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NASA NTRS2009

Methods Reduce Cost, Enhance Quality of Nanotubes

For all the challenges posed by the microgravity conditions of space, weight is actually one of the more significant problems NASA faces in the development of the next generation of U.S. space vehicles. For the Agency s Constellation Program, engineers at NASA centers are designing and testing new vessels as safe, practical, and cost-effective means of space travel following the eventual retirement of the space shuttle. Program components like the Orion Crew Exploration Vehicle, intended to carry astronauts to the International Space Station and the Moon, must be designed to specific weight requirements to manage fuel consumption and match launch rocket capabilities; Orion s gross liftoff weight target is about 63,789 pounds. Future space vehicles will require even greater attention to lightweight construction to help conserve fuel for long-range missions to Mars and beyond. In order to reduce spacecraft weight without sacrificing structural integrity, NASA is pursuing the development of materials that promise to revolutionize not only spacecraft construction, but also a host of potential applications on Earth. Single-walled carbon nanotubes are one material of particular interest. These tubular, single-layer carbon molecules - 100,000 of them braided together would be no thicker than a human hair - display a range of remarkable characteristics. Possessing greater tensile strength than steel at a fraction of the weight, the nanotubes are efficient heat conductors with metallic or semiconductor electrical properties depending on their diameter and chirality (the pattern of each nanotube s hexagonal lattice structure). All of these properties make the nanotubes an appealing material for spacecraft construction, with the potential for nanotube composites to reduce spacecraft weight by 50 percent or more. The nanotubes may also feature in a number of other space exploration applications, including life support, energy storage, and sensor technologies. NASA s various efforts with carbon nanotubes have made it a global leader in this field. Among the many examples are Johnson Space Center s Carbon Nanotube Project, which focuses on bulk nanotube production, purification, and application, and Goddard Space Flight Center s improved arc discharge method of nanotube production, developed under the direction of Jeannette Benavides (featured in Spinoff 2007 and 2008). While the Agency continues its own research, it partners with private companies to advance this unique technology for use on Earth as well as among the stars.

Source record↗

NASA NTRS2009

The Role of Guidance, Navigation, and Control in Hypersonic Vehicle Multidisciplinary Design and Optimization

Airbreathing hypersonic systems offer distinct performance advantages over rocket-based systems for space access vehicles. However, these performance advantages are dependent upon advances in current state-of-the-art technologies in many areas such as ram/scramjet propulsion integration, high temperature materials, aero-elastic structures, thermal protection systems, transition to hypersonics and hypersonic control elements within the framework of complex physics and new design methods. The complex interactions between elements of an airbreathing hypersonic vehicle represent a new paradigm in vehicle design to achieve the optimal performance necessary to meet space access mission objectives. In the past, guidance, navigation, and control (GNC) analysis often follows completion of the vehicle conceptual design process. Individual component groups design subsystems which are then integrated into a vehicle configuration. GNC is presented the task of developing control approaches to meet vehicle performance objectives given that configuration. This approach may be sufficient for vehicles where significant performance margins exist. However, for higher performance vehicles engaging the GNC discipline too late in the design cycle has been costly. For example, the X-29 experimental flight vehicle was built as a technology demonstrator. One of the many technologies to be demonstrated was the use of light-weight material composites for structural components. The use of light-weight materials increased the flexibility of the X- 29 beyond that of conventional metal alloy constructed aircraft. This effect was not considered when the vehicle control system was designed and built. The impact of this is that the control system did not have enough control authority to compensate for the effects of the first fundamental structural mode of the vehicle. As a result, the resulting pitch rate response of the vehicle was below specification and no post-design changes could recover the desired capability.

Ouzts, Peter J.↗

NASA NTRS2012

Interactive Schematic Integration Within the Propellant System Modeling Environment

Task requirements for rocket propulsion test preparations of the test stand facilities drive the need to model the test facility propellant systems prior to constructing physical modifications. The Propellant System Modeling Environment (PSME) is an initiative designed to enable increased efficiency and expanded capabilities to a broader base of NASA engineers in the use of modeling and simulation (M&S) technologies for rocket propulsion test and launch mission requirements. PSME will enable a wider scope of users to utilize M&S of propulsion test and launch facilities for predictive and post-analysis functionality by offering a clean, easy-to-use, high-performance application environment.

