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

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At least 919 records · Page 51

Production of microchannel plates using nano-scale additive manufacturing

Microchannel plate (MCP) detectors have been the workhorse detector for many applications, including space borne ultra-violet imaging and spectrographic instruments. Recent advances in additive manufacturing (AM) have enabled fabrication of complex structures with nano-scale resolution facilitating the production of highly customizable MCPs. Using AM to produce MCPs potentially has many advantages over traditional fused glass substrates, including better material control (e.g., more robust glasses or ceramics), better control of microscopic features (e.g., unique pore geometries to improve performance), and better control of macroscopic features (e.g., printing precision curved surfaces for focal plane matching). Through a collaboration with industry, national laboratory, and university partners, small format microcapillary array substrates were produced using a standard polymer photoresin. In conclusion, these substrates were functionalized using atomic layer deposition and their performance was compared to current state-of-the-art Pb-glass and borosilicate-glass MCPs.

36 MATERIALS SCIENCE↗

Development of space stable thermal control coatings for use on large space vehicles

The development of a large scale manufacturing method for the production of a stable zinc orthotitanate pigment is discussed. Major emphasis was placed on the evaluation of ultraviolet radiation stability tests of pigments derived from coprecipitated and individually precipitated oxalates. Emphasis was also placed on an investigation of the conditions (time and temperature) leading to high reflectance and high optical stability. Paints were formulated in OI-650 and in OI-650G vehicles from pigments which were prepared at various temperatures. Analyses of ultraviolet irradiation test data were conducted regarding optimum pigment preparation parameters and treatment conditions.

Gilligan, J. E.↗

Development of space stable thermal control coatings for use on large space vehicles

The development of a large scale manufacturing method for the production of a stable zinc orthotitanate pigment is discussed. Major emphasis was placed on the evaluation of the radiation stability of Tektronix, Inc. pigments and of the conditions (time and temperature) leading to high reflection and high optical stability. Paints were formulated in OI-650 and in OI-650G vehicles from pigments which were prepared at various temperatures, some of which were chemically treated to remove ZnO. Ultraviolet irradiation tests of these paints were performed, and observations made regarding optimum pigment preparation parameters.

Gilligan, J. E.↗

Development of space stable thermal control coatings for use on large space vehicles

The development of a large scale manufacturing method for the production of a stable zinc orthotitanate pigment is studied, with emphasis placed on the comprehensive analysis of the properties and environmental stability of oxalate precursor zinc orthotitanate pigments and of the preparative conditions (time and temperature) leading to optimum properties and optical stability.

Gilligan, J. E.↗

Development of space stable thermal control coatings for use on large space vehicles

The development of a large scale manufacturing method for the production of a stable zinc orthotitanate pigment by means of an oxalate co-precipitation method is examined. Pigments were prepared at various temperatures, and major emphasis was placed on the determination of the important parameters of post-precipitation firing and treatment. A large-scale process for the modification of a glass resin binder was developed and paints were formulated using the binder.

Gilligan, J. E.↗

Development of structural composite mirror technology for submillimeter space telescopes

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

Freeland, R. E.↗

Process-driven roadmap for depositing super duplex stainless steel via wire Arc additive manufacturing

Here, this study systematically investigates the effects of shielding gas, bead spacing, weld mode, and travel speed on the phase balance, porosity, and hardness of wire arc additively manufactured (WAAM) super duplex stainless steel (ER2594). Robotic WAAM was employed to fabricate multilayer walls under systematically varied process conditions, followed by phase transformation simulations, X-ray computed tomography (XCT), electron backscatter diffraction (EBSD), and microhardness evaluation. Thermodynamic simulations predicted rapid cooling of AM process can suppress the potential formation of deleterious precipitates which was later validated via cross-sectional microstructure analyses of printed samples. XCT revealed porosity levels below 0.2% for all deposits, with reduced travel speed significantly lowering defect volume. Microstructural analyses revealed the evolution of various austenite precipitates, including grain boundary austenite (GBA), Widmanstätten austenite (WA), and intergranular austenite (IGA), sequentially upon cooling of the ferrite phase. Among all process parameters, weld transfer mode exhibited the strongest influence on phase balance; pulsed mode promoted higher ferrite retention (~ 36%) compared to RapidX mode. No consistent relationship between stabilized phase fraction and captured microhardness was observed. This work provides critical insights for optimizing WAAM parameters to control phase balance and mechanical performance, which is essential for producing high-integrity super duplex stainless-steel components for nuclear and marine applications.

