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All sourcesNASA NTRSDOE OSTI
NASA NTRS2018

Channel Wall Nozzle Manufacturing and Hot-Fire Testing Using a Laser Wire Direct Closeout Technique for Liquid Rocket Engines

A regeneratively-cooled nozzle for liquid rocket engine applications is a significant cost of the overall engine due to the complexities of manufacturing a large thin-walled structure that must operate in extreme temperature and pressure environments. The National Aeronautics and Space Administration (NASA) has been investigating and advancing methods for fabrication of liquid rocket engine channel wall nozzles to realize further cost and schedule improvements over traditional techniques. The methods being evaluated are targeting increased scale required for current NASA and commercial space programs. Several advanced rapid fabrication methods are being investigated for forming of the inner liner, producing the coolant channels, closeout of the coolant channels, and fabrication of the manifolds. NASA's Marshall Space Flight Center (MSFC) has completed process development and subscale hot-fire testing of a series of these advanced fabrication channel wall nozzle technologies to gather performance data in a relevant environment. The primary fabrication technique being discussed in this paper is Laser Wire Direct Closeout (LWDC). This process has been developed to significantly reduce the time required for closeouts of regeneratively-cooled slotted liners. It allows for channel closeout to be formed in place in addition to the structural jacket without the need for channel fillers or complex tooling. Additional technologies were also tested as part of this program including water jet milling and arc-based additive manufacturing deposition. Each nozzle included different fabrication features, materials, and methods to demonstrate durability in a hot-fire environment. The results of design, fabrication, and hot-fire testing are discussed in this paper.

Gradl, Paul R.↗
NASA NTRS2018

Cumulative Distribution of Ballistic Impact Failures of Common Twisted-Pair Data Cables at Orbital Speeds

Data wire cable runs are a significant presence on the exterior of the International Space Station (ISS), and continued ISS mission support requires detailed assessment of cables due to micrometeoroid and orbit debris (MMOD) impact. These data wire cables are twisted-pair cables consisting of two 22AWG stranded conductors and fillers inside a tight fitting braided copper shield. The copper shield and its contents are covered with a jacket that has a nominal outer diameter of 3.76 mm and beta-cloth tape. The ISS engineering community has identified two loss-of-function mechanisms for these cables: open circuits due to severed conductors within the cable, and short circuits due to contact between conductors or grounded components. As these data cables are low power systems, short circuits are not expected to burn away the contact, so both open and short circuits are considered permanent loss-of-function for the cable. A total of ninety-seven impact experiments have been performed into these cables to develop a statistical model for the failure of these cables to be used in reliability studies. The experimental work has yielded cumulative distribution functions for these cables for steel and aluminum components of the orbital debris environment at representative speeds and impact obliquities.

Miller, Joshua E.↗
NASA NTRS2018

Materials International Space Station Experiment-9 (MISSE-9) Polymers and Composites Experiment

Spacecraft in low Earth orbit (LEO) are subjected to harsh environmental conditions, including radiation (cosmic rays, ultraviolet, x-ray, and charged particle radiation), micrometeoroids and orbital debris, temperature extremes, thermal cycling, and atomic oxygen (AO). These environmental exposures can result in erosion, embrittlement and optical property degradation, threatening spacecraft performance and durability. To increase our understanding of effects such as AO erosion and radiation induced embrittlement of spacecraft materials, NASA Glenn has developed a series of experiments flown as part of the Materials International Space Station Experiment (MISSE) missions on the exterior of the International Space Station (ISS). These experiments have provided critical LEO space environment durability data such as AO erosion data for many materials and mechanical properties changes after long term space exposure. In continuing these studies, a new experiment called the Polymers and Composites Experiment has been selected for flight on the MISSE-Flight Facility (MISSE-FF). The Polymers and Composites Experiment will be flown as part of the MISSE-9 mission, the inaugural mission of MISSE-FF manifested on SpaceX-14. This experiment includes 138 samples being flown in ram, wake or zenith orientations for space environmental durability assessment. The primary objective is to determine the LEO AO erosion yield, Ey (the volume loss per incident oxygen atom (cm3/atom)), of polymers, composites, and coated samples, as a function of solar irradiation and AO fluence. In addition, epoxy samples with varying levels of ZnO powder are included to study the effect of filler quantity on AO erosion. An AO Scattering Chamber is included to help improve the understanding of AO scattering mechanisms for improved AO undercutting modeling. Indium tin oxide (ITO) coated samples are included to validate the durability of ITO conductive coatings in LEO. Tensile samples of Teflon fluorinated ethylene propylene (FEP) of varying thicknesses and back-surface coatings will be flown in wake and zenith orientations to study radiation embrittlement versus thickness, and the effect of heating on FEP embrittlement. Finally, shape memory composite and cosmic ray shielding samples will be flown for LEO durability assessment. This paper presents an overview of the MISSE-9 Polymers and Composites Experiment.