Coote, David↗

NASA NTRS2002

Initial Mechanical Testing of Superalloy Lattice Block Structures Conducted

The first mechanical tests of superalloy lattice block structures produced promising results for this exciting new lightweight material system. The testing was performed in-house at NASA Glenn Research Center's Structural Benchmark Test Facility, where small subelement-sized compression and beam specimens were loaded to observe elastic and plastic behavior, component strength levels, and fatigue resistance for hundreds of thousands of load cycles. Current lattice block construction produces a flat panel composed of thin ligaments arranged in a three-dimensional triangulated trusslike structure. Investment casting of lattice block panels has been developed and greatly expands opportunities for using this unique architecture in today's high-performance structures. In addition, advances made in NASA's Ultra-Efficient Engine Technology Program have extended the lattice block concept to superalloy materials. After a series of casting iterations, the nickel-based superalloy Inconel 718 (IN 718, Inco Alloys International, Inc., Huntington, WV) was successfully cast into lattice block panels; this combination offers light weight combined with high strength, high stiffness, and elevated-temperature durability. For tests to evaluate casting quality and configuration merit, small structural compression and bend test specimens were machined from the 5- by 12- by 0.5-in. panels. Linear elastic finite element analyses were completed for several specimen layouts to predict material stresses and deflections under proposed test conditions. The structural specimens were then subjected to room-temperature static and cyclic loads in Glenn's Life Prediction Branch's material test machine. Surprisingly, the test results exceeded analytical predictions: plastic strains greater than 5 percent were obtained, and fatigue lives did not depreciate relative to the base material. These assets were due to the formation of plastic hinges and the redundancies inherent in lattice block construction, which were not considered in the simplified computer models. The fatigue testing proved the value of redundancies since specimen strength was maintained even after the fracture of one or two ligaments. This ongoing test program is planned to continue through high-temperature testing. Also scheduled for testing are IN 718 lattice block panels with integral face sheets, as well as specimens cast from a higher temperature alloy. The initial testing suggests the value of this technology for large panels under low and moderate pressure loadings and for high-risk, damage-tolerant structures. Potential aeropropulsion uses for lattice blocks include turbine-engine actuated panels, exhaust nozzle flaps, and side panel structures.

Krause, David L.↗

NASA NTRS1983

Photovoltaic research and development in Japan

The status of the Japanese photovoltaic (PV) R&D activities was surveyed through literature searches, private communications, and site visits in 1982. The results show that the Japanese photovoltaic technology is maturing rapidly, consistent with the steady government funding under the Sunshine Project. Two main thrusts of the Project are: (1) completion of the solar panel production pilot plants using cast ingot and sheet silicon materials, and (2) development of large area amorphous silicon solar cells with acceptable efficiency (10 to 12%). An experimental automated solar panel production plant rated at 500 kW/yr is currently under construction for the Sunshine Project for completion in March 1983. Efficiencies demonstrated by experimental large are amorphous silicon solar cells are approaching 8%. Small area amorphous silicon solar cells are, however, currently being mass produced and marketed by several companies at an equivalent annual rate of 2 MW/yr for consumer electronic applications. There is no evidence of an immediate move by the Japanese PV industry to enter extensively into the photovoltaic power market, domestic or otherwise. However, the photovoltaic technology itself could become ready for such an entry in the very near future, especially by making use of advanced process automation technologies.

Shimada, K.↗

NASA NTRS1990

Applied aspects of laminar-flow technology

An account is given of the development status and performance levels achieved with natural laminar flow (NLF), extended wing chord laminar flow control (LFC), and hybrid laminar flow control (HLFC) concepts combining NLF and partial-chord LFC in the leading-edge region. Attention is given to NLF wing structure construction methods capable of achieving the requisite surface-irregularity tolerances, LFC through wing surface suction slots or perforated skins, and the deleterious effects of insects, ice crystals, and noise disturbance inputs on the ability of NLF, LFC, and HLFC wings to maintain effective laminar flow operation.