Grain orientation↗

Cracking Problems in Low-Voltage Chip Ceramic Capacitors

Cracking remains the major reason of failures in multilayer ceramic capacitors (MLCCs) used in in space electronics. Due to a tight quality control of space-grade components, the probability that as manufactured capacitors have cracks is relatively low, and cracking is often occurs during assembly, handling and the following testing of the systems. Majority of capacitors with cracks are revealed during the integration and testing period, but although extremely rarely, defective parts remain undetected and result in failures during the mission. This situation is aggravated by manual soldering and rework that are often used during low volume production of circuit boards for space. Although failures of MLCCs are often attributed to the post-manufacturing stresses, in many cases they are due to a combination of certain deviations in the manufacturing processes that result in hidden defects in the parts and excessive stresses during assembly and use. This report gives an overview of design, manufacturing and testing processes of MLCCs focusing on elements related to cracking problems. The existing and new screening and qualification procedures and techniques are briefly described and assessed by their effectiveness in revealing cracks. The capability of different test methods to simulate stresses resulting in cracking, mechanisms of failures in capacitors with cracks, and possible methods of selecting the most robust to manual soldering stresses capacitors are discussed.

testing↗

An Improved Thermal Conductivity Polyurethane Composite for a Space Borne 20KV Power Supply

This effort was designed to find a way to reduce the temperature rise of critical components of a 20KV High Voltage Power Supply (HVPS) by improving the overall thermal conductivity of the encapsulated modules. Three strategies were evaluated by developing complete procedures, preparing samples, and performing tests. The three strategies were: 1. Improve the thermal conductivity of the polyurethane encapsulant through the addition of thermally conductive powder while minimizing impact on other characteristics of the encapsulant. 2. Improve the thermal conductivity of the polyurethane encapsulated assembly by the addition of a slab of thermally conductive, electrically insulating material, which is to act as a heat spreader. 3. Employ a more thermally conductive substrate (Al203) with the existing encapsulation scheme. The materials were chosen based on the following criteria: high dielectric breakdown strength; high thermal conductivity, ease of manufacturing, high compliance, and other standard space qualified materials properties (low out-gassing, etc.). An optimized cure was determined by a statistical design of experiments for both filled and unfilled materials. The materials were characterized for the desired properties and a complete process was developed and tested. The thermal performance was substantially improved and the strategies may be used for space flight.

Pb free↗

Interoperability Trends in Extravehicular Activity (EVA) Space Operations for the 21st Century

No other space operations in the 21 st century more comprehensively embody the challenges and dependencies of interoperability than EVA. This discipline is already functioning at an W1paralleled level of interagency, inter-organizational and international cooperation. This trend will only increase as space programs endeavor to expand in the face of shrinking budgets. Among the topics examined in this paper are hardware-oriented issues. Differences in design standards among various space participants dictate differences in the EVA tools that must be manufactured, flown and maintained on-orbit. Presently only two types of functional space suits exist in the world. However, three versions of functional airlocks are in operation. Of the three airlocks, only the International Space Station (ISS) Joint Airlock can accommodate both types of suits. Due to functional differences in the suits, completely different operating protocols are required for each. Should additional space suit or airlock designs become available, the complexity will increase. The lessons learned as a result of designing and operating within such a system are explored. This paper also examines the non-hardware challenges presented by interoperability for a discipline that is as uniquely dependent upon the individual as EVA. Operation of space suits (essentially single-person spacecrafts) by persons whose native language is not that of the suits' designers is explored. The intricacies of shared mission planning, shared control and shared execution of joint EVA's are explained. For example, once ISS is fully functional, the potential exists for two crewmembers of different nationality to be wearing suits manufactured and controlled by a third nation, while operating within an airlock manufactured and controlled by a fourth nation, in an effort to perform tasks upon hardware belonging to a fifth nation. Everything from training issues, to procedures development and writing, to real-time operations is addressed. Finally, this paper looks to the management challenges presented by interoperability in general. With budgets being reduced among all space-faring nations, the need to expand cooperation in the highly expensive field of human space operations is only going to intensify. The question facing management is not if the trend toward interoperation will continue, but how to best facilitate its doing so. Real-world EVA interoperability experience throughout the ShuttlelMir and ISS Programs is discussed to illustrate the challenges and

