styrenic structures in an Ar/O 2 etch. Consistent with previous studies, higher amounts of Si result in greater etch resistance under H 2 /N 2 RIE, where at least ∼10 wt. % Si is necessary to exhibit sufficient etch resistance. By contrast, Ar/O 2 etching resulted in etch rates independent of Si content. We observe previously unreported surface roughening aligned with morphological domains during the H 2 /N 2 etch of modified PS-b-PPFMA BCPs. Limited in the amount of allowable Si to attain equal surface energy between blocks, these BCPs are further disqualified in forming a Si-containing mask. However, in an Ar/O 2 etch, the same BCPs exhibit suitable etch contrast and smooth domain structures, forming a uniform PS mask. Ultimately, this study uses the chemical flexibility of these materials to demonstrate the mechanisms of interactions between BCP and etch chemistry that must be considered to design effective materials for pattern transfer applications.
NASA's program for applied research and technology (ART) in Thermionic Energy Conversion (TEC) has made worthwhile contributions in a relatively short time. Materials and designs previously prohibited by in-core nucleonics and geometrics now offer new potentialities. High-temperature material effects are crucial to the level and duration of TEC performance: New electrodes must increase and maintain power output regardless of emitter-vapor deposition on collectors. They must also serve compatibly with hot-shell alloys. And while space TEC must face high-temperature vaporization problems externally as well as internally, terrestrial TEC must tolerate hot corrosive atmospheres outside and near-vacuum inside. Furthermore, some modes for decreasing interelectrode losses appear to requisite rather demanding converter geometries to produce practical power densities.
A better understanding of the factors that affect the semi-circular edge-notched compressive strength is developed, and the associated failure mode(s) of thermoplastic composite laminates with multidirectional stacking sequences are identified. The primary variables in this investigation are the resin nonlinear shear constitutive behavior, stacking sequence (orientation of plies adjacent to the 0 degree plies), resin-rich regions between the 0 degree plies and the off-axis supporting plies, fiber/matrix interfacial bond strength, and initial fiber waviness. Two thermoplastic composite material systems are used in this investigation. The materials are the commercial APC-2 (AS4/PEEK) and a poor interface experimental material, AU4U/PEEK, designed for this investigation. Notched compression specimens are studied at 21, 77, and 132 C. Geometric and material nonlinear two-dimensional finite element analysis is used to model the initiation of fiber microbuckling of both the ideal straight fiber and the more realistic initially wavy fiber. The effects of free surface, fiber constitutive properties, matrix constitutive behavior, initial fiber curvature, and fiber/matrix interfacial bond strength on fiber microbuckling initiation strain levels are considered.
This paper details the development of a Helmholtz-driven, 2-axis gimbal to position a flat mirror within 50 microradian (fine positioning) in a space environment. The gimbal is intended to travel on a deep space mission mounted on a miniature "rover" vehicle. The gimbal will perform both pointing and scanning functions. The goal for total mass of the gimbal was 25 grams. The primary challenge was to design and build a bearing system that would achieve the required accuracy in addition to supporting the relatively large mass of the mirror and the outer gimbal. The mechanism is subjected to 100-G loading without the aid of any additional caging mechanism. Additionally, it was desired to have the same level of accuracy during Earth-bound, 1-G testing. Due to the inherent lack of damping in a zero-G, vacuum environment; the ability of the gimbal to respond to very small amounts of input energy is paramount. Initial testing of the first prototype revealed exceedingly long damping times required even while exposed to the damping effects of air and 1-G friction. It is envisioned that fine positioning of the gimbal will be accomplished in very small steps to avoid large disturbances to the mirror. Various bearing designs, including materials, lubrication options and bearing geometry will be discussed. In addition various options for the Helmholtz coil design will be explored with specific test data given. Ground testing in the presence of 1-G was compounded by the local magnetic fields due to the "compass" effect on the gimbal. The test data will be presented and discussed. Additionally, rationale for estimating gimbal performance in a zero-G environment will be presented and discussed.
This project is intended to support the development of new traction drive systems that meet the targets of 100 kW/L for power electronics and 50 kW/L for electric machines with reliable operation to 300,000 miles. To meet these goals, new designs must be identified that make use of state-of-the-art and next-generation electronic materials and design methods. Designs must exploit synergies between components, for example converters designed for high-frequency switching using wide band gap (WBG) devices and ceramic capacitors. This project included: (1) a survey of available technologies; (2) investigating new technologies, that for example, reduce volume of thermal management or magnetic components; (3) the development of computer aided design tools that consider the converter volume, reliability, and electrical performance; (4) exercising the design software to evaluate performance gaps and predict the impact of certain technologies and design approaches, i.e. GaN semiconductors, ceramic capacitors, ceramic thermal management components, and select topologies; (5) building and testing hardware prototypes to validate models and concepts. The design tools enable co-optimization of the power module and passive elements and provide some design guidance. At the end of the project, new advanced computing methods, such as machine learning approaches, were considered.
