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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 865 records · Page 48

All sources NASA NTRS DOE OSTI

NASA NTRS1992

Lunar Lava Tube Sensing

Large (greater than 300 m diameter) lava tube caverns appear to exist on the Moon and could provide substantial safety and cost benefits for lunar bases. Over 40 m of basalt and regolith constitute the lava tube roof and would protect both construction and operations. Constant temperatures of -20 C reduce thermal stress on structures and machines. Base designs need not incorporate heavy shielding, so lightweight materials can be used and construction can be expedited. Identification and characterization of lava tube caverns can be incorporated into current precursor lunar mission plans. Some searches can even be done from Earth. Specific recommendations for lunar lava tube search and exploration are (1) an Earth-based radar interferometer, (2) an Earth-penetrating radar (EPR) orbiter, (3) kinetic penetrators for lunar lava tube confirmation, (4) a 'Moon Bat' hovering rocket vehicle, and (5) the use of other proposed landers and orbiters to help find lunar lava tubes.

York, Cheryl Lynn↗

NASA NTRS1994

Casting of weldable graphite/magnesium metal matrix composites with built-in metallic inserts

Technology innovations directed at the advanced development of a potentially low cost and weldable graphite/magnesium metal matrix composites (MMC) through near net shape pressure casting are described. These MMC components uniquely have built-in metallic inserts to provide an innovative approach for joining or connecting other MMC components through conventional joining techniques such as welding, brazing, mechanical fasteners, etc. Moreover, the metallic inserts trapped within the MMC components can be made to transfer the imposed load efficiently to the continuous graphite fiber reinforcement thus producing stronger, stiffer, and more reliable MMC components. The use of low pressure near net shape casting is economical compared to other MMC fabrication processes. These castable and potentially weldable MMC components can provide great payoffs in terms of high strength, high stiffness, low thermal expansion, lightweight, and easily joinable MMC components for several future NASA space structural, industrial, and commercial applications.

Lee, Jonathan A.↗

NASA NTRS2000

Nanotube Production and Applications at Johnson Space Center

Promise of applications of carbon nanotubes has led to an intense effort at NASA/JSC, especially in the area of nanotube composites. Using the extraordinary mechanical strength of nanotubes, NASA hopes to design this revolutionary lightweight material for use in aerospace applications. Current research focuses on structural polymeric materials to attempt to lower the weight of spacecraft necessary for interplanetary missions. Other applications of nanotubes are also of interest for energy storage, gas storage, nanoelectronics, field emission, and biomedical applications. In pursuit of these goals, we have set up both laser and arc production processes for nanotubes. An in-depth diagnostic study of the plasma plume in front of the laser target has been studied to try to determine nanotube growth mechanisms. Complementary studies of characterization of nanotube product have added to knowledge of growth conditions. Results of our preliminary experiments in incorporating nanotubes into composites will be presented. Morphology and mechanical properties of the nanotubes composites will be discussed.

Nikolaev, Pavel↗

NASA NTRSDate not supplied

TPSAS-NF1676L-18560-DND

The heliogyro is a helicopter-like spinning solar sail concept, conceived by MacNeal in the 1960s and studied by JPL in the 1970s. The heliogyro is a mission-enabling technology: - Membrane solar sail “blades” are compactly stowed on reels and easily deployed. - No elaborate management of large, 2-D membranes structures needed, so architecture may be scaled to very large sizes. - Lightweight due to centrifugal stiffening. Despite these advantages, development has lagged heavier, square-rigged solar sail designs (e.g., Sunjammer) due to the difficulty of fullscale ground testing. Dynamics need to be validated by (validated) analysis, followed by an affordable flight demonstration, to advance the maturity of heliogyro solar sailing technology.

Keats Wilkie↗

NASA NTRS2026

Evaluating Energy Absorption Methods for Integrated Composite Seat Designs

Composite materials have become ubiquitous in the aerospace industry due to their exceptionally light weight and high strength characteristics, as well as their unique ability to be engineered and tailored to meet specific loading conditions and performance requirements. These advanced materials offer superior strength-to-weight ratios compared to traditional metallic materials, making them particularly valuable in weight-critical aerospace applications where every pound saved translates to improved efficiency and performance. In currently operating fleets of commercial and military aircraft, composite materials have been successfully applied to critical structural components, including primary load-bearing elements such as the fuselage sections and flooring structures, which must withstand significant in-flight loads and provide passenger safety. Additionally, these materials have been specifically tailored and optimized for aerodynamic components such as wings and tail assemblies, where their ability to be molded into complex shapes while maintaining structural integrity is particularly advantageous. The application of composite materials extends beyond primary structural elements into the realm of internal cabin components, most notably in innovative seat designs where weight reduction and structural integration are paramount concerns. Modern composite seat structures can be designed to integrate multiple functions, including structural support, comfort features, and safety systems, all while maintaining the lightweight characteristics essential for aircraft performance.

