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At least 883 records · Page 49
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Nondiffractive beam shaping for enhanced optothermal control in metal additive manufacturing

High thermal gradients and complex melt pool instabilities involved in powder bed fusion–based metal additive manufacturing using focused Gaussian-shaped beams often lead to high porosity, poor morphological quality, and degraded mechanical performance. We show here that Bessel beams offer unprecedented control over the spatiotemporal evolution of the melt pool in stainless steel (SS 316L) in comparison to Gaussian beams. Notably, the nondiffractive nature of Bessel beams enables greater tolerance for focal plane positioning during 3D printing. We also demonstrate that Bessel beams significantly reduce the propensity for keyhole formation across a broad scan parameter space. High-speed imaging of the melt pool evolution and solidification dynamics reveals a unique mechanism where Bessel beams stabilize the melt pool turbulence and increase the time for melt pool solidification, owing to reduced thermal gradients. Consequently, we observe a distinctively improved combination of high density, reduced surface roughness, and robust tensile properties in 3D-printed test structures.

36 MATERIALS SCIENCE↗
NASA NTRS2012

JPL Counterfeit Parts Avoidance

SPACE ARCHITECTURE / ENGINEERING: It brings an extreme test bed for both technologies/concepts as well as procedures/processes. Design and construction (engineering) always go together, especially with complex systems. Requirements (objectives) are crucial. More important than the answers are the questions/Requirements/Tools-Techniques/Processes. Different environments force architects and engineering to think out of the box. For instance there might not be gravity forces. Architectural complex problems have common roots: in Space and on Earth. Let us bring Space down on Earth so we can keep sending Mankind to the stars from a better world. Have fun being architects and engineers...!!! This time is amazing and historical. We are changing the way we inhabit the solar systems!

counterfeit parts control↗
NASA NTRS2016

Green Monopropellant Status at Marshall Space Flight Center

NASA Marshall Space Flight Center is continuing investigations into the use of green monopropellants as a replacement for hydrazine in spacecraft propulsion systems. Work to date has been to push technology development through multiple activities designed to understand the capabilities of these technologies. Future work will begin to transition to mission pull as these technologies are mature while still keeping a solid goal of pushing technology development as opportunities become available. The AF-M315E activities began with hot-fire demonstration testing of a 1N monopropellant thruster in FY 14 and FY15. Following successful completion of the preliminary campaign, changes to the test stand to accommodate propellant conditioning capability and better control of propellant operations was incorporated to make testing more streamlined. The goal is to conduct hot-fire testing with warm and cold propellants using the existing feed system and original thruster design. Following the 1N testing, a NASA owned 100 mN thruster will be hot-fire tested in the same facility to show feasibility of scaling to smaller thrusters for cubesat applications. The end goal is to conduct a hot-fire test of an integrated cubesat propulsion system using an SLM printed propellant tank, an MSFC designed propulsion system electronic controller and the 100 mN thruster. In addition to the AF-M315E testing, MSFC is pursuing hot-fire testing with LMP-103S. Following our successful hot-fire testing of the 22N thruster in April 2015, a test campaign was proposed for a 440N LMP-103S thruster with Orbital ATK and Plasma Processes. This activity was funded through the Space Technology Mission Directorate (STMD) ACO funding call in the last quarter of CY15. Under the same funding source a test activity with Busek and Glenn Research Center for testing of 5N AF-M315E thrusters was proposed and awarded. Both activities are in-work with expected completion of hot-fire testing by the end of FY17. MSFC is continuing to coordinate with the AF and academia on understanding the chemical reactions that occur in AF-M315E. An on-going investigation of the catalyst bed species using Raman Spectroscopy through the NASA Technology Research Fellowship Program (NSTRF) is looking for ways to minimize the amount of computation required by understanding the intermediate species created in the catalyst bed. The MSFC team is also working with commercial partners through Cooperative Agreement Notices (CAN's). Partnerships with commercial and academia include work in non-catalytic ignition of AF-M315, spark ignition of hybrid cubesat systems, printed SLM tanks, and dual-mode (electric and chemical) propulsion systems is continuing.

