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At least 955 records · Page 53

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NASA NTRS2013

Using Paraffin with -10 deg C to 10 deg C Melting Point for Payload Thermal Energy Storage in SpaceX Dragon Trunk

A concept of using paraffin wax phase change material (PCM) with a melting point between -10 deg C and 10 deg C for payload thermal energy storage in a Space Exploration Technologies (SpaceX) Dragon trunk is presented. It overcomes the problem of limited heater power available to a payload with significant radiators when the Dragon is berthed to the International Space Station (ISS). It stores adequate thermal energy to keep a payload warm without power for 6 hours during the transfer from the Dragon to an ExPRESS logistics carrier (ELC) on the ISS.

Choi, Michael K.↗

NASA NTRS2016

Study of Material Consolidation at Higher Throughput Parameters in Selective Laser Melting of Inconel 718

Selective Laser Melting (SLM) is a powder bed fusion additive manufacturing process used increasingly in the aerospace industry to reduce the cost, weight, and fabrication time for complex propulsion components. SLM stands poised to revolutionize propulsion manufacturing, but there are a number of technical questions that must be addressed in order to achieve rapid, efficient fabrication and ensure adequate performance of parts manufactured using this process in safety-critical flight applications. Previous optimization studies for SLM using the Concept Laser M1 and M2 machines at NASA Marshall Space Flight Center have centered on machine default parameters. The objective of this work is to characterize the impact of higher throughput parameters (a previously unexplored region of the manufacturing operating envelope for this application) on material consolidation. In phase I of this work, density blocks were analyzed to explore the relationship between build parameters (laser power, scan speed, hatch spacing, and layer thickness) and material consolidation (assessed in terms of as-built density and porosity). Phase II additionally considers the impact of post-processing, specifically hot isostatic pressing and heat treatment, as well as deposition pattern on material consolidation in the same higher energy parameter regime considered in the phase I work. Density and microstructure represent the "first-gate" metrics for determining the adequacy of the SLM process in this parameter range and, as a critical initial indicator of material quality, will factor into a follow-on DOE that assesses the impact of these parameters on mechanical properties. This work will contribute to creating a knowledge base (understanding material behavior in all ranges of the AM equipment operating envelope) that is critical to transitioning AM from the custom low rate production sphere it currently occupies to the world of mass high rate production, where parts are fabricated at a rapid rate with confidence that they will meet or exceed all stringent functional requirements for spaceflight hardware. These studies will also provide important data on the sensitivity of material consolidation to process parameters that will inform the design and development of future flight articles using SLM.

Prater, Tracie↗

NASA NTRS2015

Source Contaminant Control for the Heat Melt Compactor

The Logistics Reduction and Repurposing project includes the heat melt compactor (HMC), a device that compacts waste containing plastic into a tile that will minimize volume, and may be used as materials for radiation shielding. During the process, a small purge gas stream is directed through the HMC chamber to transport out gasses and humidity released from the process. NASA Marshall Space Flight Center is tasked with developing and delivering a contamination control system to clean the purge gas prior to exhausting it back into the cabin for crew inhalation.

Roman, Monsi↗

NASA NTRS2015

Testing of Selective Laser Melting Turbomachinery Applicable to Exploration Upper Stage

This task is to design, fabricate, and spin test to failure a Ti6-4 hydrogen turbopump impeller that was built using the selective laser melting (SLM) fabrication process (fig. 1). The impeller is sized around upper stage engine requirements. In addition to the spin burst test, material testing will be performed on coupons that are built with the impeller.

Calvert, Marty↗

NASA NTRS2015

Stratigraphy of the Caloris Basin, Mercury: Implications for Volcanic History and Basin Impact Melt

Caloris basin, Mercury's youngest large impact basin, is filled by volcanic plains that are spectrally distinct from surrounding material. Post-plains impact craters of a variety of sizes populate the basin interior, and the spectra of the material they have excavated enable the thickness of the volcanic fill to be estimated and reveal the nature of the subsurface. The thickness of the interior volcanic plains is consistently at least 2.5 km, reaching 3.5 km in places, with thinner fill toward the edge of the basin. No systematic variations in fill thickness are observed with long-wavelength topography or azimuth. The lack of correlation between plains thickness and variations in elevation at large horizontal scales within the basin indicates that plains emplacement must have predated most, if not all, of the changes in long-wavelength topography that affected the basin. There are no embayed or unambiguously buried (ghost) craters with diameters greater than 10 km in the Caloris interior plains. The absence of such ghost craters indicates that one or more of the following scenarios must hold: the plains are sufficiently thick to have buried all evidence of craters that formed between the Caloris impact event and the emplacement of the plains; the plains were emplaced soon after basin formation; or the complex tectonic deformation of the basin interior has disguised wrinkle-ridge rings localized by buried craters. That low-reflectance material (LRM) was exposed by every impact that penetrated through the surface volcanic plains provides a means to explore near-surface stratigraphy. If all occurrences of LRM are derived from a single layer, the subsurface LRM deposit is at least 7.5-8.5 km thick and its top likely once made up the Caloris basin floor. The Caloris-forming impact would have generated a layer of impact melt 3-15 km thick; such a layer could account for the entire thickness of LRM. This material would have been derived from a combination of lower crust and upper mantle.