Digital image correlation↗

NASA NTRS2026

Micromechanical Design of Carbon Nanotube Ribbon Reinforced Polymer Composite Materials

Lightweight materials are an important component of the design of aerospace structures. Carbon nanotube materials have been considered for this purpose due to the strength and stiffness of individual nanotubes, and the commercial availability of bulk formats such as fibers. These fibers can have a ribbon cross section which results in a different design space for their composites relative to traditional reinforcements which have a round cross section. This work applies brick-and-mortar micromechanical models and classical lamination theory with an inverse approach to investigate the design space of these composites. Using this approach, the influences of fiber geometry and axial and transverse mechanical properties are mapped. Finally, a sensitivity study is performed and the relative impacts of ±10% variations in the constituent material and geometric properties are ranked. Lamina axial moduli were found to range from a maximum of 3x to 1x minimum relative to a target quasi-isotropic laminate modulus depending on the anisotropy and shear modulus of the lamina. The fiber targets depended strongly on the fiber volume fraction in the lamina and the fiber axial modulus target was found to range from 4.8x to 3.2x the quasi-isotropic laminate target. The sensitivity analysis found that the largest driver of performance was the volume fraction, followed by the fiber axial modulus. While bio-based brick-and-mortar composites, such as nacre, can benefit from reinforcement aspect ratios above 10, for carbon nanotube ribbon (or carbon fiber)/polymer composites the sensitivity study indicated that the optimal cross-sectional aspect ratio was relatively smaller, potentially less than three.

Micromechanics↗

DOE OSTI2022

Synthesis Methods for Nanoparticle Morphology Control in Energy Applications

Lightweight nano-composite materials, nano-coatings, nanocatalysts, nano-structured materials have demonstrated an ability to reduce emissions and maximize clean energy production. Nanoparticles play an important role in engineering and decarbonization for energy applications, and a wide range of nanoparticle synthesis methods have been developed to include those that enable control over particle morphology. The ability to control nanoparticle morphology allows the tailoring and improvement of material properties that will accelerate efforts towards lowering carbon emissions by developing advanced catalysts for carbon sequestration and will enhance energy efficient processes and technologies. Synthesis methods aimed towards shape control of nanoparticles have demonstrated an ability to form spheres, rods, flower-like shapes, cubes, plates, shells, and chiral geometries. Processing methods used to form these morphologies include microwave assisted synthesis, solvothermal, hydrothermal, and a wide range of capping agents. A discussion of a few of these methods is given along with results and applications.

36 MATERIALS SCIENCE↗

NASA NTRS2001

Overview of SBIR Phase II Work on Hollow Graphite Fibers

Ultra-Lightweight materials are enabling for producing space based optical components and support structures. Heretofore, innovative designs using existing materials has been the approach to produce lighter-weight optical systems. Graphite fiber reinforced composites, because of their light weight, have been a material of frequent choice to produce space based optical components. Hollow graphite fibers would be lighter than standard solid graphite fibers and, thus, would save weight in optical components. The Phase I SBIR program demonstrated it is possible to produce hollow carbon fibers that have strengths up to 4.2 GPa which are equivalent to commercial fibers, and composites made from the hollow fibers had substantially equivalent composite strengths as commercial fiber composites at a 46% weight savings. The Phase II SBIR program will optimize processing and properties of the hollow carbon fiber and scale-up processing to produce sufficient fiber for fabricating a large ultra-lightweight mirror for delivery to NASA. Information presented here includes an overview of the strength of some preliminary hollow fibers, photographs of those fibers, and a short discussion of future plans.

Stallcup, Michael↗

DOE OSTI2014

Internal curing with lightweight aggregate produced from biomass-derived waste

Shrinkage of concrete may lead to cracking and ultimately to a reduction of the service life of concrete structures. Among known methods for shrinkage mitigation, internal curing with porous aggregates was successfully utilized in the last couple of decades for decreasing autogenous and drying shrinkage. In this paper, the internal curing performance of pre-saturated lightweight aggregates produced from biomass-derived waste (bio-LWA) was studied. In the first part of this paper, the microstructure of the bio-LWA is investigated, with special focus on their pore structure and on their water absorption and desorption behavior. The bio-LWA has large porosity and coarse pore structure, which allows them to release the entrained water at early age and counteract self-desiccation and autogenous shrinkage. In the second part, the efficiency of internal curing in mortars incorporating the bio-LWA is examined by neutron tomography, internal relative humidity and autogenous deformation measurements.

