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At least 973 records · Page 54

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DOE OSTI2024

Synthesizing, Compounding, and Characterizing a Heat Labile Polyurethane Foam

ABSTRACT A need exists for a packaging foam material that can be converted from solid to gaseous degradation products at reasonably low energy levels or temperatures, such as 100O C. This paper will primarily discuss the approaches currently being used to synthesize and characterize such a material. These approaches include the incorporation of novel polyols such as azo containing diols, polycarbonate diols, and polypropylene carbonate polyols into polyurethane foams. Characterization methods include NMR, FTIR, TGA, finite element analysis, impact strength, and others. This project will be funded for a duration of three years. Year 1 focused on developing the proposed test methods and producing an initial rigid polyurethane foam. Year 2 focuses on refining the materials and test methods. If appropriate, design of experiment (doe) techniques will be used to optimize components, component levels, density and other variables to attain required final material properties (TGA weight loss, impact strength, etc.). Year 3 focuses on scaling up to larger engineering quantities. The application for this material is in load securement for transportation of low level radioactive waste materials within the US Department of Energy (DOE) complex. Foam in place process equipment and operators will be shielded using this novel method over current practice. Current practice can involve time consuming methods of load securement in low level radiation environments. This new technique would eliminate exposure time securing the load and greatly improve the As Low As Reasonably Attainable (ALARA) conditions. The objective is to progress to higher Technical Readiness Levels (TRL) and larger pilot scale quantities. This paper discusses methodologies and presents current results to date.

Kranjc, Mark D.↗

NASA NTRS1979

Silicon Ingot Casting - Heat Exchanger Method Multi-wire Slicing - Fixed Abrasive Slicing Technique. Phase 3 Silicon Sheet Growth Development for the Large Area Sheet Task of the Low-cost Solar Array Project

Several 20 cm diameter silicon ingots, up to 6.3 kg. were cast with good crystallinity. The graphite heat zone can be purified by heating it to high temperatures in vacuum. This is important in reducing costs and purification of large parts. Electroplated wires with 45 um synthetic diamonds and 30 um natural diamonds showed good cutting efficiency and lifetime. During slicing of a 10 cm x 10 cm workpiece, jerky motion occurred in the feed and rocking mechanisms. This problem is corrected and modifications were made to reduce the weight of the bladeheat by 50%.

Schmid, F.↗

NASA NTRS1989

Design of a spanloader cargo aircraft

The design features of an aircraft capable of fulfilling a long haul, high capacity cargo mission are described. This span-loading aircraft, or flying wing, is capable of carrying extremely large payloads and is expected to be in demand to replace the slow-moving cargo ships currently in use. The spanloader seeks to reduce empty weight by eliminating the aircraft fuselage. Disadvantages are the thickness of the cargo-containing wing, and resulting stability and control problems. The spanloader presented here has a small fuselage, low-aspect ratio wings, winglets, and uses six turbofan engines for propulsion. It will have a payload capacity of 300,000 pounds plus 30 first class passengers and 6 crew members. Its projected market is transportation of freight from Europe and the U.S.A. to countries in the Pacific Basin. Cost estimates support its economic feasibility.

Weisshaar, Terrence A.↗

NASA NTRS1989

Space Station Freedom cupola definition

Following the realization that adequate Space Station Freedom viewing could not be achieved without breaking the plane of the modules, a conceptual design phase for the development of a cupola progressed from the idea of a small, bubble-type canopy to a much larger, two crewmember cupola. The evolving cupola conceptual designs were each evaluated against the requirements for providing a large field-of-view, a complete proximity control workstation with flexible and relocatable restraints, and sufficient volume for two, 95th percentile crewmembers to operate while still maintaining reasonable weight and size restrictions. As the SS Freedom program Preliminary Design Review draws closer, the cupola development phase shifts toward evaluation of viewing and operational capability. The appropriate balance of viewing, structures and operations must be achieved before the program can place confidence in a cupola design providing SS Freedom with a direct viewing workstation capable of supporting the great variety of tasks projected for the life of the station.