Cratering↗

NASA NTRS2016

Low-Melt Poly(Amic Acids) and Polyimides and Their Uses

Provided are low-melt polyimides and poly(amic acids) (PAAs) for use as adhesives, and methods of using the materials for attaching two substrates. The methods typically form an adhesive bond that is hermetically sealed to both substrates. Additionally, the method typically forms a cross-linked bonding material that is flexible.

Jolley, Scott T.↗

NASA NTRS2016

The Effect of Laser Scan Strategy on Distortion and Residual Stresses of Arches Made With Selective Laser Melting

The NASA Marshall Space Flight Center (MSFC) is developing Additive Manufacturing (AM) - both in-space AM for on-demand parts, tools, or structures, and on-earth AM for rapid, reduced-cost, small volume production of complex space-flight hardware. Selective Laser Melting (SLM) is an on-earth AM technology that MSFC is using to build Alloy 718 rocket engine components. An understanding of the SLM-718 material properties is required to design, build, and qualify these components for space flight. Residual stresses and are of particular interest for this AM process, since SLM is a series of approximately 100 micron-wide welds, where highly non-linear heating and cooling, severe thermal gradients and repeated thermal cycling can result in high residual stresses within the component. These stresses may cause degraded material properties, and warp or distort the geometry of the SLM component. The distortions can render the component out-of-tolerance when inspected, and even interrupt or halt the build process if the warped material prevents the SLM machine from operating properly. The component must be scrapped and re-designed, which is time consuming and costly. If residual stresses are better understood, and can be predicted, these effects can be mitigated early in the component's design. the compressive residual stresses in the z-direction were highest in the chess sample, followed by island then continuous. This may be due to the binding nature of the segments

Bagg, Stacey D.↗

NASA NTRS2016

Space Mission Utility and Requirements for a Heat Melt Compactor

Management of waste on long-duration space missions is both a problem and an opportunity. Uncontained or unprocessed waste is a crew health hazard and a habitat storage problem. A Heat Melt Compactor (HMC) such as NASA has been developing is capable of processing space mission trash and converting it to useful products. The HMC is intended to process space mission trash to achieve a number of objectives including: volume reduction, biological safening and stabilization, water recovery, radiation shielding, and planetary protection. This paper explores the utility of the HMC to future space missions and how this translates into HMC system requirements.

waste utilization↗

NASA NTRS2016

Materials Characterization of Electron Beam Melted Ti-6Al-4V

An in-depth material characterization of Electron Beam Melted (EBM) Ti-6Al-4V material has been completed on samples fabricated on an ARCAM A2X EBM machine. The specimens were fabricated under eight separate builds with the material divided into two lots for material testing purposes. Hot Isostatic Pressing (HIP) was utilized to close porosity from fabrication and also served as a material heat treatment to obtain the desired microstructure. The changes in the microstructure and chemistry from the powder to pre-HIP and post-HIP material have been analyzed. Several nondestructive evaluation (NDE) techniques were utilized to characterize the samples both before and after HIP. The test matrix included tensile, high cycle fatigue, low cycle fatigue, fracture toughness, and fatigue crack growth at cryogenic, room, and elevated temperatures. The mechanical properties of the EBM Ti-6Al-4V are compared to conventional Ti-6Al-4V in the annealed condition. Fractography was performed to determine failure initiation site. The EBM Ti-6Al-4V had similar or superior mechanical properties compared to conventionally manufactured Ti-6Al-4V.