Evaluating miniature slip ring materials and design techniques for high vacuum operation
A review of developments in structural optimization techniques and their interface with growing computer capabilities is presented. Structural design steps comprise functional definition of an object, an evaluation phase wherein external influences are quantified, selection of the design concept, material, object geometry, and the internal layout, and quantification of the physical characteristics. Optimization of a fully stressed design is facilitated by use of nonlinear mathematical programming which permits automated definition of the physics of a problem. Design iterations terminate when convergence is acquired between mathematical and physical criteria. A constrained minimum algorithm has been formulated using an Augmented Lagrangian approach and a generalized reduced gradient to obtain fast convergence. Various approximation techniques are mentioned. The synergistic application of all the methods surveyed requires multidisciplinary teamwork during a design effort.
A review of developments in structural optimization techniques and their interface with growing computer capabilities is presented. Structural design steps comprise functional definition of an object, an evaluation phase wherein external influences are quantified, selection of the design concept, material, object geometry, and the internal layout, and quantification of the physical characteristics. Optimization of a fully stressed design is facilitated by use of nonlinear mathematical programming which permits automated definition of the physics of a problem. Design iterations terminate when convergence is acquired between mathematical and physical criteria. A constrained minimum algorithm has been formulated using an Augmented Lagrangian approach and a generalized reduced gradient to obtain fast convergence. Various approximation techniques are mentioned. The synergistic application of all the methods surveyed requires multidisciplinary teamwork during a design effort.
A two page discussion of non-aerospace seating applications and the design of NASA's safety seat cushioning (SSC) is presented. The SSC was designed for both safety and comfort in order to replace polyurethane cushioning which is flammable and produces lethal fumes upon combustion. The SSC is composed of advanced fabric reinforced composites and is lightweight, fire-retardent, and crashworthy. The seat design consists of central elliptical tubular spring supports made of fire-resistant and fatigue-durable composites surrounded by a fire-blocking sheath. The cushioning is made crashworthy by incorporating energy-absorbing, viscoelastic layers between the nested, elliptical-hoop springs. The design is intended to provide comfortable seating that meets aircraft-loading requirements without using the conventional polyurethane materials. The designs of an aircraft seat and structural components of the SSC are also presented.
Hermetic machinery utilizing gas bearings for MW-scale supercritical CO 2 (sCO 2 ) machinery applications can have significantly lower power loss and enable improved cycle efficiency compared to conventional machinery with oil-lubricated bearings. Active magnetic bearings (AMBs) are another option anticipated to have similar power loss and load capacity to gas bearings as well as offering larger mechanical tolerances, the ability to tune properties, and high reliability due to lack of mechanical wear. AMBs also have proven commercial experience at MW-scale, though environments for high-temperature sCO 2 power cycle machinery conditions are novel. Besides the potential impact of AMBs for sCO 2 turbomachinery, the technology also offers promising benefits for steam and gas turbines for power generation, compressors and expanders for industrial heat and power, and in other oil and gas and space applications. The goals of this project were to conceptual design an AMB and perform material testing. Conceptual designs for radial and thrust AMBs were produced based on a hermetically-sealed sCO 2 machinery waste-heat recovery (WHR) application for sizing and loads, and choosing a target design temperature of 540°C useful for high-temperature sCO 2 turbines for concentrating solar power (CSP) applications. Conceptual designs were initially developed for multiple radial and thrust AMBs with spreadsheet-based calculations before selecting one of each to develop further using higher-fidelity design methods for magnetic and structural performance. It was found that the radial AMB at 540°C was feasible, but the thrust AMB needed to be limited to 315°C for high-speed operation. The decision for a reduced-temperature thrust AMB was the result of several significant conclusions: 1) Hiperco 50A, originally chosen for good magnetic performance at high temperature, had insufficient strength for high-speed operation, so it was replaced with 17-4 PH. 2) The reduced magnetic performance from 17-4 PH yielded a larger bearing size, reducing the strength margin. 3) This ultimately led to a creative design implementing a more-compact E-core topology, compared to the original (conventional) C-core, and an integral shaft-disk with Hirth joint connection. These conceptual designs are unique for the size and temperature in CO 2 , relevant for MW-scale CSP applications. Long term, high temperature test data was generated for several materials, filling a void in the current body of literature. Corrosion and magnetic performance measurements were produced for PM materials (Alnico 5-7C, Alnico 9C, and SmCo) with and without nickel-coating for environments of high-temperature CO 2 up to 550°C at atmospheric pressure and 450°C at 103 bar for up to 6,000 hours. Corrosion measurements were also produced for Hiperco 50, a SM material relevant for AMB laminations, with and without C5 coating. Comparisons were also made for 450°C and 550°C, atmospheric pressure air exposures up to 5,000 hours. Results generally show that coatings can be effective at improving oxidation resistance of the bare materials, and Alnicos generally outperformed SmCo after high-temperature exposure. In addition to technical feasibility demonstrated by the design, economic feasibility was demonstrated by updating the TEA from the reference machine, re-evaluating it with CAPEX and OPEX to reflect estimated changes from process-lubricated bearings to AMBs. AMBs were shown to be comparable in performance to process-lubricated bearings, still showing a notable improvement over conventional machinery architecture with oil-lubricated bearings.
