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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS2006

Vacuum Plasma Spray (VPS) Material Applications for Thruster Components

A variety of vacuum plasma spray (VPS) material systems have been successfully applied to injector and thrust chamber components. VPS offers a versatile fabrication process with relatively low costs to produce near net shape parts. The materials available with VPS increase operating margins and improve component life by providing superior thermal and oxidation protection in specific engine environments. Functional gradient materials (FGM) formed with VPS allow thrust chamber liners to be fabricated with GRCop-84 (an alloy of copper, chrome, and niobium) and a protective layer of NiCrAlY on the hot wall. A variety of thrust chamber liner designs have been fabricated to demonstrate the versatility of the process. Hot-fire test results have confined the improved durability and high temperature performance of the material systems for thrust chamber liners. Similar FGM s have been applied to provide superior thermal protection on injector faceplates with NiCrAlY and zirconia coatings. The durability of the applied materials has been demonstrated with hot-fire cycle testing on injector faceplates in high temperature environments. The material systems can benefit the components used in booster and main engine propulsion systems. More recent VPS efforts are focused on producing rhenium based material systems for high temperature applications to benefit in-space engines like reaction control system (RCS) thrusters.

Elam, Sandra↗
NASA NTRS2003

Combustor and Vane Features and Components Tested in a Gas Turbine Environment

The use of ceramic matrix composites (CMCs) as combustor liners and turbine vanes provides the potential of improving next-generation turbine engine performance, through lower emissions and higher cycle efficiency, relative to today s use of superalloy hot-section components. For example, the introduction of film-cooling air in metal combustor liners has led to higher levels of nitrogen oxide (NOx) emissions from the combustion process. An environmental barrier coated (EBC) siliconcarbide- fiber-reinforced silicon carbide matrix (SiC/SiC) composite is a new material system that can operate at higher temperatures, significantly reducing the film-cooling requirements and enabling lower NOx production. Evaluating components and subcomponents fabricated from these advanced CMCs under gas turbine conditions is paramount to demonstrating that the material system can perform as required in the complex thermal stress and environmentally aggressive engine environment. To date, only limited testing has been conducted on CMC combustor and turbine concepts and subelements of this type throughout the industry. As part of the Ultra-Efficient Engine Technology (UEET) Program, the High Pressure Burner Rig (HPBR) at the NASA Glenn Research Center was selected to demonstrate coupon, subcomponent feature, and component testing because it can economically provide the temperatures, pressures, velocities, and combustion gas compositions that closely simulate the engine environments. The results have proven the HPBR to be a highly versatile test rig amenable to multiple test specimen configurations essential to coupon and component testing.

Roinson, R. Craig↗
NASA NTRS1996

The Microgravity Research Experiments (MICREX) Data Base

An electronic data base identifying over 800 fluids and materials processing experiments performed in a low-gravity environment has been created at NASA Marshall Space Flight Center. The compilation, called MICREX (MICrogravity Research Experiments), was designed to document all such experimental efforts performed (1) on U.S. manned space vehicles, (2) on payloads deployed from U.S. manned space vehicles, and (3) on all domestic and international sounding rockets (excluding those of China and the former U.S.S.R.). Data available on most experiments include (1) principal and co-investigators (2) low-gravity mission, (3) processing facility, (4) experimental objectives and results, (5) identifying key words, (6) sample materials, (7) applications of the processed materials/research area, (8) experiment descriptive publications, and (9) contacts for more information concerning the experiment. This technical memorandum (1) summarizes the historical interest in reduced-gravity fluid dynamics, (2) describes the experimental facilities employed to examine reduced gravity fluid flow, (3) discusses the importance of a low-gravity fluids and materials processing data base, (4) describes the MICREX data base format and computational World Wide Web access procedures, and (5) documents (in hard-copy form) the descriptions of the first 600 fluids and materials processing experiments entered into MICREX.

Winter, C. A.↗
NASA NTRS1996

The Microgravity Research Experiments (MICREX) Data Base

An electronic data base identifying over 800 fluids and materials processing experiments performed in a low-gravity environment has been created at NASA Marshall Space Flight Center. The compilation, called MICREX (MICrogravity Research Experiments), was designed to document all such experimental efforts performed (1) on U.S. manned space vehicles, (2) on payloads deployed from U.S. manned space vehicles, and (3) on all domestic and international sounding rockets (excluding those of China and the former U.S.S.R.). Data available on most experiments include (1) principal and co-investigators, (2) low-gravity mission, (3) processing facility, (4) experimental objectives and results, (5) identifying key words, (6) sample materials, (7) applications of the processed materials/research area, (8) experiment descriptive publications, and (9) contacts for more information concerning the experiment. This technical memorandum (1) summarizes the historical interest in reduced-gravity fluid dynamics, (2) describes the experimental facilities employed to examine reduced gravity fluid flow, (3) discusses the importance of a low-gravity fluids and materials processing data base, (4) describes the MICREX data base format and computational World Wide Web access procedures, and (5) documents (in hard-copy form) the descriptions of the first 600 fluids and materials processing experiments entered into MICREX.