Burnside, Christopher G.↗
DOE OSTI2022

Photodiode-based machine learning for optimization of laser powder bed fusion parameters in complex geometries

We report the quality of parts produced through laser powder bed fusion additive manufacturing can be irregular, with complex geometries sometimes exhibiting dimensional inaccuracies and defects. For optimal part quality, laser process parameters should be selected carefully prior to printing and adjusted during the print if necessary. This is challenging since approaches to control and optimize the build parameters need to take into account the part geometry, the material, and the complex physics of laser powder bed fusion. This work describes a data-driven approach using experimental diagnostics for the optimization of laser process parameters prior to printing. A training dataset is generated by collecting high speed photodiode signal data while printing simple parts containing key geometry features with various process parameter strategies. Supervised learning approaches are employed to train both a forward model and an inverse model. The forward model takes as inputs track-wise geometry features and laser parameters and outputs the photodiode signal along the scan path. The inverse model takes as inputs the geometry features and photodiode signal and predicts the laser parameters. Given the part geometry and a desired photodiode signal, the inverse model can thus determine the required laser parameters. Two test parts which contain defect-prone features are used to assess the validity of the inverse model. The use of the model leads to improved part quality (higher dimensional accuracy, reduced dross, reduced distortion) for both test geometries.

36 MATERIALS SCIENCE↗
NASA NTRS2015

Characterization of Machine Variability and Progressive Heat Treatment in Selective Laser Melting of Inconel 718

The absence of an economy of scale in spaceflight hardware makes additive manufacturing an immensely attractive option for propulsion components. As additive manufacturing techniques are increasingly adopted by government and industry to produce propulsion hardware in human‐rated systems, significant development efforts are needed to establish these methods as reliable alternatives to conventional subtractive manufacturing. One of the critical challenges facing powder bed fusion techniques in this application is variability between machines used to perform builds. Even with implementation of robust process controls, it is possible for two machines operating at identical parameters with equivalent base materials to produce specimens with slightly different material properties. The machine variability study presented here evaluates 60 specimens of identical geometry built using the same parameters. 30 samples were produced on machine 1 (M1) and the other 30 samples were built on machine 2 (M2). Each of the 30‐sample sets were further subdivided into three subsets (with 10 specimens in each subset) to assess the effect of progressive heat treatment on machine variability. The three categories for post‐processing were: stress relief, stress relief followed by hot isostatic press (HIP), and stress relief followed by HIP followed by heat treatment per AMS 5664. Each specimen (a round, smooth tensile) was mechanically tested per ASTM E8. Two formal statistical techniques, hypothesis testing for equivalency of means and one‐way analysis of variance (ANOVA), were applied to characterize the impact of machine variability and heat treatment on six material properties: tensile stress, yield stress, modulus of elasticity, fracture elongation, and reduction of area. This work represents the type of development effort that is critical as NASA, academia, and the industrial base work collaboratively to establish a path to certification for additively manufactured parts. For future flight programs, NASA and its commercial partners will procure parts from vendors who will use a diverse range of machines to produce parts and, as such, it is essential that the AM community develop a sound understanding of the degree to which machine variability impacts material properties.

Prater, Tracie↗
NASA NTRS1994

Cytokines and immune surveillance in humans

Evidence from both human and rodent studies has indicated that alterations in immunological parameters occur after space flight. Among the parameters shown, by us and others, to be affected is the production of interferons. Interferons are a family of cytokines that are antiviral and play a major role in regulating immune responses that control resistance to infection. Alterations in interferon and other cytokine production and activity could result in changes in immunity and a possible compromise of host defenses against both opportunistic and external infections. The purpose of the present study is to explore further the effects of space flight on cyotokines and cytokine-directed immunological function. Among the tests carried out are interferon-alpha production, interferon-gamma production, interleukin-1 and -2 production, signal transduction in neutrophils, signal transduction in monocytes, and monocyte phagocytic activity. The experiments will be performed using peripheral blood obtained from human subjects. It is our intent to eventually carry out these experiments using astronauts as subjects to determine the effects of space flight on cytokine production and activity. However, these subjects are not currently available. Until they become available, we will carry out these experiments using subjects maintained in the bed-rest model for microgravity.

