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At least 919 records · Page 51

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NASA NTRS2019

Study of Sabatier Catalyst Performance for a Mars ISRU Propellant Production Plant

NASA is currently developing technologies for use in the field of in-situ resource utilization (ISRU). One of the technologies being advanced is the Sabatier, or methanation, reactor which converts carbon dioxide and hydrogen into methane gas and water at high temperatures. This paper discusses the catalyst life and performance issues for these reactors that would be expected on Mars and describes the test methods employed and observed results. The various catalysts were tested in their capacity for the continuous production of methane gas via the Sabatier reaction and the possible effects of launch vibration loads, exposure to liquid water, particulate contamination, and chemical contamination to the overall observed reaction efficacy of the catalysts evaluated.

Franco, Carolina↗

NASA NTRSDate not supplied

Porosity Prediction and Detection During Composite Cure Using Simulation and Ultrasonic In-Situ Inspection Inside and Autoclave

Composite materials offer unique benefits in aerospace applications such as increased strength-to-weight ratio and improved fatigue properties. They are increasingly being used in major commercial aircraft programs. However, current processing methods can lead to defects in composite parts, which are currently identified using post-manufacturing inspection methods. A cure defects process model has been developed to predict the formation of manufacturing defects (e.g., porosity and fiber waviness) in composites based on the cure parameters and part geometry. However, a capability to directly validate porosity during cure did not exist. Validation methods included comparing resin pressure measured during cure with predictions by the process model and inspection/microscopy after cure. This study developed a high-temperature ultrasonic inspection system to detect porosity defects in composites during autoclave cure and experimentally verify the predictions of the model. The system operated inside an autoclave within an enclosure cooled by intermittent liquid nitrogen(LN2) injections. A high-temperature 2.25 MHz ultrasonic transducer was utilized to transmit ultrasonic waves through the tool plate and into the composite material and to measure the amplitude and time of flight of the reflected waves with a 1 mm × 1 mm resolution. Porosity was observed via the ultrasonic reflections, which experienced increased attenuation in regions of high porosity. Distinct regions of increased porosity were present due to uneven pressure across the panel, which was driven by an intentional misfit between the flat caul plate and the tapered composite panel with ply drops. These observations matched the predictions of the model using the inputs from the experiment (e.g., part material and geometry, cure cycle) and were validated by post-cure ultrasonic inspection and micrographs. The in-situ inspection system was able to successfully provide defect detection and localization and can be applied to future manufacturing of composite structure for aerospace applications.

Porosity↗

NASA NTRS1972

Experimental and predicted cavitation performance of an 80.6 deg helical inducer in high temperature water

The cavitating performance of a stainless steel 80.6 degree flat-plate helical inducer was investigated in water over a range of liquid temperatures and flow coefficients. A semi-empirical prediction method was used to compare predicted values of required net positive suction head in water with experimental values obtained in water. Good agreement was obtained between predicted and experimental data in water. The required net positive suction head in water decreased with increasing temperature and increased with flow coefficient, similar to that observed for a like inducer in liquid hydrogen.

Kovich, G.↗

NASA NTRS1985

New method for determining heats of combustion of gaseous hydrocarbons

As a spin off of a system developed for monitoring and controlling the oxygen concentration in the Langley 8-foot High Temperature Tunnel, a highly accurate on-line technique was developed for determining heats of combustion of natural gas samples. It is based on measuring the ratio m/n, where m is the (volumetric) flowrate of oxygen required to enrich the carrier air in which the test gas flowing at the rate n is burned, such that the mole fraction of oxygen in the combustion product gases equals that in the carrier air. The m/n ratio is directly related to the heats of combustion of the saturated hydrocarbons present in the natural gas. A measurement of the m/n ratio for the test gas can provide a direct means of determination of its heat of combustion by using the calibration graph relating the m/n values for pure saturated hydrocarbons with their heats of combustion. The accuracy of the technique is determine solely by the accuracy with which the flowrates m and n can be measured and is of the order of 2 percent in the present study. The theoretical principles and experimental results are discussed.