Winter, C. A.↗
NASA NTRS1996

The Microgravity Research Experiments (MICREX) Data Base

An electronic data base identifying over 800 fluids and materials processing experiments performed in a low-gravity environment has been created at NASA Marshall Space Flight Center. The compilation, called MICREX (MICrogravity Research Experiments) was designed to document all such experimental efforts performed (1) on U.S. manned space vehicles, (2) on payloads deployed from U.S. manned space vehicles, and (3) on all domestic and international sounding rockets (excluding those of China and the former U.S.S.R.). Data available on most experiments include (1) principal and co-investigator (2) low-gravity mission, (3) processing facility, (4) experimental objectives and results, (5) identifying key words, (6) sample materials, (7) applications of the processed materials/research area, (8) experiment descriptive publications, and (9) contacts for more information concerning the experiment. This technical memorandum (1) summarizes the historical interest in reduced-gravity fluid dynamics, (2) describes the importance of a low-gravity fluids and materials processing data base, (4) describes thE MICREX data base format and computational World Wide Web access procedures, and (5) documents (in hard-copy form) the descriptions of the first 600 fluids and materials processing experiments entered into MICREX.

Winter, C. A.↗
NASA NTRS1996

The Microgravity Research Experiments (MICREX) Data Base, Volume 4

An electronic data base identifying over 800 fluids and materials processing experiments performed in a low-gravity environment has been created at NASA Marshall Space Flight Center. The compilation, called MICREX (MICrogravity Research Experiments), was designed to document all such experimental efforts performed (1) on U.S. manned space vehicles, (2) on payloads deployed from U.S. manned space vehicles, and (3) on all domestic and international sounding rockets (excluding those of China and the former U.S.S.R.). Data available on most experiments include (1) principal and co-investigators (2) low-gravity mission, (3) processing facility, (4) experimental objectives and results, (5) identifying key words, (6) sample materials, (7) applications of the processed materials/research area, (8) experiment descriptive publications, and (9) contacts for more information concerning the experiment. This technical Memorandum (1) summarizes the historical interest in reduced-gravity fluid dynamics, (2) describes the importance of a low-gravity fluids and materials processing data base, (4) describes the MICREX data base format and computational World Wide Web access procedures, and (5) documents (in hard-copy form) the descriptions of the first 600 fluids and materials processing experiments entered into MICREX.

Winter, C. A.↗
NASA NTRS2011

Flexible Ablators: Applications and Arcjet Testing

Flexible ablators were conceived in 2009 to meet the technology pull for large, human Mars Exploration Class, 23 m diameter hypersonic inflatable aerodynamic decelerators. As described elsewhere, they have been recently undergoing initial technical readiness (TRL) advancement by NASA. The performance limits of flexible ablators in terms of maximum heat rates, pressure and shear remain to be defined. Further, it is hoped that this emerging technology will vastly expand the capability of future NASA missions involving atmospheric entry systems. This paper considers four topics of relevance to flexible ablators: (1) Their potential applications to near/far term human and robotic missions (2) Brief consideration of the balance between heat shield diameter, flexible ablator performance limits, entry vehicle controllability and aft-body shear layer impingement of interest to designers of very large entry vehicles, (3) The approach for developing bonding processes of flexible ablators for use on rigid entry bodies and (4) Design of large arcjet test articles that will enable the testing of flexible ablators in flight-like, combined environments (heat flux, pressure, shear and structural tensile loading). Based on a review of thermal protection system performance requirements for future entry vehicles, it is concluded that flexible ablators have broad applications to conventional, rigid entry body systems and are enabling to large deployable (both inflatable and mechanical) heat shields. Because of the game-changing nature of flexible ablators, it appears that NASA's Office of the Chief Technologist (OCT) will fund a focused, 3-year TRL advancement of the new materials capable of performance in heat fluxes in the range of 200-600 W/sq. cm. This support will enable the manufacture and use of the large-scale arcjet test designs that will be a key element of this OCT funded activity.