Embrittlement↗
NASA NTRS2019

Supporting NASA Science with High-Altitude Long-Endurance Aircraft

NASA Earth Science and Aeronautics researchers have been involved in development and use of High Altitude Long Endurance (HALE) unmanned aircraft systems (UAS) since the 1990's. The NASA Environmental Research Aircraft Sensor and Technology Program (ERAST) demonstrated the promise of HALE aircraft for providing observations while also proving the importance of triple-redundant avionics to improve system reliability for large unmanned aircraft. Early efforts to develop an operational HALE capability for earth observations languished for nearly two decades owing to insufficient solar panel efficiency, battery power density, and light-weight, yet strong, materials. During this time NASA researchers focused on using the Global Hawk to demonstrate the utility of providing diurnal measurements over severe storms (ie. HS3) and to track stratospheric water vapor transport (ATTREX). Recent significant commercial investments are now leading to the realization of a long-held goal of week- to month-long sustained observations and measurements from the stratosphere. In addition to a historical review of NASA use and interest in HALE aircraft, this paper will present current concepts for exploiting current and planned HALE aircraft capabilities including in situ characterization of atmospheric composition and dynamics as well as imagery collection. NASA researchers anticipate HALE will provide a useful means to test smallsat instruments and components. Observations from HALE-based instruments might also provide useful gap-filler observations to flagship satellite missions where the repeat time doesn't allow for measurements of quickly changing phenomenon. HALE will likely also provide measurements and communications relay to facilitate other aircraft in multi-aircraft campaigns. We will also report on progress towards a NASA-funded flight test planned for summer 2019 of a solar-electric vehicle designed to carry 7kg (15lbs) for 30 days at 20km altitude.

earth observations↗
NASA NTRS2019

A Design Methodology for Optimizing and Integrating Composite Materials in Gear Structures

The application of composite materials to gear structures is complex because of the gear shape, the need for precise dimensional tolerances, and the complex dynamic load condition. Methods are presented in this work to design and optimize an integrated composite hub-web structure that can be used as part of a hybrid composite-steel gear. The composite hub-web structure is a planar structure with a large decrease in thickness from the hub to the rim. Methods for design and optimization of this variable-thickness structure are presented along with a method for forming braided prepreg material to conform to the shape of this structure. A layered approach is presented that integrates cut plies or filler materials for thickness buildup with continuous-fiber layers for the primary load path. An additional gear design concept is presented that has an axially extended continuous-fiber composite structure that can be combined with the planar structure. A proposed optimization methodology is introduced where an optimized design is output for each type of optimization simulation. Through this process, composite knowledge can be incorporated in the optimization, and more control is given over the design during the process. The methods in this study provide a tool for designing and optimizing composite structures for gears and other high-power-density applications.

optimization↗
NASA NTRS2019

Demonstrating Next Generation High-Altitude, Long Endurance Aircraft for Earth Science