Weaver, Laurie A.↗

NASA NTRS2000

Airframe Design and Integration

The objectives of the project this viewgraph presentation summarizes include the following: (1) Decompose operational, safety, and cost requirements into a comprehensive and consistent set of design criteria for different structural and material concepts for Reusable Launch Vehicles (RLVs); (2) Develop compliance methods to ensure that different structural and material concepts are assessed at a consistent and adequate level of fidelity and safety; (3) Develop and assess weight reduction potential of integrated airframe concepts for RLVs, e.g., Thermal Protection System (TPS)/TPS Support/Cryogenic Tank System; (4) Compare performance and weight of various airframe structural and material concepts and structural arrangements and identify technology development needs; and (5) Develop high fidelity parametric models that include airframe structural interactions and major design drivers. The approaches taken to complete these objectives include the definition of vehicle requirements, airframe structural design requirements, load conditions, factors of safety, and integrated concepts.

Scotti, Stephen↗

NASA NTRS2014

A Fully Non-metallic Gas Turbine Engine Enabled by Additive Manufacturing

The Non-Metallic Gas Turbine Engine project, funded by NASA Aeronautics Research Institute (NARI), represents the first comprehensive evaluation of emerging materials and manufacturing technologies that will enable fully nonmetallic gas turbine engines. This will be achieved by assessing the feasibility of using additive manufacturing technologies for fabricating polymer matrix composite (PMC) and ceramic matrix composite (CMC) gas turbine engine components. The benefits of the proposed effort include: 50 weight reduction compared to metallic parts, reduced manufacturing costs due to less machining and no tooling requirements, reduced part count due to net shape single component fabrication, and rapid design change and production iterations. Two high payoff metallic components have been identified for replacement with PMCs and will be fabricated using fused deposition modeling (FDM) with high temperature capable polymer filaments. The first component is an acoustic panel treatment with a honeycomb structure with an integrated back sheet and perforated front sheet. The second component is a compressor inlet guide vane. The CMC effort, which is starting at a lower technology readiness level, will use a binder jet process to fabricate silicon carbide test coupons and demonstration articles. The polymer and ceramic additive manufacturing efforts will advance from monolithic materials toward silicon carbide and carbon fiber reinforced composites for improved properties. Microstructural analysis and mechanical testing will be conducted on the PMC and CMC materials. System studies will assess the benefits of fully nonmetallic gas turbine engine in terms of fuel burn, emissions, reduction of part count, and cost. The proposed effort will be focused on a small 7000 lbf gas turbine engine. However, the concepts are equally applicable to large gas turbine engines. The proposed effort includes a multidisciplinary, multiorganization NASA - industry team that includes experts in ceramic materials and CMCs, polymers and PMCs, structural engineering, additive manufacturing, engine design and analysis, and system analysis.

manufacturing↗

NASA NTRS2015

Optoelectronic Infrastructure for Radio Frequency and Optical Phased Arrays

Optoelectronic integrated circuits offer radiation-hardened solutions for satellite systems in addition to improved size, weight, power, and bandwidth characteristics. ODIS, Inc., has developed optoelectronic integrated circuit technology for sensing and data transfer in phased arrays. The technology applies integrated components (lasers, amplifiers, modulators, detectors, and optical waveguide switches) to a radio frequency (RF) array with true time delay for beamsteering. Optical beamsteering is achieved by controlling the current in a two-dimensional (2D) array. In this project, ODIS integrated key components to produce common RF-optical aperture operation.

Cai, Jianhong↗

NASA NTRS2016

Nanotechnology

Present an overview of the Nanotechnology Project at NASA's Game Changing Technology Industry Day. Mature and demonstrate flight readiness of CNT reinforced composites for future NASA mission applicationsSounding rocket test in a multiexperiment payloadIntegrate into cold gas thruster system as propellant storageThe technology would provide the means for reduced COPV mass and improved damage tolerance and flight qualify CNT reinforced composites. PROBLEM/NEED BEING ADDRESSED:Reduce weight and enhance the performance and damage tolerance of aerospace structuresGAME-CHANGING SOLUTION:Improve mechanical properties of CNTs to eventually replace CFRP –lighter and strongerFirst flight-testing of a CNT reinforced composite structural component as part of an operational flight systemUNIQUENESS:CNT manufacturing methods developedFlight qualify CNT reinforced composites