Thermal Protection↗
NASA NTRS1993

Method for producing a hybridization of detector array and integrated circuit for readout

A process is explained for fabricating a detector array in a layer of semiconductor material on one substrate and an integrated readout circuit in a layer of semiconductor material on a separate substrate in order to select semiconductor material for optimum performance of each structure, such as GaAs for the detector array and Si for the integrated readout circuit. The detector array layer is lifted off its substrate, laminated on the metallized surface on the integrated surface, etched with reticulating channels to the surface of the integrated circuit, and provided with interconnections between the detector array pixels and the integrated readout circuit through the channels. The adhesive material for the lamination is selected to be chemically stable to provide electrical and thermal insulation and to provide stress release between the two structures fabricated in semiconductor materials that may have different coefficients of thermal expansion.

Fossum, Eric R.↗
NASA NTRS1994

Simulation studies for surfaces and materials strength

Computer simulation studies were conducted to investigate materials properties. All the calculations were carried out using atomic level simulation techniques which are based on semiempirical or model functions. During this project, functions with varying degrees of complexity were derived and employed in simulations. Investigations include covalently bonded materials as well as systems involving metal atoms. For small clusters calculated results provided information on various energy- and structure-related properties along with vibrational characteristics. Also, energy barriers for configurational transitions were calculated for selected cases. Simulation calculations for surfaces produced new results in areas related to surface energies, reconstructions and relaxations, surface defects, surface stresses as well as adsorption and nucleation processes. Simulations were also performed on bulk materials. Calculated results provided an atomic level understanding on energetics and structures of point defects, crystal stability, elastic properties, and materials strength for various systems. Calculations involving polymeric materials include studies of polar polymer melts and polymer/solid interfaces. Simulations employing specially developed codes provided significant information about energetics and conformational characteristics of different polymeric chains.

Halicioglu, Timur↗
NASA NTRS1972

Changes in some physical properties induced by vacuum heat treatment

A method is proposed for reducing or eliminating outgassing of materials by heat treating them in vacuum prior to use. This may be performed on the raw material prior to manufacturing and installation or after fabrication of parts. Processing of a fabricated part can be performed only on relatively small parts and on assemblies containing no components which are affected by the required temperatures and pressures. Processing conditions of temperature and time are dependent on the particular application and the materials involved. Silicone-coated fiber glass cloth was vacuum-heat treated for 100 hrs at 400 + or - 25 F at pressures of 0.001 torr or less. The materials were tested in terms of tensile strength and tear properties in both the smooth and several creased configurations. Data obtained on one side silicone coated fiber glass showed large reductions in these properties as a result of the vacuum-heat treatment. The problem was alleviated by coating both sides of the fiber glass.

Hultquist, A. E.↗
NASA NTRS1989

Non-contact true temperature measurements in the microgravity environment

The theory developed is shown to be capable of calculating true temperature of any material from radiance measurements at a number of different wavelengths. This theory was also shown to be capable of predicting the uncertainty in these calculated temperatures. An additional advantage of these techniques is that they can estimate the emissivity of the target simultaneously with the temperature. This aspect can prove to be very important when a fast method of generating reflectivity vs. wavelength or emissivity vs. wavelength data is required. Experiments performed on various materials over a range of temperatures and experimental conditions were used to verify the accuracy of this theory.

Khan, Mansoor A.↗
NASA NTRS2013

Post-Flight Evaluation of PICA and PICA-X - Comparisons of the Stardust SRC and Space-X Dragon 1 Forebody Heatshield Materials

Phenolic Impregnated Carbon Ablator (PICA) was developed at NASA Ames Research Center. As a thermal protection material, PICA has the advantages of being able to withstand high heat fluxes with a relatively low density. This ablative material was used as the forebody heat shield material for the Stardust sample return capsule, which re-entered the Earths atmosphere in 2006. Based on PICA, SpaceX developed a variant, PICA-X, and used it as the heat shield material for its Dragon spacecraft, which successfully orbited the Earth and re-entered the atmosphere during the COTS Demo Flight 1 in 2010. Post-flight analysis was previously performed on the Stardust PICA heat shield material. Similarly, a near-stagnation core was obtained from the post-flight Dragon 1 heat shield, which was retrieved from the Pacific Ocean. Materials testing and analyses were performed on the core to evaluate its ablation performance and post-flight properties. Comparisons between PICA and PICA-X are made where applicable. Stardust and Dragon offer rare opportunities to evaluate materials post-flight - this data is beneficial in understanding material performance and also improves modeling capabilities.