Singh, J. J.↗

NASA NTRS1984

A new method for acoustic containerless processing of materials

The development of an acoustic positioner, which uses only one acoustic mode in chambers of rectangular, cylindrical, and spherical geometries, for high-temperature containerless processing of materials in space is described. The objective of the single-mode positioner is to develop sufficient acoustic forces to stably localize and manipulate molten materials. In order to attain this goal the transducer power, energy transfer medium, and chamber geometry and dimensions need to be optimized. The use of a variable frequency compression driver or solid-state piezoelectric transducer to optimize these properties is investigated; it is determined that a solid-state transducer would be most applicable for optimizing the positioner. The positioning capabilities of this single-mode positioner are discussed. The dependence of the acoustic forces on temperature and ambient pressure is studied. The development of a levitator to process a molten sample at 1500 C in the space environment using the cylindrical (011) mode is illustrated.

Barmatz, M.↗

NASA NTRS2016

Processing Near-Infrared Imagery of the Orion Heatshield During EFT-1 Hypersonic Reentry

The Scientifically Calibrated In-Flight Imagery (SCIFLI) team captured high-resolution, calibrated, near-infrared imagery of the Orion capsule during atmospheric reentry of the EFT-1 mission. A US Navy NP-3D aircraft equipped with a multi-band optical sensor package, referred to as Cast Glance, acquired imagery of the Orion capsule's heatshield during a period when Orion was slowing from approximately Mach 10 to Mach 7. The line-of-sight distance ranged from approximately 65 to 40 nmi. Global surface temperatures of the capsule's thermal heatshield derived from the near-infrared intensity measurements complemented the in-depth (embedded) thermocouple measurements. Moreover, these derived surface temperatures are essential to the assessment of the thermocouples' reliance on inverse heat transfer methods and material response codes to infer the surface temperature from the in-depth measurements. The paper describes the image processing challenges associated with a manually-tracked, high-angular rate air-to-air observation. Issues included management of significant frame-to-frame motions due to both tracking jerk and jitter as well as distortions due to atmospheric effects. Corrections for changing sky backgrounds (including some cirrus clouds), atmospheric attenuation, and target orientations and ranges also had to be made. The image processing goal is to reduce the detrimental effects due to motion (both sensor and capsule), vibration (jitter), and atmospherics for image quality improvement, without compromising the quantitative integrity of the data, especially local intensity (temperature) variations. The paper will detail the approach of selecting and utilizing only the highest quality images, registering several co-temporal image frames to a single image frame to the extent frame-to-frame distortions would allow, and then co-adding the registered frames to improve image quality and reduce noise. Using preflight calibration data, the registered and averaged infrared intensity images were converted to surface temperatures on the Orion capsule's heatshield. Temperature uncertainties will be discussed relative to uncertainties of surface emissivity and atmospheric transmission loss. Comparison of limited onboard surface thermocouple data to the image derived surface temperature will be presented.

Spisz, Thomas S.↗

NASA NTRSDate not supplied

Dielectric Energy Storage Materials for Space Sensors: Effect of Processing on the Performance

This paper explores the development of innovative materials for the dielectric energy storage for space components. The CaCuN 3 Ti 4 O 12 or CCTO belonging to perovskite family is of interest due to its colossal dielectric constant. It was demonstrated that materials synthesized at low temperature show nonequilibrium state and exhibit differences in the dielectric and resistivity values. The goal is to obtain high dielectric constant along with high resistivity values for achieving enhanced breakdown voltage. By using other members of the perovskite structures, it was demonstrated that similar colossal dielectric constant is observed and is dependent on processing methods. We have used heterovalent and dissimilar sized atom to replace Ca +2 ion. Accordingly, we replaced Ca +2 ion with heavy Ga +3 ion and developed gallium-based material system, Ga 2/3 Cu 3 Ti 4 O 12 . Following successful synthesis, we measured its dielectric constant and resistivity and compared with CCTO material system. Results of five sets of samples showed that lower temperature processing demonstrated mechanism of grain growth, but due to copper flow in high temperature processed samples dielectric constant and resistivity values were different.