This paper will address NASA activities to monitor and study Earth processes from long-duration unmanned aircraft systems (UAS). NASA is currently supporting both large and small UAS development and demonstration. In a follow-on to previous work, NASA Armstrong Flight Research Center is hosting test flights of a large AeroVironment solar-powered aircraft, while NASA Ames Research Center is supporting the demonstration of a light-weight solar powered aircraft by Swift Engineering. Both are designed for long duration, multi-day flight. NASA Earth Science and Aeronautics researchers have been involved in the development and use of High Altitude Long Endurance (HALE) UAS since the 1990's. The NASA Environmental Research Aircraft Sensor and Technology Program (ERAST) demonstrated the promise of HALE aircraft for providing observations while also proving the importance of triple-redundant avionics to improve system reliability for large unmanned aircraft. Early efforts to develop an operational HALE capability for earth observations languished for nearly two decades owing to insufficient solar panel efficiency, battery power density, and light-weight, yet strong, materials. During this time NASA researchers focused on using the Global Hawk to demonstrate the utility of providing diurnal measurements over severe storms (i.e. HS3) and to track stratospheric water vapor transport (ATTREX). Recent significant commercial investments are now leading to the realization of a long-held goal of week- to month-long sustained observations and measurements from the stratosphere. In addition to a historical review of NASA use and interest in HALE aircraft, this paper will present current concepts for exploiting current and planned HALE aircraft capabilities including in situ characterization of atmospheric composition and dynamics as well as imagery collection and internet connectivity. NASA researchers anticipate HALE will also provide a useful means to test smallsat instruments and components. Observations from HALE-based instruments might also provide useful gap-filler observations to flagship satellite missions where the repeat time doesn't allow for measurements of quickly changing phenomenon. HALE will likely also provide measurements and communications relay to facilitate other aircraft in multi-aircraft campaigns. We will also report on progress towards a NASA-supported flight tests solar electric vehicles planned for 2019. One is the Swift Engineering UAS designed to carry 7kg (15lbs) for 30 days at 20km altitude. The other is the AeroVironment Hawk 30, also designed for multi-day flight.

high-altitude↗
NASA NTRS2021

Modeling and Analysis of Fluted-Core Composite Structures for Aerospace Applications

Fiber-reinforced composites are becoming more frequently used for aerospace applications, and because of mass and stiffness requirements, sandwich composites are often selected where shell-type structures are needed. However, traditional-core sandwich composites can exhibit certain manufacturing and in-service problems that have the potential to be alleviated through the use of other sandwich composite concepts. Fluted-core sandwich composite structures, which consist of integral angled web members with structural radius fillers, or noodles, spaced between laminate face sheets, is one such alternative and is considered herein. Because the noodles can consist of unidirectional fiber and can represent a significant amount of the total fluted-core cross section, accurate prediction of the structural response requires that the noodles be modeled with sufficient detail. Previous work showed that the structural response of fluted-core sandwich composite structures could be accurately represented with detailed finite element analysis using a combination of solid and shell elements. In these models, solid elements were used to represent the noodles and shell elements were used to represent the webs and faces. However, this previous solid-noodle modeling approach was also quite computationally intensive, and therefore not practical for large or complicated structures. In this document, a less computationally intensive shell-noodle approach, wherein the entire fluted-core sandwich composite construction is modeled with shell elements, is discussed and predicted structural responses are compared with those of the solid-noodle approach. It is found that by proper selection of certain geometric parameters (thickness and offset of the shell elements that represent the noodle), the shell-noodle modeling approach can be made “structurally equivalent” to the solid-noodle modelling approach.

Leonard Oremont↗
NASA NTRS2020

The Wide-field VLBA Calibrator Survey: WFCS

This paper presents the results of the largest very long baseline interferometry (VLBI) absolute astrometry campaign to date of 13,645 radio source observations with the Very Long Baseline Array. Of these, 7220 have been detected, including 6755 target sources that have never been observed with VLBI before. This makes the present VLBI catalog the largest ever published. The positions of the target sources have been determined with the median uncertainty of 1.7 mas, and 15,542 images of 7171 sources have been generated. Unlike previous absolute radio astrometry campaigns, observations were made at 4.3 and 7.6 GHz simultaneously using a single wide-band receiver. Because of the fine spectral and time resolutions, the field of view was 4'–8'—much greater than the 10''–20'' in previous surveys. This made possible the use of input catalogs with low position accuracy and the detection of a compact component in extended sources. Unlike previous absolute astrometry campaigns, both steep- and flat-spectrum sources were observed. The observations were scheduled in the so-called filler mode to fill the gaps between other high-priority programs. This was achieved by the development of the totally automatic scheduling procedure.