PICA-X↗
NASA NTRS2000

Electric Plasma Arc-Lamp Combustor Liner Durability Test System Developed

Silicon carbide matrix composites are candidate materials for high-temperature combustor liners. Because through-the-thickness thermal gradients are the primary cause of stress on combustor liners, a unique test facility was developed at the NASA Glenn Research Center at Lewis Field to simulate in-service pure thermal stress distributions in fiber reinforced silicon carbide cylinders. It was developed initially under Phase II of the High- Speed Research Program. This test stand can accommodate 8-in.-long test cylinders that have outer diameters of 4 in. and a wall thickness of about 0.08 to 0.12 in. One cylinder at a time is loaded vertically into the test stand. Water-cooled plates enclose the open ends of the cylinder and provide cooling. Load plates on the exterior side of the water-cooled plates provide support and compression loads. To evaluate a combustor liner material s potential performance, researchers induce thermal gradients with an axisymmetric, direct-current, electric arc within the cylinder while refrigerated air at a rate of 1.5 lb/sec impinges on the outside surface of the cylinder. The achievable through-the-thickness thermal gradient is predicted to be in excess of 200 C. The 8-in. long, 0.5-in.-diameter plasma arc emits full spectrum visible light; radiant intensity exceeds 300 Watts per square centimeters to produce temperatures in excess of 1500 C on materials with emissivity near unity. Because the system does not rely upon the combustion of fuels to achieve the related thermal conditions, ancillary environmental reactions with the sample are eliminated. The system incorporates a standard mechanical test frame, which can impose constant as well cyclical axial stresses up to 2200 lb upon the test piece. Silicon-carbide-fiber reinforced silicon carbide matrix composite cylinders were instrumented with thin-film thermocouples to obtain through-the-thickness thermal flux measurements. Inside wall temperatures reached 1200 C with only 250 A of current. One of the special features of this configuration is the creation of hoop stress states within the cylinder, which up this point have not been obtainable in planar coupon tests. This facility will allow various operational modes, including accelerated tests of thermal transients simulating the effects of repeated engine ignition as well as prescribed thermal and mechanical histories to simulate various duty cycle profiles. Tests can now be performed on thermal-barrier-coated metallic liners and ceramic composite liners that require a combination of high heat flux and controlled mechanical stresses.

Goldsby, Jon C.↗
NASA NTRS2019

Regolith Particle Erosion of Material in Aerospace Environments

This paper studies the effect of exposing thermal control S13GP:6N/LO-I white paint, Kapton flex cable, fiber optic cable, HEPA filter, and M55J graphite composite to high-velocity regolith environment that spacecraft landing on Mars are commonly exposed to. Due to the similarity between the Mars 2020 Rover design and Mars Science Laboratory design, it is expected that the Mars 2020 rover will be exposed to a similar high-speed regolith environment that the Mars Science Laboratory was exposed to. This environment is replicated to test the survivability of susceptible materials. The testing is performed at the University of Dayton Research Institute in Dayton, Ohio. The experiments expose different materials to basaltic–like particles ranging in size from approximately 40 μm to 2 cm, at velocities ranging from 19 m/s to 250 m/s, with varied particle fluxes (measured in mg/cm2). Depending on the size of the particle used, the particles can either embed in or erode the material. Posttest analysis shows that all materials tested will survive the expected environment observed during the Mars 2020 landing event. Some materials are tested to failure in order to better characterize material response. Materials that fail in some test scenarios include the paint, fiber optic cable, and the graphite composite. After being exposed to regolith, the α/ε ratio of the paint increased by ~37% due to particles embedding in the paint. Darkening of the paint can negatively affect thermal control of the rover. With high particle mass fluxes, the paint eventually degraded enough to expose the aluminum substrate. When impacted by a 1.5 cm particle traveling at 20 m/s, the fiber optic cable did not sever, but the impact did cause the cable to deform enough to crack the glass, which resulted in a significant increase in attenuation, rendering the cable unable to transmit data. The graphite composite also failed when exposed to high particle fluxes. All of the observed failures occurred for test cases above the expected landing environment with significant margin. Tests performed beyond the requirements help characterize how well these materials will survive in even more extreme environments for future missions.