Braslow, A. L.↗

NASA NTRS2016

NH11B-1726: FrankenRaven: A New Platform for Remote Sensing

Small, modular aircraft are an emerging technology with a goal to maximize flexibility and enable multi-mission support. This reports the progress of an unmanned aerial system (UAS) project conducted at the NASA Ames Research Center (ARC) in 2016. This interdisciplinary effort builds upon the success of the 2014 FrankenEye project to apply rapid prototyping techniques to UAS, to develop a variety of platforms to host remote sensing instruments. In 2016, ARC received AeroVironment RQ-11A and RQ-11B Raven UAS from the US Department of the Interior, Office of Aviation Services. These aircraft have electric propulsion, a wingspan of roughly 1.3m, and have demonstrated reliability in challenging environments. The Raven airframe is an ideal foundation to construct more complex aircraft, and student interns using 3D printing were able to graft multiple Raven wings and fuselages into FrankenRaven aircraft. Aeronautical analysis shows that the new configuration has enhanced flight time, payload capacity, and distance compared to the original Raven. The FrankenRaven avionics architecture replaces the mil-spec avionics with COTS technology based upon the 3DR Pixhawk PX4 autopilot with a safety multiplexer for failsafe handoff to 2.4 GHz RC control and 915 MHz telemetry. This project demonstrates how design reuse, rapid prototyping, and modular subcomponents can be leveraged into flexible airborne platforms that can host a variety of remote sensing payloads and even multiple payloads. Modularity advances a new paradigm: mass-customization of aircraft around given payload(s). Multi-fuselage designs are currently under development to host a wide variety of payloads including a zenith-pointing spectrometer, a magnetometer, a multi-spectral camera, and a RGB camera. After airworthiness certification, flight readiness review, and test flights are performed at Crows Landing airfield in central California, field data will be taken at Kilauea volcano in Hawaii and other locations.

remote sensing↗

NASA NTRSDate not supplied

Mars Sample Receiving Facility Research and Development to Enable Preservation, Safe Containment, and Scientific Research of Martian Samples on Earth

NASA and ESA are working together to plan a joint campaign to potentially bring back the first Martian samples to Earth in the early 2030s. On the surface of Mars, the Mars 2020Perseverance Rover is selecting and packaging samples that could be returned to Earth for careful examination by an international team of scientists. In preparation for this historic sample return, advance planning is underway to design and build a Mars Sample Receiving Facility (SRF) in the mid-2020s. In 2022, a Mars Sample Receiving Facility Assessment Study(MSAS) will be conducted to further define construction modality and capability options for a facility in the conterminous United States. Since Mars Sample Return (MSR) is currently categorized as a planetary protection restricted Earth return, this new facility would feature biosafety level 4 (BSL-4)-like high containment to protect Earth’s biosphere from any potential hazard. In addition, the facility also requires integration of cleanroom technologies to mitigate against terrestrial contamination and preserve sample integrity for science investigations. The integration of both clean handling and high containment requires significant technology research and development (R&D) by the mid-2020s to support the definition and planning of a SRF before commencing the site specific design phase. The SRF project will need to solidify the inorganic, organic, and biological contamination control (CC) requirements for the facility. This could entail a translation of Mars 2020 mission CC requirements for geologic material to engineering requirements for surfaces and airborne molecular contamination inside isolators and cleanrooms. In tandem, the project will need to determine precision cleaning and sterilization approaches for cleanrooms, isolators, equipment, and tools. Initial material selections for the facility construction materials, cleanrooms, isolators, and BSL-4 suits/garments are an important activity. The recent construction of the OSIRIS-REx and Hayabusa2 curation cleanroom laboratories greatly benefited from early materials testing, before the design phase, to reduced organic outgassing and particulate shedding inside the laboratory. While the early biohazard investigations in the SRF may deem the samples safe to release to laboratories throughout the world, sterilization methods need to be defined to safely release Martian samples. One key aspect of enabling simultaneous sample containment and cleanliness is the concept of a Double-Walled Isolator (DWI) that ESA has been pursuing. Further R&D is needed about DWIs, sample handling, and instrumentation interfaces before beginning the SRF site specific design phase. A working isolator/DWI engineering model should be developed and fabricated. Isolator sizes, connections, pass-through antechambers, and configurations and basic interfaces with instruments and tools as well as the use of robotic, mechanical, and/or human manipulation need to be considered. Inert high purity gas supply (one-pass or recirculation) and other isolator utilities must be determined. Special accommodations for large instruments (e.g., XCT,SEM, etc.) need to be developed. Techniques for opening the sample tubes packaged by M2020and extracting the headspace gas while keeping samples pristine will be challenging, requiring additional R&D, and engagement of the M2020 project. In addition, careful micromanipulation for subdivision and packaging of samples will also need to be included. These combined R&D activities are important before commencing the SRF design phase to ensure safe biohazard containment, sample preservation, and science integrity for the samples that would be studied in the SRF and in laboratories around the world.

mars sample return↗

NASA NTRS1984

Composites for large transports - Facing the challenge

NASA has undertaken development and test programs in collaboration with the large transport aircraft construction industry, in order to remove existing barriers to the use of composite material primary structures and to assess their advantages in terms of both acquisition cost and mission performance. These programs are expected to reach design technology readiness for wing and fuselage structures by 1988, paving the way for the validation of design and manufacturing methods in the early 1990s. While composites promise a reduction in fuselage manufacturing costs, it is judged that the relative cost of a metallic wing will be more difficult to surpass. Nevertheless, a 40 percent wing weight saving may more than compensate for increased wing structure cost.