36 MATERIALS SCIENCE↗

NASA NTRS2014

Manufacturing Challenges Associated with the Use of Metal Matrix Composites in Aerospace Structures

Metal Matrix Composites (MMCs) consist of a metal alloy reinforced with ceramic particles or fibers. These materials possess a very high strength to weight ratio, good resistance to impact and wear, and a number of other properties which make them attractive for use in aerospace and defense applications. MMCs have found use in the space shuttle orbiter's structural tubing, the Hubble Space Telescope's antenna mast, control surfaces and propulsion systems for aircraft, and tank armors. The size of MMC components is severely limited by difficulties encountered in joining these materials using fusion welding. Melting of the material results in formation of an undesirable phase (formed when molten Aluminum reacts with the reinforcement) which leaves a strength depleted region along the joint line. Friction Stir Welding (FSW) is a relatively nascent solid state joining technique developed at The Welding Institute (TWI) in 1991. The process was first used at NASA to weld the super lightweight external tank for the Space Shuttle. Today FSW is used to join structural components of the Delta IV, Atlas V, and Falcon IX rockets as well as NASA's Orion Crew Exploration Vehicle and Space Launch System. A current focus of FSW research is to extend the process to new materials, such as MMCs, which are difficult to weld using conventional fusion techniques. Since Friction Stir Welding occurs below the melting point of the workpiece material, this deleterious phase is absent in FSW-ed MMC joints. FSW of MMCs is, however, plagued by rapid wear of the welding tool, a consequence of the large discrepancy in hardness between the steel tool and the reinforcement material. This chapter summarizes the challenges encountered when joining MMCs to themselves or to other materials in structures. Specific attention is paid to the influence of process variables in Friction Stir Welding on the wear process characterizes the effect of process parameters (spindle speed, traverse rate, and length of joint) on the wear process. A phenomenological model of the wear process was constructed based on the rotating plug model of Friction Stir Welding. The effectiveness of harder tool materials (such as Tungsten Carbide, high speed steel, and tools with diamond coatings) to combat abrasive wear is also explored. In-process force, torque, and vibration signals are analyzed to assess the feasibility of in situ monitoring of tool shape changes as a result of wear (an advancement which would eliminate the need for off-line evaluation of tool condition during joining). Monitoring, controlling, and reducing tool wear in FSW of MMCs is essential to implementation of these materials in structures (such as launch vehicles) where they would be of maximum benefit. The work presented here is extendable to machining of MMCs, where wear of the tool is also a limiting factor.

Prater, Tracie↗

NASA NTRS2013

Characterization of Thermal and Mechanical Impact on Aluminum Honeycomb Structures

This study supports NASA Kennedy Space Center's research in the area of intelligent thermal management systems and multifunctional thermal systems. This project addresses the evaluation of the mechanical and thermal properties of metallic cellular solid (MCS) materials; those that are lightweight; high strength, tunable, multifunctional and affordable. A portion of the work includes understanding the mechanical properties of honeycomb structured cellular solids upon impact testing under ambient, water-immersed, liquid nitrogen-cooled, and liquid nitrogen-immersed conditions. Additionally, this study will address characterization techniques of the aluminum honeycomb's ability to resist multiple high-rate loadings or impacts in varying environmental conditions, using various techniques for the quantitative and qualitative determination for commercial applicability.

Robinson, Christen M.↗

NASA NTRSDate not supplied

Thermal, Structural, and Rotordynamics Refinements to the Superconducting Rotor of A 1.4 Mw Partially Superconducting Machine for Electrified Aircraft

NASA is developing the high efficiency megawatt motor (HEMM), a 1.4 MW partially superconducting machine, to ad-dress the need for highly efficient, lightweight, MW-class ma-chines to support aviation sustainability efforts. This paper presents progress on the thermal, structural, and rotordynamics aspects of HEMM’s superconducting rotor. Emissivity measurements of gold coated cobalt iron and titanium parts are presented and then used to correlate a thermal model of the rotor to existing data from a thermo-electrical test of the full-scale rotor. Lessons learned from the correlated model are presented, including a rank ordering of the contributors to the temperature of the superconducting coils. An updated structural design of the HEMM rotor is presented and compared to the prior design. Finite element analysis demonstrates that the updated design improves stress margins while reducing magnetic flux leakage and retaining thermal performance. The key conclusions of the rotordynamics design are presented.

electrified aircraft propulsion↗

NASA NTRS1980

Space Shuttle External Tank Project status

The External Tank Project is reviewed with emphasis on the DDT&E and production phases and the lightweight tank development. It is noted that the DDT&E phase is progressing well with the structural and ground vibration test article programs complete, the propulsion test article program progressing well, and the component qualification and verification testing 92% complete. New tools and facilities are being brought on line to support the increased build rate for the production phase. The lightweight tank, which will provide additional payload in orbit, is progressing to schedule with first delivery in early 1982.