Dielectric Energy↗

NASA NTRS1967

Second Application of the "Successive Transformations Method" to Predict the Safest Lunar Landing Site for an Astronaut: Report 3

The purpose of the first application of the "Successive Transformations Method" described in the second report was to determine, for a manned spacecraft, the optimum landing site on the moon. The results obtained, made by extrapolating the temperature TO furnished by Surveyor, can be summarized as follows: (1) The method is efficient in allowing selection of the optimum landing area. ( 2 ) The zrea selected is extensive and relatively flat; consequently, it is sufficient to allow trine for the difficult landing operation which results from the high speed of the spacecraft when reaching the moon. ( 3 ) The relative temperature obtained is lower than that where Surveyor landed. In this third report, a second application of the "Successive Transformations" is described to determine the safest conditions of a given landing site for the astronaut, especially in relation to determining the composition of the lunar surface material. As a means of accomplishing this task, it is the intent of this paper to analyze lunar craters since they are present over so much of the lunar surface.

Rojas, Hector R.↗

NASA NTRS2000

Non-Intrusive, Laser-Based Imaging of Jet-A Fuel Injection and Combustion Species in High Pressure, Subsonic Flows

The emphasis of combustion research efforts at NASA Glenn Research Center (GRC) is on collaborating with industry to design and test gas-turbine combustors and subcomponents for both sub- and supersonic applications. These next-generation aircraft combustors are required to meet strict international environmental restrictions limiting emissions. To meet these goals, innovative combustor concepts require operation at temperatures and pressures far exceeding those of current designs. New and innovative diagnostic tools are necessary to characterize these flow streams since existing methods are inadequate. The combustion diagnostics team at GRC has implemented a suite of highly sensitive, nonintrusive optical imaging methods to diagnose the flowfields of these new engine concepts. By using optically accessible combustors and flame-tubes, imaging of fuel and intermediate combustion species via planar laser-induced fluorescence (PLIF) at realistic pressures are now possible. Direct imaging of the fuel injection process through both planar Mie scattering and PLIF methods is also performed. Additionally, a novel combination of planar fuel fluorescence imaging and computational analysis allows a 3-D examination of the flowfield, resulting in spatially and temporally resolved fuel/air volume distribution maps. These maps provide detailed insight into the fuel injection process at actual conditions, thereby greatly enhancing the evaluation of fuel injector performance and other combustion phenomena. Stable species such as CO2, O2, N2, H2O, and hydrocarbons are also investigated by a newly demonstrated 1-D, spontaneous Raman spectroscopic method. This visible wavelength Raman technique allows the acquisition of quantitative, stable species concentration measurements from the flow.

Locke, R. J.↗

NASA NTRS2004

Thermally Conductive Metal-Tube/Carbon-Composite Joints

An improved method of fabricating joints between metal and carbon-fiber-based composite materials in lightweight radiators and heat sinks has been devised. Carbon-fiber-based composite materials have been used in such heat-transfer devices because they offer a combination of high thermal conductivity and low mass density. Metal tubes are typically used to carry heat-transfer fluids to and from such heat-transfer devices. The present fabrication method helps to ensure that the joints between the metal tubes and the composite-material parts in such heat-transfer devices have both (1) the relatively high thermal conductances needed for efficient transfer of heat and (2) the flexibility needed to accommodate differences among thermal expansions of dissimilar materials in operation over wide temperature ranges. Techniques used previously to join metal tubes with carbon-fiber-based composite parts have included press fitting and bonding with epoxy. Both of these prior techniques have been found to yield joints characterized by relatively high thermal resistances. The present method involves the use of a solder (63 percent Sn, 37 percent Pb) to form a highly thermally conductive joint between a metal tube and a carbon-fiber-based composite structure. Ordinarily, the large differences among the coefficients of thermal expansion of the metal tube, solder, and carbon-fiber-based composite would cause the solder to pull away from the composite upon post-fabrication cooldown from the molten state. In the present method, the structure of the solder is modified (see figure) to enable it to deform readily to accommodate the differential thermal expansion.