Miller, Gerald E.↗

Aerospace News: Space Shuttle Commemoration. Volume 2, No. 7

The complex space shuttle design was comprised of four components: the external tank, two solid rocket boosters (SRB), and the orbiter vehicle. Six orbiters were used during the life of the program. In order of introduction into the fleet, they were: Enterprise (a test vehicle), Columbia, Challenger, Discovery, Atlantis and Endeavour. The space shuttle had the unique ability to launch into orbit, perform on-orbit tasks, return to earth and land on a runway. It was an orbiting laboratory, International Space Station crew delivery and supply replenisher, satellite launcher and payload delivery vehicle, all in one. Except for the external tank, all components of the space shuttle were designed to be reusable for many flights. ATK s reusable solid rocket motors (RSRM) were designed to be flown, recovered, and the metal components reused 20 times. Following each space shuttle launch, the SRBs would parachute into the ocean and be recovered by the Liberty Star and Freedom Star recovery ships. The recovered boosters would then be received at the Cape Canaveral Air Force Station Hangar AF facility for disassembly and engineering post-flight evaluation. At Hangar AF, the RSRM field joints were demated and the segments prepared to be returned to Utah by railcar. The segments were then shipped to ATK s facilities in Clearfield for additional evaluation prior to washout, disassembly and refurbishment. Later the refurbished metal components would be transported to ATK s Promontory facilities to begin a new cycle. ATK s RSRMs were manufactured in Promontory, Utah. During the Space Shuttle Program, ATK supported NASA s Marshall Space Flight Center whose responsibility was for all propulsion elements on the program, including the main engines and solid rocket motors. On launch day for the space shuttle, ATK s Launch Site Operations employees at Kennedy Space Center (KSC) provided lead engineering support for ground operations and NASA s chief engineer. It was ATK s responsibility to have a representative in Firing Room 2 at KSC in case of potential motor problems. However, the last time ATK was responsible for a space shuttle launch slip was 1989. During launch, engineers were also stationed in Promontory on teleconference with counterparts at KSC in the event their support was required.

Source record↗

Applying Additive Manufacturing to a New Liquid Oxygen Turbopump Design

A liquid oxygen turbopump has been designed at Marshall Space Flight Center as part of the in-house, Advanced Manufacturing Demonstrator Engine (AMDE) project. Additive manufacturing, specifically direct metal laser sintering (DMLS) of Inconel 718, is used for 77% of the parts by mass. These parts include the impeller, turbine components, and housings. The near-net shape DMLS parts have been delivered and final machining is underway. Fabrication of the traditionally manufactured hardware is also proceeding. Testing in liquid oxygen is planned for Q2 of FY2017. This topic explores the design of the turbopump along with fabrication and material testing of the DMLS hardware.

O'Neal, Derek↗

Applying Additive Manufacturing to a New Liquid Oxygen Turbopump Design

A liquid oxygen turbopump has been designed at Marshall Space Flight Center as part of the in-house, Advanced Manufacturing Demonstrator Engine (AMDE) project. Additive manufacturing, specifically direct metal laser sintering (DMLS) of Inconel 718, is used for 77% of the parts by mass. These parts include the impeller, turbine components, and housings. This paper discusses the impacts of the DMLS fabrication technique on the design of the turbopump and lessons learned during DMLS hardware fabrication and material testing.