Bohon, H. L.↗

NASA NTRS1991

SEI power source alternatives for rovers and other multi-kWe distributed surface applications

Results of the study performed to support the Space Exploration Initiative (SEI) which investigated power system alternatives for the rover vehicles and servicers that would be used for construction and operation of a lunar base is described. Using the mission requirements and power profiles that were subsequently generated for each of these rovers and servicers, candidate power sources incorporating various power generation and energy storage technologies were identified. The technologies were those believed most appropriate to the SEI missions, and included solar, electrochemical, and isotope systems. The candidates were characterized with respect to system mass, deployed area and volume. For each of the missions a preliminary selection was made. Results of this study depict the available power sources in light of the mission requirements as they are currently defined.

Bents, D. J.↗

NASA NTRS1995

Third NASA Workshop on Wiring for Space Applications

This workshop addressed key technology issues in the field of electrical power wiring for space applications, and transferred information and technology related to space wiring for use in government and commercial applications. Speakers from space agencies, U.S. Federal labs, industry, and academia presented program overviews and discussed topics on arc tracking phenomena, advancements in insulation materials and constructions, and new wiring system topologies.

Hammoud, Ahmad↗

NASA NTRS2012

Flexible Thermal Protection System Development for Hypersonic Inflatable Aerodynamic Decelerators

The Hypersonic Inflatable Aerodynamic Decelerators (HIAD) project has invested in development of multiple thermal protection system (TPS) candidates to be used in inflatable, high downmass, technology flight projects. Flexible TPS is one element of the HIAD project which is tasked with the research and development of the technology ranging from direct ground tests, modelling and simulation, characterization of TPS systems, manufacturing and handling, and standards and policy definition. The intent of flexible TPS is to enable large deployable aeroshell technologies, which increase the drag performance while significantly reducing the ballistic coefficient of high-mass entry vehicles. A HIAD requires a flexible TPS capable of surviving aerothermal loads, and durable enough to survive the rigors of construction, handling, high density packing, long duration exposure to extrinsic, in-situ environments, and deployment. This paper provides a comprehensive overview of key work being performed within the Flexible TPS element of the HIAD project. Included in this paper is an overview of, and results from, each Flexible TPS research and development activity, which includes ground testing, physics-based thermal modelling, age testing, margins policy, catalysis, materials characterization, and recent developments with new TPS materials.

DelCorso, Joseph A.↗

NASA NTRS2016

A Robust, Gravity-Insensitive, High-Temperature Condenser for Water Recovery

Regenerative life support systems are vital for NASA's future long-duration human space exploration missions. A Heat Melt Compactor (HMC) system is being developed by NASA to dry and compress trash generated during space missions. The resulting water vapor is recovered and separated from the process gas flow by a gravity-insensitive condenser. Creare is developing a high-temperature condenser for this application. The entire condenser is constructed from metals that have excellent resistance to chemical attack from contaminants and is suitable for high-temperature operation. The metal construction and design configuration also offer greatest flexibility for potential coating and regeneration processes to reduce biofilm growth and thus enhancing the reliability of the condenser. The proposed condenser builds on the gravity-insensitive phase separator technology Creare developed for aircraft and spacecraft applications. This paper will first discuss the design requirements for the condenser in an HMC system that will be demonstrated on the International Space Station (ISS). Then, it will present the overall design of the condenser and the preliminary thermal test results of a subscale condenser. Finally, this paper will discuss the predicted performance of the full-size condenser and the development plan to mature the technology and enhance its long-term reliability for a flight system.