Davis, R. M.↗

NASA NTRS1991

Development of structural composite mirror technology for submillimeter space telescopes

The technical approach to the design, manufacturing, testing, and analytical simulation of lightweight graphite/epoxy mirrors is described. The precision segmented reflector (PSR) program has produced (1) 1.0-m graphite/epoxy panels with areal densities of 7 kg/sq m as-manufactured surface precision near 1 micron rms, (2) 0.5-m panels with figure changes less than 1 micron rms for temperature reductions of 100 K, (3) analytical performance-prediction capability with submicron accuracy relative to panel thermal distortion, and (4) a unique thermal vacuum test facility for structural composite mirrors.

Freeland, R. E.↗

NASA NTRS1993

Lightweight Phase-Change Material For Solar Power

Lightweight panels containing phase-change materials developed for use as heat-storage elements of compact, lightweight, advanced solar dynamic power system. During high insolation, heat stored in panels via latent heat of fusion of phase-change material; during low insolation, heat withdrawn from panels. Storage elements consist mainly of porous carbon-fiber structures imbued with germanium. Developed for use aboard space station in orbit around Earth, also adapted to lightweight, compact, portable solar-power systems for use on Earth.

Stark, Philip↗

DOE OSTI2016

Lightweight Mechanical Metamaterials with Tunable Negative Thermal Expansion

Ice floating on water is a great manifestation of negative thermal expansion (NTE) in nature. The limited examples of natural materials possessing NTE have stimulated research on engineered structures. Previous studies on NTE structures were mostly focused on theoretical design with limited experimental demonstration in two-dimensional planar geometries. Here, in this work, aided with multimaterial projection microstereolithography, we experimentally fabricate lightweight multimaterial lattices that exhibit significant negative thermal expansion in three directions and over a temperature range of 170 degrees. Such NTE is induced by the structural interaction of material components with distinct thermal expansion coefficients. The NTE can be tuned over a large range by varying the thermal expansion coefficient difference between constituent beams and geometrical arrangements. Our experimental results match qualitatively with a simple scaling law and quantitatively with computational models.

36 MATERIALS SCIENCE↗

DOE OSTI2013

Optimization of Nano-Carbon Materials for Hydrogen Sorption

Research undertaken has added to the understanding of several critical areas, by providing both negative answers (and therefore eliminating expensive further studies of unfeasible paths) and positive feasible options for storage. Theoretical evaluation of the early hypothesis of storage on pure carbon single wall nanotubes (SWNT) has been scrutinized with the use of comprehensive computational methods (and experimental tests by the Center partners), and demonstrated that the fundamentally weak binding energy of hydrogen is not sufficiently enhanced by the SWNT curvature or even defects, which renders carbon nanotubes not practical media. More promising direction taken was towards 3-dimensional architectures of high porosity where concurrent attraction of H2 molecule to surrounding walls of nano-scale cavities can double or even triple the binding energy and therefore make hydrogen storage feasible even at ambient or somewhat lower temperatures. An efficient computational tool has been developed for the rapid capacity assessment combining (i) carbon-foam structure generation, (ii) accurate empirical force fields, with quantum corrections for the lightweight H2, and (iii) grand canonical Monte Carlo simulation. This made it possible to suggest optimal designs for carbon nanofoams, obtainable via welding techniques from SWNT or by growth on template-zeolites. As a precursor for 3D-foams, we have investigated experimentally the synthesis of VANTA (Vertically Aligned NanoTube Arrays). This can be used for producing nano-foams. On the other hand, fluorination of VANTA did not show promising increase of hydrogen sorption in several tests and may require further investigation and improvements. Another significant result of this project was in developing a fundamental understanding of the elements of hydrogen spillover mechanisms. The benefit of developed models is the ability to foresee possible directions for further improvement of the spillover mechanism.

08 HYDROGEN↗

NASA NTRS1973

Development of a lightweight body-mounted solar cell array with a high power to weight ratio.

Three lightweight solar cell arrays have been fabricated with a high power-to-weight ratio. These arrays incorporate resistance welded interconnections, improved antireflection coating on the solar cell and lightweight substrates. Two of the substrates were constructed of magnesium with different structural geometry, while the third substrate was conventional aluminum honeycomb. All arrays utilized thin solar cells having a titanium-palladium-silver contact system and an antireflection coating of titanium oxide. The cells were welded with silver plated molybdenum interconnections. The two arrays having magnesium substrates exhibited a power/weight of 70.4 W/kg (32 W/lb.) and 81 W/kg (36.8 W/lb.), while the conventional array demonstrated a power/weight of 45.2 W/kg (20.6 W/lb.).

Somberg, H.↗