Nanotechnology↗

NASA NTRSDate not supplied

Technology Drives Exploration: How NASA Is Embracing Additive Manufacturing

NASA has over 60 years of technology development that enabled human space and space science exploration “for the benefit of all humankind”. This presentation will start with the overview of NASA’s organization structure; the roles NASA’s leadership plays as well as 10 regional centers’ focused areas and capabilities. It will also highlight NASA’s Mission Directorates –Science, Human, Aeronautics, and Technology. With the onset of the newer and still evolving procurement business model (NASA being a buyer, instead of maker), a question remains: which is the right framework under which NASA can best integrate the capabilities of commercial, international, and other US government entities into a coherent exploration strategy? Another critical consideration is identifying which critical technologies to invest in NASA and which capabilities are better suited for commercialization as NASA as a buyer. Additive Manufacturing (AM) is certainly changing the space industry and providing new opportunities to travel to low earth orbit and explore our universe. New design opportunities –not previously possible –for new high performance metal alloys, light-weighting, managing thermal, structural, and dynamic loads are being enabled by AM. This presentation will showcase the vast portfolio of NASA’s AM activities in the last 13 years; transportation from Earth to Destination, Habitat at Destination, Lander from Station to Surface, and Science mission spacecrafts. NASA’s technical excellence is being leveraged heavily in the AM and Commercial Space community through collaborative projects, partnership agreements, tech transfer program. Examples of challenges of AM implementation as well as opportunities will be discussed.

Alison Park↗

NASA NTRS1985

Overview of the 1985 NASA Lewis Research Center SP-100 free-piston Stirling engine activities

This effort is keyed on the design, fabrication, assembly, and testing of a 25 kWe Stirling space-power technology-feasibility demonstrator engine. Another facet of the SP-100 project covers the status of a 9000-hr endurance test conducted on a 2 kWe free-piston Stirling/linear alternator system employing hydrostatic gas bearings. Dynamic balancing of the RE-1000 engine (a 1 kWe free-piston Stirling engine) using a passive dynamic absorber will be discussed along with the results of a parametric study showing the relationships of Stirling power converter specific weight and efficiency as functions of Stirling engine heater to cooler temperature ratio. Planned tests will be described covering a hydrodynamic gas bearing concept for potential SP-100 application.

Slaby, J.↗

NASA NTRS1985

Overview of the 1985 NASA Lewis Research Center SP-100 free-piston Stirling engine activities

Slaby, J. G.↗

NASA NTRS2014

Conceptual Launch Vehicle and Spacecraft Design for Risk Assessment

One of the most challenging aspects of developing human space launch and exploration systems is minimizing and mitigating the many potential risk factors to ensure the safest possible design while also meeting the required cost, weight, and performance criteria. In order to accomplish this, effective risk analyses and trade studies are needed to identify key risk drivers, dependencies, and sensitivities as the design evolves. The Engineering Risk Assessment (ERA) team at NASA Ames Research Center (ARC) develops advanced risk analysis approaches, models, and tools to provide such meaningful risk and reliability data throughout vehicle development. The goal of the project presented in this memorandum is to design a generic launch 7 vehicle and spacecraft architecture that can be used to develop and demonstrate these new risk analysis techniques without relying on other proprietary or sensitive vehicle designs. To accomplish this, initial spacecraft and launch vehicle (LV) designs were established using historical sizing relationships for a mission delivering four crewmembers and equipment to the International Space Station (ISS). Mass-estimating relationships (MERs) were used to size the crew capsule and launch vehicle, and a combination of optimization techniques and iterative design processes were employed to determine a possible two-stage-to-orbit (TSTO) launch trajectory into a 350-kilometer orbit. Primary subsystems were also designed for the crewed capsule architecture, based on a 24-hour on-orbit mission with a 7-day contingency. Safety analysis was also performed to identify major risks to crew survivability and assess the system's overall reliability. These procedures and analyses validate that the architecture's basic design and performance are reasonable to be used for risk trade studies. While the vehicle designs presented are not intended to represent a viable architecture, they will provide a valuable initial platform for developing and demonstrating innovative risk assessment capabilities.