Leonid Petrov↗
NASA NTRS2021

Improved Potting of Litz Wires for High Power Density Electric Motor

Specific details including selections of process materials, tooling/fixture setups, and a step-by-step procedure for scaling-up demonstrations of the newly developed potting process, namely vacuum-assisted axial injection potting (VaAIP) have been fully developed for the stator winding of high power density electric motors for the future electrified aircrafts. Various essential pre-trial subtasks identified for the full-scale demonstrations were carried out. To date, optimization of cure condition and thermal stability of the coating epoxy and determination of optimum application conditions and thermal stability of the high temperature encapsulant wax were completed successfully and other subtasks were under way. The efforts to enhance thermal conductivity of the selected potting compound by adding conductive nano fillers such as boron nitride nanosheets (BNNS) have also been advanced. Initially, selection of the best mixing method and procedures was attempted via extensive and systematic experimental design.

Litz wire↗
NASA NTRS2021

Specific Heat of Epoxies and Mixtures Containing Silica, Carbon Lamp Black, and Graphite

We present specific heat measurements in the 2 – 20 K range of several commercially available epoxies (Stycast 1266, Stycast 2850FT, EPO-TEK 377, and EPO-TEK 377H) and mixtures of one of these epoxy binders and fillers such as silica, carbon lamp black, and graphite. The results are briefly described in the context of the Debye model.

Thermosetting polymers↗
NASA NTRSDate not supplied

Atomic Oxygen Environment and Effects Overview

Atomic oxygen is the most predominant constituent in the low Earth orbital environment between the altitudes of 180 and 650 km. It is also a major constituent of the Mars orbital environment. It is very chemically reactive and can oxidize many spacecraft surfaces to form volatile reaction products. The importance of understanding atomic oxygen reactions with materials has led to both flight experiments in low Earth orbit and ground-based testing in vacuum chambers containing atomic oxygen to study its’ effect on materials. Testing has been performed in order to determine the extent of the atomic oxygen reaction and assess material and component durability. In addition, the effectiveness of mitigation techniques such as application of a protective coating, adding fillers, or using shielding and getter materials has also been studied both in flight and ground-based experiments. This presentation will focus on defining atomic oxygen environments, discussing its effect on spacecraft materials, and describing some of the testing and mitigation techniques that have been investigated.

Atomic Oxygen, Low Earth Orbit, Low Mars Orbit, ox↗
NASA NTRSDate not supplied

Fully Coupled Aeroelastic Stability Analysis of Adaptive Shape Memory Alloy Structural Technologies for Airframe Noise Reduction

The objective of this work is the development of computational models and analysis of the coupled fluid-structure response of a slat gap filler (SGF) noise treatment applied to the leading-edge-slat component of a high-lift system typical of modern transport aircraft. The representative airframe chosen for this work is NASA’s High-lift Common Research Model (CRM-HL) in a baseline high-lift configuration. Superelastic shape memory alloys (SMAs) have been identified as enabling materials for these structural treatments. Since the technology elements rely upon having a highly reconfigurable structure, designs must be assessed for static aeroelastic deflection as well as dynamic aeroelastic stability using coupled computational fluid dynamics (CFD) and nonlinear computational structural dynamics (NL CSD) tools. The technical approach consists of solving for the flow field around the entire vehicle using a global CFD model, followed by extraction of relevant local subdomain data for CFD and NL-CSD co-simulations. The SGF design is assessed using both 2D and 3D co-simulations to predict quasi-static aeroelastic deformations and to assess dynamic aeroelastic stability.

Fluid structure interaction↗
NASA NTRS2022

Building and Breaking Carbon Composites with REACTER

Carbon-based composites have become indispensable materials in aerospace and other high-performance applications, yet obtaining a detailed, nanoscale understanding of their morphology and failure mechanisms using only experimental methods remains a difficult challenge. REACTER is a versatile computational modeling tool for atomistic molecular dynamics simulations designed to model chemical reactions at the speed and length scales of classical force fields. In this work, several recent features of REACTER were applied to the creation and subsequent mechanical testing of two classes of carbon composites: carbon nanotube (CNT) composites and carbon fiber reinforced polymers (CFRP). A network of CNTs was grown dynamically using the new ‘create atoms’ feature of REACTER. The CNT filler was embedded into a polyarylacetylene (PAA) matrix by simulated in situ polymerization to obtain the final composite model. To generate the second class of carbon composite, fully carbonized (graphitic) carbon fiber morphologies were created by the method of Desai et al. [1], but using the advanced reaction constraints framework of REACTER. Two fiber models were created, representing a circular carbon fiber core and a flat surface, and similarly infiltrated with resin to obtain the final CFRP structure. Failure mechanisms were elucidated by simulating mechanically induced bond breaking, as characterized by third order DFT-based tight-binding simulations, via a reaction constraint on the total potential energy of the involved atoms.