Sonnenfeld, Gerald↗
NASA NTRS2008

Virtual Satellite

Virtual Satellite (VirtualSat) is a computer program that creates an environment that facilitates the development, verification, and validation of flight software for a single spacecraft or for multiple spacecraft flying in formation. In this environment, enhanced functionality and autonomy of navigation, guidance, and control systems of a spacecraft are provided by a virtual satellite that is, a computational model that simulates the dynamic behavior of the spacecraft. Within this environment, it is possible to execute any associated software, the development of which could benefit from knowledge of, and possible interaction (typically, exchange of data) with, the virtual satellite. Examples of associated software include programs for simulating spacecraft power and thermal- management systems. This environment is independent of the flight hardware that will eventually host the flight software, making it possible to develop the software simultaneously with, or even before, the hardware is delivered. Optionally, by use of interfaces included in VirtualSat, hardware can be used instead of simulated. The flight software, coded in the C or C++ programming language, is compilable and loadable into VirtualSat without any special modifications. Thus, VirtualSat can serve as a relatively inexpensive software test-bed for development test, integration, and post-launch maintenance of spacecraft flight software.

Hammrs, Stephan R.↗
NASA NTRS2015

Characterization of Machine Variability and Progressive Heat Treatment in Selective Laser Melting of Inconel 718

The absence of an economy of scale in spaceflight hardware makes additive manufacturing an immensely attractive option for propulsion components. As additive manufacturing techniques are increasingly adopted by government and industry to produce propulsion hardware in human-rated systems, significant development efforts are needed to establish these methods as reliable alternatives to conventional subtractive manufacturing. One of the critical challenges facing powder bed fusion techniques in this application is variability between machines used to perform builds. Even with implementation of robust process controls, it is possible for two machines operating at identical parameters with equivalent base materials to produce specimens with slightly different material properties. The machine variability study presented here evaluates 60 specimens of identical geometry built using the same parameters. 30 samples were produced on machine 1 (M1) and the other 30 samples were built on machine 2 (M2). Each of the 30-sample sets were further subdivided into three subsets (with 10 specimens in each subset) to assess the effect of progressive heat treatment on machine variability. The three categories for post-processing were: stress relief, stress relief followed by hot isostatic press (HIP), and stress relief followed by HIP followed by heat treatment per AMS 5664. Each specimen (a round, smooth tensile) was mechanically tested per ASTM E8. Two formal statistical techniques, hypothesis testing for equivalency of means and one-way analysis of variance (ANOVA), were applied to characterize the impact of machine variability and heat treatment on six material properties: tensile stress, yield stress, modulus of elasticity, fracture elongation, and reduction of area. This work represents the type of development effort that is critical as NASA, academia, and the industrial base work collaboratively to establish a path to certification for additively manufactured parts. For future flight programs, NASA and its commercial partners will procure parts from vendors who will use a diverse range of machines to produce parts and, as such, it is essential that the AM community develop a sound understanding of the degree to which machine variability impacts material properties.

Prater, T.↗
NASA NTRS1993

Determination of the mass properties of a manipulator

Space applications for telerobotics requires a manipulator that is robust to the large payload variations that occur in a zero-g environment. One approach to provide the required performance for this large payload variation is to provide inertial decoupling to the controller. The equations to generate the required joint torques can be obtained in several manners but the independent parameters required to perform the calculations are difficult to obtain. This presentation consists of an overview of the inertial decoupling control system and discusses how to reduce the inertial parameter set to a minimum and obtain the required parameter set to a minimum and obtain the required parameter vector using sensed joint positions and torques. In addition, as telerobotic technology becomes more prevalent in the space environments the ability to emulate the effect of zero-g in a one-g environment is critical in learning how to perform tasks in space. To emulate the zero-g environment it is necessary to remove the effect of gravity on the manipulator by determining the feedforward joint torques. A subset of the algorithm developed to obtain the decoupling parameters is used to obtain the gravity offload parameters. These parameters are used to eliminate the effect of gravity. The algorithm is validated on Martin Marietta/NASA Langley's, 7 Degrees-Of-Freedom (DOF) Flight Telerobotic Servicer Hydraulic Manipulator Test Bed. A video portraying actual results of the algorithm is provided.