Titanium↗

NASA NTRS2016

Ring Resonator for Detection of Melting Brine Under Shallow Subsurface of Mars

Laboratory experimental evidence using Raman spectroscopy has shown that liquid brine may form below the shallow subsurface of Mars. A simpler experimental method to verify the presence of liquid brine or liquid water below Mars surface is needed. In this paper, a ring resonator is used to detect the phase change between frozen water and liquid water below a sandy soil that simulates the Mars surface. Experimental data shows that the ring resonator can detect the melting of thin layers of frozen brine or water up to 15 mm below the surface.

brine↗

NASA NTRS2016

InSitu SEM Investigation of Microstructural Damage Evolution and Strain Relaxation in a Melt Infiltrated SiC/SiC Composite

With CMC components poised to complete flight certification in turbine engines on commercial aircraft within the near future, there are many efforts within the aerospace community to model the mechanical and environmental degradation of CMCs. Direct observations of damage evolution are needed to support these modeling efforts and provide quantitative measures of damage parameters used in the various models. This study was performed to characterize the damage evolution during tensile loading of a melt infiltrated (MI) silicon carbide reinforced silicon carbide (SiC/SiC) composite. A SiC/SiC tensile coupon was loaded to a maximum global stress of 30 ksi in a tensile fixture within an SEM while observations were made at 5 ksi increments. Both traditional image analysis and DIC (digital image correlation) were used to quantify damage evolution. With the DIC analysis, microscale damage was observed at the fiber-matrix interfaces at stresses as low as 5 ksi. First matrix cracking took place between 20 and 25 ksi, accompanied by an observable relaxation in strain near matrix cracks. Matrix crack opening measurements at the maximum load ranged from 200 nm to 1.5 m. Crack opening along the fiber-matrix interface was also characterized as a function of load and angular position relative to the loading axis. This characterization was funded by NASA GRC and was performed to support NASA GRC modeling of SiC/SiC environmental degradation

testing↗

NASA NTRS2017

Ar-Ar Thermochronlogy of Apollo 12 Impact-Melt Breccia 12033,638-1

We have undertaken an Ar-Ar thermochronology investigation as part of a coordinated multichronometer analysis of a single Apollo 12 impact- melt breccia to demonstrate the wide range of information that can be obtained for a single complex rock. This has implications for the age of formation, component makeup, and subsequent impact/shock and exposure history of the sample. This study also serves as a capabilities demonstration for the proposed MoonRise Mission [1]. The goal of this investigation is to elucidate the history of this sample through coordinated 40Ar*/39Ar, Sm-Nd, Rb-Sr and zircon 207Pb-206Pb ages along with geochemical and petrographic context on a relatively small (approximately 450 mg) sample. Here, we report preliminary results of the Ar-Ar thermochronology.

Crow, C. A.↗

NASA NTRS2016

Ring Resonator for Detection of Melting Brine Under Shallow Subsurface of Mars

Mars↗

NASA NTRS2017

The Onset of the Cataclysm: In Situ Dating of a Nearside Basin Impact-Melt Sheet Or, There and Not Back Again

Impact-melt samples from Apollo Luna are 3.85-4.1 Ga, tied to Imbrium, Serenitatis, Crisium, Nectaris, plus other craters? May have been caused by destabilization of material in early solar system by dynamic forces such as gas drag and gravitational interactions Coincident with the oldest rocks on the Earth and later than the earliest isotopic signs of life on Earth. Earth was already a planet with oceans, plate tectonics, and single celled life What was happening on the Moon before 3.9 Ga affected the course of life on Earth, the structure of our Solar System, and the dynamics of extra solar planetary systems.

Cohen, Barbara A.↗

NASA NTRS2017

Heat Melt Compactor Development Progress

The status of the Heat Melt Compactor (HMC) development project is reported. HMC Generation 2 (Gen 2) has been assembled and initial testing has begun. A baseline mission use case for trash volume reduction, water recovery, trash sterilization, and the venting of effluent gases and water vapor to space has been conceptualized. A test campaign to reduce technical risks is underway. This risk reduction testing examines the many varied operating scenarios and conditions needed for processing trash during a space mission. The test results along with performance characterization of HMC Gen 2 will be used to prescribe requirements and specifications for a future ISS flight Technology Demonstration. We report on the current status, technical risks, and test results in the context of an ISS vent-to-space Technology Demonstration.