Abid, Mohamed↗
NASA NTRS1988

Tribology of ceramics: Report of the Committee on Tribology of Ceramics

The current state of knowledge of ceramic surface structures, composition, and reactivity is reviewed. The tribological requirements of advanced mechanical systems now being deployed (in particular, heat engines) exceed the capabilities of traditional metallic-based materials because of the high temperatures encountered. Advanced ceramic materials for such applications are receiving intense scrutiny, but there is a lack of understanding of the properties and behavior of ceramic surfaces and the influence of processing on the properties of ceramics is described. The adequacy of models, ranging form atomic to macro, to describe and to predict ceramic friction and wear are discussed, as well as what is known about lubrication at elevated temperatures. From this analysis, recommendations are made for coordination, research, and development that will lead to better performance of ceramic materials in tribological systems.

Source record↗
NASA NTRS2014

Printable Spacecraft: Flexible Electronic Platforms for NASA Missions

Why printed electronics? Why should NASA use printed electronics to make a spacecraft? Three words provide the answer: universal, impactful, progressive. The technology is universal because the applications it can affect are broad and diverse from simple sensors to fully functional spacecraft. The impact of flexible, printed electronics range from straightforward mass, volume and cost savings all the way to enabling new mission concepts. The benefits of the technology will become progressively larger from what is achievable today so that investments will pay dividends tomorrow, next year and next decade. We started off three years ago asking the question can you build an entire spacecraft out of printed electronics? In other words, can you design and fabricate a fully integrated, electronic system that performs the same end-to-end functions of a spacecraft - take scientific measurements, perform data processing, provide data storage, transmit the data, powers itself, orients and propels itself - all out of thin flexible sheets of printed electronics? This "Printable Spacecraft" pushes the limits of printed flexible electronics performance. So the answer is yes, more or less. In our studies for the NIAC (NASA Innovative Advanced Concepts) program, we have explored this question further, to explain more completely what "more or less" means and to outline what is needed to make the answer a definitive "yes". Despite its appealing "Flat Stanley"-like (a book series by Jeff Brown) qualities, making a Printable Spacecraft is not as easy as flattening the Cassini spacecraft with a bulletin board, as was Stanley Lamchop's fate. But, if NASA invests in the design challenges, the materials challenges, the performance challenges of printed electronics, it might find itself with a spacecraft that can enable as many adventures and advantages as Flat Stanley including putting it in an envelope and mailing it to the planet of your choice. You just have to let your imagination take over. In this report we document the work of the Phase 2 Printable Spacecraft task conducted under the guidance and leadership of the NIAC program. In Phase One of the NIAC task entitled "Printable Spacecraft", we investigated the viability of printed electronics technologies for creating multi-functional spacecraft platforms. Mission concepts and architectures that could be enhanced or enabled with this technology were explored. In Phase 2 we tried to answer the more practical questions such as can you really build a multi-functional printed electronic spacecraft system? If you do, can it survive the space environment? Even if it can, what benefit does a printable system provide over a traditional implementation of a spacecraft?

Materials↗
NASA NTRS1991

Analysis of advanced optical glass and systems

Optical lens systems performance utilizing optical materials comprising reluctant glass forming compositions was studied. Such special glasses are being explored by NASA/Marshall Space Flight Center (MSFC) researchers utilizing techniques such as containerless processing in space on the MSFC Acoustic Levitation Furnace and on the High Temperature Acoustic Levitation Furnace in the conceptual design phase for the United States Microgravity Laboratory (USML) series of shuttle flights. The application of high refractive index and low dispersive power glasses in optical lens design was investigated. The potential benefits and the impacts to the optical lens design performance were evaluated. The results of the studies revealed that the use of these extraordinary glasses can result in significant optical performance improvements. Recommendations of proposed optical properties for potential new glasses were also made. Applications of these new glasses are discussed, including the impact of high refractive index and low dispersive power, improvements of the system performance by using glasses which are located outside of traditional glass map, and considerations in establishing glass properties beyond conventional glass map limits.

Johnson, R. Barry↗
NASA NTRS1993

LDEF materials data bases

The Long Duration Exposure Facility (LDEF) and the accompanying experiments were composed of and contained a wide variety of materials representing the largest collection of materials flown in low Earth orbit (LEO) and retrieved for ground based analysis to date. The results and implications of the mechanical, thermal, optical, and electrical data from these materials are the foundation on which future LEO space missions will be built. The LDEF Materials Special Investigation Group (MSIG) has been charged with establishing and developing data bases to document these materials and their performance to assure not only that the data are archived for future generations but also that the data are available to the spacecraft user community in an easily accessed, user-friendly form. This paper discusses the format and content of the three data bases developed or being developed to accomplish this task. The hardware and software requirements for each of these three data bases are discussed along with current availability of the data bases. This paper also serves as a user's guide to the MAPTIS LDEF Materials Data Base.

Funk, Joan G.↗