Goldenberg, Stewart↗
NASA NTRSDate not supplied

Updated Analysis of the Trash Compaction and Processing System: Water Collected from Trash, Evaluation of the Source Contaminant Control System, and Zotek® F30 Foam Processing

The Trash Compaction and Processing System (TCPS) aims to reduce volume, biologically safen, physically stabilize, manage effluents, and recover resources from astronaut trash in the International Space Station (ISS). At NASA Ames Research Center (ARC), there are two test systems: the Heat Melt Compactor (HMC), which compacts the trash into a tile with temperature and pressure, and the Source Contaminant Control System (SCCS), which is the gas management subsystem aimed to reduce contaminants by converting them into carbon dioxide (CO 2 ) and water (H 2 O) vapor. Both the HMC and SCCS serve as test systems that support TCPS development by conducting risk reduction activities associated with an ISS technology demonstration. In this paper, the risk reduction activities discussed are the testing of different trash models for operational scenarios in the HMC, investigating the water extracted from those trash models, and managing the gaseous effluents from the trash via contaminant conversion through the SCCS. The HMC has undergone several tests of different trash models and cases in which a containment bag is used or not. For the first topic, this paper will analyze the water collected and recovered from these tests and analyze the effect of specific trash containment bags. For the second topic, this paper will individually evaluate the carbon bed and catalytic oxidizer (CatOx) to understand what components the carbon bed removes and what contaminants are converted in the CatOx. For the third and final topic, this paper will discuss Zotek® F30 foam processing in the HMC unit and testing verification in correlation to defined TCPS requirements. A foam model was added to reduce the volume of foam that take up space in the ISS. Overall, this paper is a compilation and an updated analysis of tests conducted in the lab-scale TCPS at ARC within the past year.

TCPS↗
NASA NTRS1992

Software architecture for a distributed real-time system in Ada, with application to telerobotics

The architecture structure and software design methodology presented is described in the context of telerobotic application in Ada, specifically the Engineering Test Bed (ETB), which was developed to support the Flight Telerobotic Servicer (FTS) Program at GSFC. However, the nature of the architecture is such that it has applications to any multiprocessor distributed real-time system. The ETB architecture, which is a derivation of the NASA/NBS Standard Reference Model (NASREM), defines a hierarchy for representing a telerobot system. Within this hierarchy, a module is a logical entity consisting of the software associated with a set of related hardware components in the robot system. A module is comprised of submodules, which are cyclically executing processes that each perform a specific set of functions. The submodules in a module can run on separate processors. The submodules in the system communicate via command/status (C/S) interface channels, which are used to send commands down and relay status back up the system hierarchy. Submodules also communicate via setpoint data links, which are used to transfer control data from one submodule to another. A submodule invokes submodule algorithms (SMA's) to perform algorithmic operations. Data that describe or models a physical component of the system are stored as objects in the World Model (WM). The WM is a system-wide distributed database that is accessible to submodules in all modules of the system for creating, reading, and writing objects.