Developing new metal hydrides is a critical step toward efficient hydrogen storage in carbon-neutral energy systems. However, existing materials databases, such as the Materials Project, contain a limited number of well-characterized hydrides, which constrains the discovery of optimal candidates. This work presents a framework that integrates causal discovery with a lightweight generative machine learning model to generate novel metal hydride candidates that may not exist in current databases. Using a dataset of 450 samples (270 training, 90 validation, and 90 testing), the model generates 1000 candidates. After ranking and filtering, six previously unreported chemical formulas and crystal structures are identified, four of which are validated by density functional theory simulations and show strong potential for future experimental investigation. Overall, the proposed framework provides a scalable and time-efficient approach for expanding hydrogen storage datasets and accelerating materials discovery.
The power conversion efficiency of organic solar cells (OSCs) is exceeding 20%, an advance in which morphology optimization has played a significant role. It is generally accepted that the processing solvent (or solvent mixture) can help optimize morphology, impacting the OSC efficiency. Here we develop OSCs that show strong tolerance to a range of processing solvents, with all devices delivering high power conversion efficiencies around 19%. By investigating the solution states, the film formation dynamics and the characteristics of the processed films both experimentally and computationally, we identify the key factors that control morphology, that is, the interactions between the side chains of the acceptor materials and the solvent as well as the interactions between the donor and acceptor materials. Our work provides new understanding on the long-standing question of morphology control and effective guides to design OSC materials towards practical applications, where green solvents are required for large-scale processing.
This paper presents a status update of the design and development of an improved nozzle for the Advanced Solid Rocket Motor (ASRM). The ASRM nozzle incorporates advanced state-of-the-art design features and materials which contribute to enhanced safety, reliability, performance, and producibility for the space shuttle boosters. During 1992 the nozzle design progressed through a successful Preliminary Design Review (PDR). An improved ablative material development program also culminated in the selection of new standard and low density carbon cloth phenolic prepreg offering reduced variability and improved process attributes. A subscale motor test series to evaluate new materials and design features was also completed. An overview update of the matured design characteristics, supporting analysis, key development-program results and program status and plans is reported.
In the execution of this proposal, we will first examine current and developing spacecraft materials and evaluate their ability to attenuate adverse biological mutational events in mammalian cell systems and reduce the rate of cancer induction in mice harderian glands as a measure of their protective qualities. The HZETRN code system will be used to generate a database on GCR attenuation in each material. If a third year of funding is granted, the most promising and mission-specific materials will be used to study the impact on mission cost for a typical Mars mission scenario as was planned in our original two year proposal at the original funding level. The most promising candidate materials will be further tested as to their transmission characteristics in Fe and Si ion beams to evaluate the accuracy of the HZETRN transmission factors. Materials deemed critical to mission success may also require testing as well as materials developed by industry for their radiation protective qualities (e.g., Physical Sciences Inc.) A study will be made of designing polymeric materials and composite materials with improved radiation shielding properties as well as the possible improvement of mission-specific materials.
The International Space Station (ISS) program is of such complexity and scale that there have been numerous issues addressed regarding safety of materials: from design to manufacturing, test, launch, assembly on-orbit, and operations. A selection of lessons learned from the ISS materials perspective will be provided. Topics of discussion are: flammability evaluation of materials with connection to on-orbit operations; toxicity findings for foams; compatibility testing for materials in fluid systems; and contamination control in precision clean systems and critical space vehicle surfaces.