Launch Vehicle↗

NASA NTRS2022

The Global L-Band Observatory for Water Cycle Studies (Glows)– SMAP continuity Mission

SMOS and SMAP radiometers have demonstrated the ability to monitor soil moisture and sea surface salinity and continue to provide high quality radiometric measurements to this day in extended mission operations. It is important to maintain data continuity for these science measurements. The proposed instrument concept (Global L-band active/passive Observatory for Water cycle Studies - GLOWS) will enable low-cost L-band data continuity (that includes both L-band radar and radiometer measurements). The objective of this project is to develop key instrument technology to enable L-band observations using an Earth Venture class satellite. Specifically, a new deployable reflectarray lens antenna is being developed that will enable a smaller EELV Secondary Payload Adapter (ESPA) Grande-class satellite mission to continue the L-band observations at SMAP and SMOS resolution and accuracy at substantially lower cost, size, and weight

SMAP↗

NASA NTRSDate not supplied

Uncertainty Estimates for Fitting Zernike Polynomials to Discrete Data

Zernike polynomials are a widely used metric in modern optical analysis. They conveniently represent surfaces as a series of weighted terms corresponding to various optical aberrations. Ideally, each term is independent of others in the series, but Zernike polynomials lose this property when working with sets of discrete data. This gives rise to uncertainty in each polynomial’s actual contribution and affects metrology and simulation estimates of their relative weights. Several factors influencing these estimates are the number and arrangement of sample locations, the method for calculating the weights, and the total number of Zernike terms used in the calculation. Discussed is the uncertainty associated with linear regression using random sampling. Other topics reviewed are complex Zernike polynomials and vector spaces of functions.

Zernike Polynomials↗

DOE OSTI2022

Low Cost, High Volume, Carbon Fiber Precursor for Plasma Oxidation

Light weighting with carbon fiber is critical to improving the energy efficiency of wind turbines, airplanes, and automobiles, but the high cost of carbon fiber continues to limit market growth and applications. Half of this cost is in the raw materials. For the carbon fiber market to reach the next level of adoption, the cost of both the raw materials and conversion must be reduced. This project considered the combination of low-cost, textile-grade precursors combined with the increased efficiency of plasma oxidation to greatly reduce the cost of carbon fiber. The primary objective of this project was to make industrial-grade carbon fiber (550 ksi tensile strength, 35 Msi tensile modulus) from textile-grade PAN precursors, something that cannot be achieved with conventional oxidation and to date has not been achieved with any technology. To accomplish this, the project team iteratively optimized the process conditions in the plasma oxidation and carbonization stages to maximize the tensile properties of the resultant carbon fibers. This involved implementing experimental designs for both stages, whereby process conditions (e.g. temperature) were varied and correlated to fiber properties. Samples of oxidized PAN fibers (OPFs) were prepared using a small pilot-scale plasma oxidation oven at 4XTechnologies (4XT). The thermal, chemical, and physical properties of OPF samples were analyzed by the University of Tennessee (UTK) and Oak Ridge National Laboratory (ORNL). The OPF samples were then converted to carbon fiber by subsequent low- and high-temperature carbonization using a lab-scale furnace at ORNL. The resultant carbon fibers were tested for tensile strength also at ORNL, and the results were fed back into the experimental design. Of the hundreds of carbon fiber samples produced over the course of the project, the best sample had an average break strength of 479 ksi and modulus of 33 Msi. While the best tensile properties achieved fell short of the final project targets of 550 ksi for break strength and 35 Msi for modulus, the team demonstrated the potential to produce industrial-grade carbon fiber using textile-grade precursors. The best performing fiber samples had tensile properties that are 87% of the goal for tensile strength and 94% of the goal for tensile modulus. With additional optimization work, it is likely that the targets could be achieved, since only a fraction of the process parameter space was explored during this project. 4XT and its affiliate (4M) have already secured funding through private equity, and there is a CRADA (Cooperative Research and Development Agreement) project currently underway with the Carbon Fiber Technology Center (CFTF) at ORNL to continue this research. Additionally, while not an original goal of the project, the carbon fibers for most samples had diameters >8.5μm. This is considerably larger than commercially available carbon fiber products, which can impart unique properties to the composites (e.g. increased compressive strength) and decrease manufacturing costs even further. Moreover, these fibers were oxidized with plasma oxidation using residence times ranging <60mins, which would be considered fast for normal diameter fibers, but it is as much as 5x faster when factoring in the diameter of the fibers.