Olsen, Douglas R.↗
NASA NTRSDate not supplied

Evaluating The Relationships Between Supine Propriorception Assessments with Upright Functional Mobility and Balance Tests

INTRODUCTION Upon return to Earth, spaceflight sensorimotor adaptations can result in impaired posture and locomotion [1], [2], and current exercise countermeasures in the International Space Station are not sufficient to maintain sensorimotor function. In-flight countermeasures and assessment tools for sensorimotor function are needed to mitigate risks associated with mission-critical task performance upon return to Earth or arrival to 0.38 G on Mars. One proposed countermeasure for proprioceptive deconditioning includes training on a tilt board device [3], which will be tested in an upcoming bed rest study. In preparation for the said study, the objective of this pilot study is to compare performance in supine proprioceptive assessments to performance in functional upright activities. The results are intended to guide the selection of supine assessment tools for the upcoming bedrest study and the development of future inflight proprioceptive training and assessment tools for exploration missions. METHODS Seventeen healthy participants (8 males and 9 females, 27.9 ± 8.5 years) provided informed consent as approved by the Institutional Review Board (IRB) at NASA. A horizontal air-bearing sled was used to provide a proprioceptive challenge in a supine body orientation, allowing for mediolateral motion with minimal friction during supine stance [4]. Participants were loaded axially (30 to 60% body weight) with their feet on a vertically oriented tilt board and instructed to perform supine assessment activities using custom software that displays a cursor controlled by tilting the tilt board. In a single-leg static activity on the tilt board (TB-St), performance was measured as the percent time spent on a center target during a 30-second trial. During a two-feet dynamic activity on the tilt board (TB-Dy), performance was measured as the number of targets captured in 30 seconds. These supine tasks were compared to performance during two upright activities used to represent upright performance: completion time for a functional mobility task (FMT) [2],[5] and a performance score from force plate sway data during 30-second single-leg upright standing (USL). RESULTS AND DISCUSSION A Spearman's rank-order correlation was run to assess the relationship between upright and supine assessments. There were statistically significant, strong correlations between scores for the FMT and each TB activity, including TB-St, rs(17) = 0.50, p<0.05, TB-Dy3, rs(17) = 0.73, p<0.001, and TB-Dy9, rs(15) = 0.53, p<0.05. There were no statistically significant correlations between USL and each TB activity. Despite a lack of correlation with upright single-leg balance, the ability of the TB to indicate upright performance in the FMT is promising, as this task is a standard post-flight measure designed to characterize locomotor dysfunction [2], [5]. CONCLUSION These efforts will inform the selection of an appropriate sensorimotor assessment method for the upcoming bed rest study and similar future studies. While current work uses a bed rest analog to develop these technologies, future work aims to prepare capabilities for future in-flight sensorimotor training and assessment to mitigate the risks of proprioception impairment after spaceflight. ACKNOWLEDGEMENTS This work was supported by the University Space Research Association Internship Program. REFERENCES [1] Mulavara A.P. et al (2018) Med Sci Sports Exerc, 50(9), 1961-1980. [2] Mulavara A.P. et al (2010) Exp Brain Res, 202(3), 649-659. [3] Macaulay T.R. et al (2021) Front. Syst. Neurosci., 15, 658-985. [4] Goel R. et al (2017) Front. Syst. Neurosci, 11. [5] Koppelmans V. et al (2013) BMC Neurology, 12.

R Bellisle↗
DOE OSTI2024

Microstructural Engineering and Accelerated Test Method Development to Achieve Low Cost, High Performance Solutions for Hydrogen Storage and Delivery

This project made advancements in developing lower cost steel alloys with novel microstructural design for use in hydrogen refueling infrastructure such as storage, compressors, and dispensing components, and utilizing accelerated test methods to efficiently evaluate variations in alloy and microstructure design. The project specifically sought to design alloys with lower nickel contents to reduce alloy cost, which was accomplished through substituting manganese for nickel along with other alloy additions to control deformation characteristics known to be important for hydrogen embrittlement resistance. Through Mn substitutions for nickel, austenitic and duplex austenite-ferrite steels were successfully developed with lower cost than currently available commercial stainless steel products that are employed for hydrogen refueling infrastructure. The steels were processed to achieve comparable strength and toughness in hydrogen environments as the commercially available steels containing high Ni contents. To evaluate mechanical performance in hydrogen, a testing methodology was employed to compare ubiquitous laboratory testing using electrochemical hydrogen charging in a liquid electrolyte to less accessible high pressure gaseous testing. While the application of these steels is in high pressure gaseous environments, the electrochemical hydrogen charging tests produced comparable results. Additionally, the Los Alamos Neutron Scatting Center enabled characterization of deformation mechanisms of the steel alloys in the presence of hydrogen, which has been associated with steel alloy characteristics associated with hydrogen embrittlement. Finally, a fracture mechanics based test bed model was developed to predict the influence of hydrogen gas pressure and fatigue conditions on fatigue lifetimes of pressure vessel steels. Together, these developments can be employed to enable lower cost hydrogen fueling infrastructure and more reliable prediction of steel alloy components in hydrogen service conditions. In particular, the newly alloys have the potential to replace stainless steels, having demonstrated comparable performance at substantially reduced cost.