Polymer↗
NASA NTRSDate not supplied

Building and Breaking Carbon Composites with REACTER

Carbon composites have become indispensable for aerospace and other high-performance applications, and a detailed picture of their morphology and failure mechanisms remains difficult to obtain through experiment. REACTER is a versatile computational modeling tool for atomistic molecular dynamics designed to model chemical reactions at the speed and length scales of classical force fields.1 In this work, several recent features of REACTER were applied to the creation and subsequent mechanical testing of two classes of carbon composites, carbon-fiber reinforced polymers (CFRP) and carbon nanotube (CNT) composites. Carbon fiber core morphologies were created by the method of Desai et al.,2 but using the advanced reaction constraints framework of REACTER, their proposed multistep procedure was reduced to a single uninterrupted molecular dynamics simulation. The carbon fiber filler was embedded into a polymer matrix by simulated in situ polymerization of several thermosetting resins, including bismaleimide and polyarylacetylene, to obtain the final CFRP model. To generate the second class of carbon composite, CNT networks were grown dynamically using the new ‘create atoms’ feature of REACTER, and similarly infiltrated with resin to obtain CNT composites. The resulting models were compared directly to experiment using simulated high resolution transmission electron microscopy and x-ray diffraction. Failure mechanisms were elucidated by simulating mechanically induced bond breaking, as characterized by third-order DFT-based tight-binding (DFTB3) simulations, via a reaction constraint on the total potential energy of the involved atoms.

Molecular Dynamics↗
NASA NTRSDate not supplied

Initial Results of the MISSE-Flight Facility Polymers and Composites Experiment 1-4 (PCE 1-4)

Spacecraft in low Earth orbit (LEO) are subjected to harsh environmental conditions, including radiation (cosmic rays, ultraviolet (UV), x-ray and charged particle radiation), micrometeoroids and orbital debris, temperature extremes, thermal cycling, and atomic oxygen (AO). These environmental exposures can result in erosion, embrittlement and optical property degradation of susceptible materials threatening spacecraft performance and durability. To increase our understanding of effects such as AO erosion and radiation induced embrittlement of spacecraft materials, NASA Glenn Research Center has developed a series of experiments that are flown as part of the Materials International Space Station Experiment (MISSE) missions on the exterior of the International Space Station (ISS). These experiments have provided critical space environmental durability data such as AO erosion data of polymers and composites, and radiation induced mechanical property degradation of spacecraft insulation materials, after long term space exposure. In continuing these studies, four Glenn experiments with 365 flight samples have been flown on ISS’s external MISSE-Flight Facility (MISSE-FF). These experiments are the Polymers and Composites Experiment-1 (PCE-1) flown as part of the inaugural MISSE-9 mission, the PCE-2 flown as part of the MISSE-10 mission, the PCE-3 flown as part of the MISSE-12 and MISSE-15 missions, and the PCE-4 flown as part of the MISSE-13 mission. The primary objective of the PCE 1-4 experiments is to determine the AO and radiation durability of spacecraft polymers and composites. In addition, each experiment has a wide variety of spacecraft materials and hence they each have numerous additional sample objectives. Each of the PCE 1-4 is designed to examine the consequences of AO interactions including AO erosion yield (Ey) and optical and thermal property characterization. Several polymers were flown in both ram and zenith flight orientations to determine the effect of varying solar to AO ratios on Ey. Common spacecraft materials including Teflon FEP, white Tedlar and Upilex-S were included on multiple MISSE missions so erosion dependence on environment exposure can be determined. The PCE-1 includes epoxy composite samples with varying ZnO levels to determine the effect of inorganic filler level on AO durability. And, a variety of samples were flown to characterize AO scattering and AO undercutting processes. All four PCE experiments include samples to provide better insight into radiation durability of polymers and composites. The MISSE-9 PCE-1 includes Teflon FEP tensile samples flown in the wake and zenith direction so variations in radiation exposure from the different flight directions can provide insight into radiation induced embrittlement of Teflon FEP. Teflon FEP tensile samples were also flown in the wake direction as part of the MISSE-13 PCE-4. In addition, shape memory alloys, shape memory composites, melanin based composites, stressed and unstressed gossamer sun shield materials, coated and uncoated docking seal samples, and new solar cell cover slides were flown for space radiation durability and/or shielding assessment. This paper provides an overview of Glenn’s PCE 1-4 MISSE-FF experiments and provides initial post-flight observations and results.