36 MATERIALS SCIENCE↗

NASA NTRS1992

The unique challenge of managing an undergraduate Get-Away-Special experiment

A group of Bringham Young University (BYU) undergraduate students has undertaken an experiment to design and build a normal incidence soft x ray robotics telescope for solar observations. The design phase of this, GOLDHELOX project, has now been completed and final construction and modifications are in progress. The design and manufacture of the payload is under the direction of team leaders and a system's integrator. A goal of this project is educating and furnishing experiences in space engineering and physics for undergraduate students. Our main source of funding is NASA and the BYU Colleges of Physical and Mathematical Sciences and Engineering and Technology. This project is possible because of the NASA Get-Away Special (GAS) program. The only feasible alternative is using an expensive sounding rocket. We estimate the sun tracking and guidance package alone would cost upwards of a million dollars -- at least ten times our entire budget. Because of the GAS program, we simplified the construction, operation, and programming of the instruments with resulting savings in weight, cost, and time spent.

Roming, Peter W. A.↗

NASA NTRS1994

Wing design for a civil tiltrotor transport aircraft

The goal of this research is the proper tailoring of the civil tiltrotor's composite wing-box structure leading to a minimum-weight wing design. With focus on the structural design, the wing's aerodynamic shape and the rotor-pylon system are held fixed. The initial design requirement on drag reduction set the airfoil maximum thickness-to-chord ratio to 18 percent. The airfoil section is the scaled down version of the 23 percent-thick airfoil used in V-22's wing. With the project goal in mind, the research activities began with an investigation of the structural dynamic and aeroelastic characteristics of the tiltrotor configuration, and the identification of proper procedures to analyze and account for these characteristics in the wing design. This investigation led to a collection of more than thirty technical papers on the subject, some of which have been referenced here. The review of literature on the tiltrotor revealed the complexity of the system in terms of wing-rotor-pylon interactions. The aeroelastic instability or whirl flutter stemming from wing-rotor-pylon interactions is found to be the most critical mode of instability demanding careful consideration in the preliminary wing design. The placement of wing fundamental natural frequencies in bending and torsion relative to each other and relative to the rotor 1/rev frequencies is found to have a strong influence on the whirl flutter. The frequency placement guide based on a Bell Helicopter Textron study is used in the formulation of frequency constraints. The analysis and design studies are based on two different finite-element computer codes: (1) MSC/NASATRAN and (2) WIDOWAC. These programs are used in parallel with the motivation to eventually, upon necessary modifications and validation, use the simpler WIDOWAC code in the structural tailoring of the tiltrotor wing. Several test cases were studied for the preliminary comparison of the two codes. The results obtained so far indicate a good overall agreement between the two codes.

Rais-Rohani, Masoud↗

NASA NTRS2000

Overview of TPS Tasks

The objectives of the project summarized in this viewgraph presentation are the following: (1) Develop a lightweight and low cost durable Thermal Protection System (TPS) for easy application to reusable launch vehicle payload launchers; (2) Develop quickly processed composite TPS processing and repair techniques; and (3) Develop higher temperature capability tile TPS. The benefits of this technology include reduced installation and operations cost, enhanced payload capability resulting from TPS weight reduction, and enhanced flight envelope and performance resulting from higher temperature capability TPS which can result in improved safety.

Johnson, Sylvia M.↗