08 HYDROGEN↗
NASA NTRS2024

Bending Performance of Tungsten Printed Via Laser Powder Bed Fusion With Ceramic Dispersion Modified Powder Feedstock

Additively manufactured tungsten is a candidate refractory material for high-temperature aerospace and nuclear fusion/fission applications. The printability of pure tungsten is challenged by cracking defects arising from the metal’s high brittle-to-ductile transition temperature and low solubility of interstitial impurities. Furthermore, the cast microstructure inherent to the laser powder bed fusion (L-PBF) process has limited strength compared to worked microstructures common in wrought tungsten. Aside from process-related techniques to mitigate defects and increase strength (e.g., heated build chambers, multi-laser systems, low oxygen environmental control, etc.), micro-alloying additions can positively influence tungsten printability and strength. In this work, pure tungsten L-PBF feedstock was modified with 1 wt% additions of ceramic compound nano-powders. Wrought and printed bars were evaluated in four-point bending. Flexural strength and fractography were primary means of comparison to assess the effect of the feedstock modification on printed tungsten mechanical performance.

Additive Manufacturing↗
DOE OSTI2023

A combination interferometric and morphological image processing approach to rapid quality assessment of additively manufactured cellular truss core components

Advanced manufacturing (AM) processes such as laser powder bed fusion (LPBF) are increasingly capable of fabricating components with useful and unprecedented mechanical properties by incorporating complex internal bracing structures. From the standpoint of quality control and assessment, however, internally complex assemblies present significant build-verification challenges. Here we propose a hybrid approach to the inspection involving the application of computer-aided speckle interferometry (CASI) and morphological image processing as a rapid, inexpensive, and facile method for AM quality control. The described methodology has low capital equipment costs, is full-field and non-contact, can be used in an industrial setting, and has very low requirements in terms of operator training and expertise. Consisting primarily of the combination of image processing software with a simple optical system of variable sensitivity, the method is shown to be effective for inspection of a titanium honeycomb component subjected to differential pressure. Results are compared to those achieved with computed tomography (CT), immersion ultrasound testing (UT), and optical holographic interferometry. Here we propose several possible processing strategies for automated quality assessment based on this powerful hybrid approach.

36 MATERIALS SCIENCE↗
NASA NTRS1988

Spacecraft Fire-Safety Experiments for Space Station: Technology Development Mission

Definitions, overall descriptions, and preliminary apparatus and instrumentation requirements are presented for three spacecraft fire-safety experiments appropriate for inclusion in a growth-version of the Space Station. The experiments are as follows: 1. Combustion and Flame Spread of Typical Spacecraft Materials in a Low­ Velocity Convective Flow in Low Gravity 2. Fire and Fire-Extinguishant Interactions with Various Fire Scenarios in Low Gravity 3. Smoldering and Deep-Seated Combustion in Low Gravity. The experiments were selected from an assessment of recommendations for advanced technologies for prevention, detection, and control of fires in spacecraft. The experiments and their facilities are intended to constitute a portion of a Spacecraft Fire Safety Technology Development Mission (TDM). Basic requirements for the mission study are that the Space Station is essential for the accomplishment of the experimental objectives and that the technology being developed is appropriate for the growth version of the Space Station. The advantages of these three experiments are that, not only do they explore problems relevant to the Space Station operation and utilization, but also they constitute tests adaptable to two multiuse facilities installed in the Space Station laboratory module, the Combustion Tunnel Facility and the Combustion Facility. Three additional spacecraft fire-safety experiments, essential precursors to the TD M for near-term performance, are also described as follows: 1. Near-Term Testing of Materials for Combustion and Flame Spread 2. Near-Term Extinguishment of Fires in a Low-Gravity Test Bed 3. Post-Fire Recovery of Sensitive Electrical and Electronic Equipment. For all the experiments, the study defines accommodations in terms of first-order space, mass, power, consumables, and crew-time estimates. The study also reviews the key problems to be addressed, namely experiment safety hazards, non-intrusive diagnostics development and waste-products disposal. A preliminary task and time schedule for design, development, and experiment fabrication is proposed.