Copeland, Robert J.↗

NASA NTRS2007

Feasibility Study of Vapor-Mist Phase Reaction Lubrication Using a Thioether Liquid

A primary technology barrier preventing the operation of gas turbine engines and aircraft gearboxes at higher temperatures is the inability of currently used liquid lubricants to survive at the desired operating conditions over an extended time period. Current state-of-the-art organic liquid lubricants rapidly degrade at temperatures above 300 C; hence, another form of lubrication is necessary. Vapor or mist phase reaction lubrication is a unique, alternative technology for high temperature lubrication. The majority of past studies have employed a liquid phosphate ester that was vaporized or misted, and delivered to bearings or gears where the phosphate ester reacted with the metal surfaces generating a solid lubricious film. This method resulted in acceptable operating temperatures suggesting some good lubrication properties, but the continuous reaction between the phosphate ester and the iron surfaces led to wear rates unacceptable for gas turbine engine or aircraft gearbox applications. In this study, an alternative non-phosphate liquid was used to mist phase lubricate a spur gearbox rig operating at 10,000 rpm under highly loaded conditions. After 21 million shaft revolutions of operation the gears exhibited only minor wear.

Morales, Wilfredo↗

NASA NTRS1991

Photoionization modeling of Magellanic Cloud planetary nebulae. I

The results of self-consistent photoionization modeling of 38 Magellanic Cloud PNe are presented and used to construct an H-R diagram for the central stars and to obtain both the nebular chemical abundances and the physical parameters of the nebulae. T(eff)s derived from nebular excitation analysis are in agreement with temperatures derived by the classical Zanstra method. There is a linear correlation between log T(eff) and the excitation class. The majority of the central stars in the sample with optically thick nebulae have masses between 0.55 and 0.7 solar mass and are observed during their hydrogen-burning excursion toward high temperatures. Optically thin objects are found scattered throughout the H-R diagram, but tend to have a somewhat smaller mean mass. Type I PN are found to have high core masses and to lie on the descending branch of the evolutionary tracks. The nebular mass of the optically thick objects is closely related to the nebular radius, and PN with nebular masses over one solar are observed.

Dopita, M. A.↗

NASA NTRS1989

Probabilistic structural analysis of space propulsion system turbine blades

Probabilistic loads and stress analysis methods are presently applied to the second-stage blade of the SSME's high-pressure fuel turbopump, in order to illustrate how loads and stress responses can be quantified probabilistically and how the sensitivity of such component- and engine-level independent variables as engine inlet temperatures and local seal wear within the turbopump can be determined. Attention is given to a method for the derivation of probabilistic pressure, temperature, and centrifugal steady-state load descriptions of this second-stage blade from the top of the airfoil to its intersection with the firtree. Dependent-load random variables are obtained from a multilevel physical model in which duty cycle-dependent deterministic loads and related probabilistic variations are accounted for.