ECLSS↗

NASA NTRS2018

Impact of Powder Variability on the Microstructure and Mechanical Behavior of Selective Laser Melted Alloy 718

Powder-bed additive manufacturing processes use fine powders to build parts layer-by-layer. Alloy 718 powder feedstocks for selective laser melting (SLM) additive manufacturing are produced commercially by both gas and rotary atomization and are available typically in the 10-45 or 15-45 microns size ranges. A comprehensive investigation was conducted to understand the impact of powder variability on the microstructure and mechanical behavior of SLM 718 heat treated to Aerospace Material Specification (AMS) 5664. This study included sixteen virgin powders and three once-recycled powders within the 10-45 and 15-45 microns size ranges that were obtained from seven direct source suppliers and one reseller. Although alike as highly regular spheroids, these powders showed distinct differences in composition (especially Al, C and N contents), particle size distributions, and powder features such as degree of agglomeration, fusion and surface roughness. Compositional differences expectedly had the strongest impact on microstructure. High N and C contents formed TiN-nitrides and/or (Nb,Ti,Mo)-C carbides on the grain boundaries, prevented recrystallization during heat treatment, and resulted in retained (001)-scalloped shaped grains that ranged from 19 to 41 microns in average size. In the absence of this particle pinning, the average grain size of the heat treated SLM 718 ranged from 51 microns to 90 microns. Room temperature tensile and high cycle fatigue (HCF) testing compared as-fabricated (AF) and low stress ground (LSG) surface conditions. Tensile testing revealed consistent behavior between the two surface conditions and amongst the powder lots. The finer grained SLM 718 builds displayed the lowest tensile properties. A SLM 718 build fabricated from a powder with eight times lower C content showed statistically better tensile properties presumably due to enhanced coarsening of (delta)-Ni3Nb precipitates. The specimens from once-recycled powders had slightly higher tensile strengths and slightly higher ductility compared to their virgin equivalents; once-recycling also did not substantially degrade the mean HCF life. The LSG fatigue lives agreed with conventionally manufactured 718 data, while AF lives exhibited a knock-down due to surface roughness. The fatigue lives of AF specimens were statistically equivalent across powder lots except for one and failures typically initiated at stress concentrators associated with SLM surface asperities. Fatigue testing of low stress ground specimens result in both transgranular and within facet crack initiations. More than half of the cracks initiated from these facets for the machined condition; however, these facets appeared to be within grains that were larger-than-average in size. A nitrogen-atomized powder with fine prior particles of TiN-nitrides and M(Ti,Nb,Mo)C carbides from atomization on powder surfaces resulted in the best fatigue performance with segregation of these particles to the SLM 718 grain boundaries leading to higher resistance to early-stage crack propagation. Typically the fine-grained builds with minor phases along the grain boundaries did not perform well in fatigue, whereas a larger-grain build with lower carbon content and coarser delta-Ni3Nb precipitates showed the next best HCF response. Further details of the build microstructure and its impact on tensile and fatigue behavior was considered.

laser deposition↗

NASA NTRS2015

Selective Laser Melting Inconel 718 Restart Study

Selective Laser Melting (SLM) machines can occasionally shut down (such as in the event of a power failure), which requires the SLM build to be restarted. It has been observed that machine restarts can produce visible "restart lines" in the part, and, in at least one instance, a test specimen containing a restart line exhibited poor mechanical properties. The goal of this study is to evaluate the effect of different machine restart factors on the mechanical properties of the produced SLM material. Test specimens were produced by varying time to restart, the number of re-sinters, and whether or not the build required re-levelling. These are build variables that are typically controlled by the machine operator. Test results indicate that re-leveling and using three re-sinters produces acceptable material. Statistical analysis indicates that re-leveling and re-sintering have strong effects on the resulting material properties. Additionally, the visibility of a restart line loosely correlates with material properties such that obvious restart lines tended to indicate worse material properties.

Tilson, William G.↗

NASA NTRS2018

Observed Response of the Raindrop Size Distribution to Changes in the Melting Layer

Vertical variability in the raindrop size distribution (RSD) can disrupt the basic assumption of a constant rain profile that is customarily parameterized in radar-based quantitative precipitation estimation (QPE) techniques. This study investigates the utility of melting layer (ML) characteristics to help prescribe the RSD, in particular the mass-weighted mean diameter (Dm), of stratiform rainfall. We utilize ground-based polarimetric radar to map the ML and compare it with Dm observations from the ground upwards to the bottom of the ML. The results show definitive proof that a thickening, and to a lesser extent a lowering, of the ML causes an increase in raindrop diameter below the ML that extends to the surface. The connection between rainfall at the ground and the overlying microphysics in the column provide a means for improving radar QPE at far distances from a ground-based radar or close to the ground where satellite-based radar rainfall retrievals can be ill-defined.

Weather↗