Youngblood, Wallace W.↗
NASA NTRS2006

Summary of Stirling Convertor Testing at GRC

The NASA Glenn Research Center (GRC) has been testing free-piston Stirling convertors for potential use in radioisotope power systems. These convertors tend to be in the 35 to 80 watt electric power output range. Tests at GRC have accumulated over 80,000 hours of operation. Test articles have been received from Infinia Corporation of Kennewick, WA and from Sunpower of Athens, OH. Infinia designed and built the developmental Stirling Technology Demonstration Convertors (TDC) in addition to the more advanced Test Bed and Engineering Unit convertors. GRC has eight of the TDC's under test including two that operate in a thermal vacuum environment. Sunpower designed and developed the EE- 35 and the Advanced Stirling Convertor (ASC). GRC has six of the EE-35's and is preparing for testing multiple ASC's. Free-piston Stirling convertors for radioisotope power systems make use of non-contacting operation that eliminates wear and is suited for longterm operation. Space missions with radioisotope power systems are often considered that extend from three to 14 years. One of the key capabilities of the GRC test facility is the ability to support continuous, unattended operation. Hardware, software, and procedures for preparing the test articles were developed to support these tests. These included the processing of the convertors for minimizing the contaminants in the working fluid, developing a helium charging system for filling and for gas sample analysis, and the development of new control software and a high-speed protection circuit to insure safe, round-the-clock operation. Performance data of Stirling convertors over time is required to demonstrate that a radioisotope power system is capable of providing reliable power for multi-year missions. This paper will discuss the status of Stirling convertor testing at GRC.

Schreiber, Jeffrey G.↗
NASA NTRS2006

Summary of Stirling Convertor Testing at NASA Glenn Research Center

The NASA Glenn Research Center (GRC) has been testing free-piston Stirling convertors for potential use in radioisotope power systems. These convertors tend to be in the 35 to 80 W electric power output range. Tests at GRC have accumulated over 80,000 hr of operation. Test articles have been received from Infinia Corporation of Kennewick, Washington and from Sunpower of Athens, Ohio. Infinia designed and built the developmental Stirling Technology Demonstration Convertors (TDC) in addition to the more advanced Test Bed and Engineering Unit convertors. GRC has eight of the TDC's under test including two that operate in a thermal vacuum environment. Sunpower designed and developed the EE-35 and the Advanced Stirling Convertor (ASC). GRC has six of the EE- 35 s and is preparing for testing multiple ASC s. Free-piston Stirling convertors for radioisotope power systems make use of non-contacting operation that eliminates wear and is suited for long-term operation. Space missions with radioisotope power systems are often considered that extend from three to 14 years. One of the key capabilities of the GRC test facility is the ability to support continuous, unattended operation. Hardware, software, and procedures for preparing the test articles were developed to support these tests. These included the processing of the convertors for minimizing the contaminants in the working fluid, developing a helium charging system for filling and for gas sample analysis, and the development of new control software and a high-speed protection circuit to insure safe, round-the-clock operation. Performance data of Stirling convertors over time is required to demonstrate that a radioisotope power system is capable of providing reliable power for multi-year missions. This paper will discuss the status of Stirling convertor testing at GRC.

Schreiber, Jeffrey G.↗