Newell, J. F.↗

NASA NTRS2018

Thermal Protection Systems Technology Transfer from Apollo and Space Shuttle to the Orion Program

This paper describes how the Orion program is utilizing the Thermal Protection System (TPS) experience from the Apollo and Space Shuttle programs to reduce program risk and improve affordability to meet NASA's future manned exploration missions. The Orion program successfully completed the Exploration Flight Test (EFT-1) mission in 2014 and is currently assembling, integrating, and testing the next spacecraft for the Exploration Mission (EM-1) to meet the flight test objectives of an unmanned orbital mission to the moon and return to earth in 2019. The Orion spacecraft production operations are located in the Neil Armstrong Operations and Checkout (O&C) facility at the Kennedy Space Center (KSC) providing an affordable and seamless delivery approach of vehicles directly to the launch site eliminating spacecraft transportation and additional checkout testing. Innovative vehicle design, manufacturing and test operations approaches are maturing and evolving with each Orion vehicle build to support the challenging NASA exploration mission requirements beyond Low Earth Orbit (LEO) while reducing program cost and schedule impacts. An example of Orion's evolution is the incorporation of an improved heat shield design, assembly and testing approach to meet the higher re-entry velocities for a lunar return for the EM-1 mission. The EFT- 1 heat shield was based on the Apollo heat shield manufacturing processes and was assembled at a supplier location and then transported to KSC for final integration. The EM-1 heat shield is now manufactured, assembled, tested, and installed into the spacecraft at the O&C facility reducing program cost and production schedules. The transition of the Space Shuttle TPS capabilities has enabled Orion to provide a human rated capsule design using proven materials and processes established over years of orbiter re-entry missions. The Orion Crew Module (CM) TPS configuration is derived from the Apollo CM approach utilizing improved materials and processes developed from the Space Shuttle program. The Orion EFT-1 heat shield utilized the Avcoat ablative material from Apollo which was injected into a honeycomb substrate and has been updated for EM-1 incorporating a block configuration bonded to a composite shell structure. This approach utilizes the proven Avcoat material for the heat shield ablator and is utilizing derived bonding and inspection methods and techniques from the Space Shuttle tile experience. The Orion back shell TPS configuration is based on Space Shuttle tile designs using proven tile materials and coatings. The Orion forward bay cover utilizes the high temperature tiles similar to the back shell tiles and low temperature blankets derived from the Space Shuttle program reducing weight impacts. Space Shuttle Multi-Layer Insulation (MLI) is installed in the Orion capsule to control the interior temperature environment providing a light weight design. These TPS design approaches have performed successfully on the Orion first flight test on EFT-1 and are incorporated in the configuration for the next flight test for EM-1. Completion of these two flight tests will certify the TPS for the Orion program for human rated exploration missions and has reduced the development cost to the Orion program. In addition to transitioning the Space Shuttle TPS design configurations to Orion, the supporting manufacturing infrastructure, manufacturing processes, and inspection methods are also incorporated into the Orion assembly operations at KSC. This has avoided significant startup schedule and costs impacts of new capabilities and development of support operations necessary to fabricate, install, inspect, and validate the TPS installations for the Orion spacecraft. The Thermal Protection System Facility (TPSF) which supported the Space Shuttle program provides the heat shield Avcoat blocks and the back shell AETB-8 tiles for Orion program. Extending the existing Space Shuttle TPS operations at KSC provides onsite support to the Orion spacecraft assembly operations. A significant benefit to the Orion program is the transition of the Space Shuttle technician work force at KSC. This highly skilled workforce was able to transition to the Orion program and immediately support the TPS installation operations. They brought with them the human rated manufacturing and assembly operations culture that was critical to the Space Shuttle success avoiding the retraining cost and schedule impacts of a new workforce to Orion. The technician skills certification program from the Space Shuttle was found to be compatible with the Lockheed Martin technician certification programs enabling a seamless training process utilizing process similarity avoiding the cost of retraining the work force to Orion standards. The existing workforce is certificated for multiple processes enabling reassignment of technicians to other tasks in the Orion AI&P operations reducing the overall touch labor manpower requirements. Additional benefits of using the Space Shuttle workforce is the incorporation of the lessons learned from Space Shuttle processes to improve the Orion TPS processes. This has resulted in a continuous evolution of TPS processes to improve the producibility and reduce the program cost for the TPS for the Orion program. Transitioning the Apollo and Space Shuttle TPS designs, processes, and technician workforce has been instrumental in enabling Orion to successfully meet the program challenges for NASA's exploration missions of the future.