atomic oxygen↗
NASA NTRS2023

Experimental Investigation of Block-TPS Fence/Gap Roughness Effects on Transition Onset and Turbulent Heating at Mach 6

An experimental investigation of boundary-layer transition and convective surface heating on wind tunnel models that simulated aeroshells comprised of multiple blocks of thermal protection system (TPS) material has been performed. Two representative entry vehicle geometries, a sphere-cone aeroshell and a sphere-cone aeroshell, were considered. Multiple cast ceramic models of each geometry were fabricated with varying fence heights or gap depths to represent gap fillers that either protrude above, or are recessed below, the TPS blocks due to differential ablation during reentry. Wind tunnel testing was performed at Mach 6 over a range of Reynolds numbers sufficient to produce laminar, transitional, and turbulent flow. Convective surface heating and boundary-layer transition onset data were obtained using global phosphor thermography. The experimental heating data are presented herein, as are comparisons to laminar and turbulent smooth-wall heat transfer distributions from computational flow field simulations.

Aerothermodynamics↗
NASA NTRS2022

Updated Orbital Monitoring and Dynamical Masses for Nearby M-dwarf Binaries

Young M-type binaries are particularly useful for precise isochronal dating by taking advantage of their extended pre-main sequence evolution. Orbital monitoring of these low-mass objects becomes essential in constraining their fundamental properties, as dynamical masses can be extracted from their Keplerian motion. Here, we present the combined efforts of the AstraLux Large Multiplicity Survey, together with a filler sub-programme from the SpHere INfrared Exoplanet (SHINE) project and previously unpublished data from the FastCam lucky imaging camera at the Nordical Optical Telescope (NOT) and the NaCo instrument at the Very Large Telescope (VLT). Building on previous work, we use archival and new astrometric data to constrain orbital parameters for 20 M-type binaries. We identify that eight of the binaries have strong Bayesian probabilities and belong to known young moving groups (YMGs). We provide a first attempt at constraining orbital parameters for 14 of the binaries in our sample, with the remaining six having previously fitted orbits for which we provide additional astrometric data and updated Gaia parallaxes. The substantial orbital information built up here for four of the binaries allows for direct comparison between individual dynamical masses and theoretical masses from stellar evolutionary model isochrones, with an additional three binary systems with tentative individual dynamical mass estimates likely to be improved in the near future. We attained an overall agreement between the dynamical masses and the theoretical masses from the isochrones based on the assumed YMG age of the respective binary pair. The two systems with the best orbital constrains for which we obtained individual dynamical masses, J0728 and J2317, display higher dynamical masses than predicted by evolutionary models.

Astrometry / binaries↗
NASA NTRS2023

Characterization of Slat Noise Radiation from a High-Lift Common Research Model

A test campaign was conducted in the open-jet test section of the NASA Langley 14- by 22-Foot Subsonic Tunnel on a 10%-scale, semispan version of a High-Lift Common Research Model (CRM-HL) incorporating a leading-edge slat, trailing-edge flap and removable high-fidelity main landing gear. Aerodynamic and far field acoustic measurements were obtained on baseline and acoustically treated model configurations using an ensemble of time-averaged and unsteady surface pressure sensors paired with a traversing 97-microphone phased array viewing the pressure side of the airframe. A modified version of the DAMAS deconvolution method incorporating corrections for shear layer acoustic wave decorrelation was employed to determine the locations and strengths of relevant noise sources along the span of the slat and in the vicinity of the flap edges and landing gear. The main goal of the test campaign was to use the surface pressure and array data to evaluate the effectiveness of various slat noise reduction concepts. It was found that slat-gap fillers produced significant broadband noise reduction with minimal aerodynamic performance penalties for all Mach numbers and airfoil angles of attack that were investigated. The test campaign clearly demonstrated the noise reduction benefits that can be obtained by applying appropriate treatments to leading-edge slats on commercial transport-class aircraft.

Aeronautics Research Mission Directorate↗