O’Neal, T. Derek↗

Powder Bed Fusion Additive Manufacturing of JBK-75

JBK-75 is an iron-nickel derivative alloy of A-286 that has been of interest to NASA’s propulsion community for use in fuel injectors and other components that are used in hot, corrosive environments. To enable the rapid production of these components in JBK-75, Marshall Space Flight Center has developed parameters for manufacturing fully dense JBK-75 components using powder bed fusion additive manufacturing (PBFAM). These parameters were developed in a two-step development. First, the depth of laser penetration in the powdered material was measured across a spectrum of laser powers to determine the optimal power necessary for generating the desired meltpool depth. The parameter set’s vector-to-vector spacing was then then tailored to guarantee the full densification of the desired area. The results of this development was a readily implementable parameter that produced 99.6% dense material when using a 147W power running at 600mm/s with a 85μm(32%) vector-to-vector spacing.

Jones, Z. C.↗

Space processing applications payload equipment study. Volume 2C: Data acquisition and process control

The services provided by the Spacelab Information Management System are discussed. The majority of the services are provided by the common-support subsystems in the Support Module furnished by the Spacelab manufacturer. The information processing requirements for the space processing applications (SPA) are identified. The requirements and capabilities for electric power, display and control panels, recording and telemetry, intercom, and closed circuit television are analyzed.

Kayton, M.↗

SCRL-Model for Human Space Flight Operations Enterprise Supply Chain

This paper will present a Supply Chain Readiness Level (SCRL) model that can be used to evaluate and configure adaptable and sustainable program and mission supply chains at an enterprise level. It will also show that using SCRL in conjunction with Technology Readiness Levels (TRLs), Manufacturing Readiness Levels (MRLs) and National Aeronautics Space Administrations (NASA s) Project Lifecycle Process will provide a more complete means of developing and evaluating a robust sustainable supply chain that encompasses the entire product, system and mission lifecycle. In addition, it will be shown that by implementing the SCRL model, NASA can additionally define supplier requirements to enable effective supply chain management (SCM). Developing and evaluating overall supply chain readiness for any product, system and mission lifecycle is critical for mission success. Readiness levels are presently being used to evaluate the maturity of technology and manufacturing capability during development and deployment phases of products and systems. For example, TRLs are used to support the assessment of the maturity of a particular technology and compare maturity of different types of technologies. MRLs are designed to assess the maturity and risk of a given technology from a manufacturing perspective. In addition, when these measurement systems are used collectively they can offer a more comprehensive view of the maturity of the system. While some aspects of the supply chain and supply chain planning are considered in these familiar metric systems, certain characteristics of an effective supply chain, when evaluated in more detail, will provide an improved insight into the readiness and risk throughout the supply chain. Therefore, a system that concentrates particularly on supply chain attributes is required to better assess enterprise supply chain readiness.

Tucker, Brian↗

Ultralight Fabric Reflux Tube (UFRT) Thermal/Vacuum Test

Spacecraft thermal control systems are essential to provide the necessary environment for the crew and equipment to function adequately on space missions. The Ultralight Fabric Reflux Tube (UFRT) was developed by Pacific Northwest Laboratory (PNL) as a lightweight radiator concept to be used on planetary-type missions (e.g., Moon, Mars). The UFRT consists of a thin-walled tube (acting as the fluid boundary), overwrapped with a low-mass ceramic fabric (acting as the primary pressure boundary). The tubes are placed in an array in the vertical position with the evaporators at the lower end. Heat is added to the evaporators, which vaporizes the working fluid. The vapor travels to the condenser end above and cools as heat is radiated to the environment. The fluid condensed on the tube wall is then returned to the evaporator by gravity. The primary objectives for the fiscal year 1994 program included the design and fabrication of prototype UFRTs and thermal/vacuum chamber testing of these test articles. Six UFRTS, with improved titanium liners, were successfully manufactured and provided to the Johnson Space Center in July 1994. Five were tested in a thermal/vacuum chamber in September 1994. Data obtained to characterize the performance of the UFRTs under simulated lunar conditions demonstrated the design concept successfully. In addition, a trade study showed that an optimized/improved UFRT could achieve as much as a 25% mass savings in the heat rejection subsystem of future planetary-type thermal control systems.

Hurlbert, K. M.↗