Stewart, Michael↗

NASA NTRS2009

Silicon Wafer-Scale Substrate for Microshutters and Detector Arrays

The silicon substrate carrier was created so that a large-area array (in this case 62,000+ elements of a microshutter array) and a variety of discrete passive and active devices could be mounted on a single board, similar to a printed circuit board. However, the density and number of interconnects far exceeds the capabilities of printed circuit board technology. To overcome this hurdle, a method was developed to fabricate this carrier out of silicon and implement silicon integrated circuit (IC) technology. This method achieves a large number of high-density metal interconnects; a 100-percent yield over a 6-in. (approximately equal to 15-cm) diameter wafer (one unit per wafer); a rigid, thermally compatible structure (all components and operating conditions) to cryogenic temperatures; re-workability and component replaceability, if required; and the ability to precisely cut large-area holes through the substrate. A method that would employ indium bump technology along with wafer-scale integration onto a silicon carrier was also developed. By establishing a silicon-based version of a printed circuit board, the objectives could be met with one solution. The silicon substrate would be 2 mm thick to survive the environmental loads of a launch. More than 2,300 metal traces and over 1,500 individual wire bonds are required. To mate the microshutter array to the silicon substrate, more than 10,000 indium bumps are required. A window was cut in the substrate to allow the light signal to pass through the substrate and reach the microshutter array. The substrate was also the receptacle for multiple unpackaged IC die wire-bonded directly to the substrate (thus conserving space over conventionally packaged die). Unique features of this technology include the implementation of a 2-mmthick silicon wafer to withstand extreme mechanical loads (from a rocket launch); integrated polysilicon resistor heaters directly on the substrate; the precise formation of an open aperture (approximately equal to 3x3cm) without any crack propagation; implementation of IR transmission blocking techniques; and compatibility with indium bump bonding. Although designed for the microshutter arrays for the NIRSpec instrument on the James Webb Space Telescope, these substrates can be linked to microshutter applications in the photomask generation and stepper equipment used to make ICs and microelectromechanical system (MEMS) devices.

Jhabvala, Murzy↗

NASA NTRS1992

Directional solidification processing of alloys using an applied electric field

A method is provided for obtaining an alloy having an ordered microstructure which comprises the steps of heating the central portion of the alloy under uniform temperature so that it enters a liquid phase while the outer portions remain solid, applying a constant electric current through the alloy during the heating step, and solidifying the liquid central portion of the alloy by subjecting it to a temperature-gradient zone so that cooling occurs in a directional manner and at a given rate of speed while maintaining the application of the constant electric current through the alloy. The method is particularly suitable for use with nickel-based superalloys. The method of the present invention produces an alloy having superior characteristics such as reduced segregation. After subsequent precipitation by heat-treatment, the alloys produced by the present invention will have excellent strength and high-temperature resistance.

McKannan, Eugene C.↗

NASA NTRS1972

Bonding titanium to Rene 41 alloy

Pair of intermediate materials joined by electron beam welding method welds titanium to Rene 41 alloy. Bond is necessary for combining into one structure high strength-to-density ratio titanium fan blades and temperature resistant nickel-base alloy turbine-buckets in VTOL aircraft lift-fan rotor.

Scott, R. W.↗

NASA NTRS1976

Electrical properties of epoxies and film resistors

The reliability of hybrid microcircuits has been enhanced in recent years by the use of organic adhesives as a replacement for solder and eutectics. The epoxies have been the most effective and widely used material for this application. Methods for measuring the electrical and mechanical properties of epoxies are developed. Data are given for selected conductive adhesives at high and low frequencies. The temperature coefficients of resistance of thick film resistors are presented.

Sergent, J. E.↗