Chen, Weibo↗

NASA NTRS2019

Hydrogen Recovery by Methane Pyrolysis to Elemental Carbon

Use of a Sabatier reactor to recover the oxygen from the carbon dioxide exhaled by the crew on the International Space Station has been limited by the loss of the hydrogen contained in the methane it generates. Maximizing the oxygen recovered requires the hydrogen to be recovered from the methane product and recycled back to the Sabatier reactor. We describe the use of a tailored methane pyrolysis reactor to completely recover this hydrogen. The carbon-containing byproduct is elemental carbon, which is generated in the form of easily handled, non-sooty material that may have various uses. The process of creating this tailored carbon vapor deposition process involved exploration of the effects of temperature, pressure, substrate design and other variables to develop a high yield process that cleanly generates the desired products. Reaction kinetics and kinetics modelling were used to specify the temperature, pressure and reactor volume required to achieve the target conversion and to assure that the final average density was as high as possible. Reactor design included the selection of materials that will survive the high temperatures and environment in the pyrolysis reactor, and thermal modeling to achieve the required temperatures with minimum power consumption. The successful construction and demonstration of a brassboard prototype will allow the results of the chemical, thermal and mechanical models to be validated and should provide a useful alternative for a completely closed loop ECLS system. Integration of this technology with state-of-the-art (SOA) Sabatier hardware on ISS requires a complete understanding of the effects of impurities in the product hydrogen on the Sabatier catalyst. SOA Sabatier catalyst was evaluated over short and long-term exposure to anticipated contaminants to identify effects.

Yates, Stephen F.↗

NASA NTRS2019

Hydrogen Recovery by Methane Pyrolysis to Elemental Carbon

Yates, Stephen F.↗

NASA NTRS2004

Flywheel Technology

Throughout the summer of 2004, I am working on a number of different projects. While located in the Space Power and Propulsion Test Engineering branch, my main area of study is flywheel technology. I have been exposed to flywheels, their components, and their uses in today's society. I have been able to experience numerous flywheels here in the flywheel lab at NASA Glenn. My first main project was to explore the attributes and physical characteristics of a flywheel. Our branch was constructing a flywheel demonstration to be presented at the public open house taking place in June. Our Flywheel Interactive Demo, or FIDO, represents a real life multi-flywheel system here at NASA. I was given the opportunity to learn about how these flywheels store energy and are able to position a satellite. With all of this new knowledge, I was able to create the posters that explained how our demonstration worked. I also composed a step-by-step process made up of four experiments that any visitor could follow and perform on FIDO. By stepping through these experiments, the individual learns how a flywheel works. They not only read the explanation of what is happening, but they are also able to see it happen. Creating these two posters not only taught me, but also helped teach the general public during the open house, how flywheel technology is a very important part of our future. Through my research, I have learned that flywheels are able to store massive amounts of energy. They can be described as an electro-mechanical battery that stores kinetic energy while rotating. The faster it rotates, the more energy it stores. Their lifetime is about triple that of an ordinary battery. Flywheels also have the ability to combine energy storage with attitude control all in a single system. Attitude control is the ability to position a satellite as required. FIDO helps us to understand the rotational force (torque) that is applied upon a turn-table or satellite during wheel acceleration/deceleration. My other main project that I have just begun is to create a flywheel presentation, brochure, and video all explaining the history, applications, early attempts, and working processes of modem flywheels. These items are all usefull tools for educating school children and even adults about flywheels. This task will require a large amount of research and skills in the use of multiple applications. My goal this summer is to learn the dynamics and uses of a flywheel in today s society, and then inform and encourage the public about flywheels. I am able to express my knowledge by creating some effective as well as attractive posters, presentations, brochures, videos, etc. that are able to explain how a flywheel works along with how our FIDO demonstration simulates a real flywheel. My goal is underway, and should be successfully reached with the help of my mentor, other coworkers, and fellow interns.

Ritchie, Lisa M.↗

NASA NTRS1996

Engineering Development Program of a Closed Aluminum-Oxygen Semi-cell System for an Unmanned Underwater Vehicle: An Update

Most emerging unmanned undersea vehicle (UUV) missions require significantly longer range and endurance than is achievable with existing battery technology. The Aluminum-Oxygen (Al-O2) semi-cell is a candidate technology capable of providing a significant improvement in endurance compared to the silver-zinc battery technology currently in use in UUVs and compares favorably to other proposed UUV power systems not only in performance, but also in safety and logistics. An Al-O2 semi-cell system is under development, consisting of a cell stack, gas management, oxygen storage, electrolyte management coolant and controller subsystems. It is designed to replace the existing silver-zinc battery and meet existing weight, volume, electrical and thermal requirements, therefore minimizing modification to the UUV. A detailed system design is complete. A component and material endurance test to evaluate compatibility and reliability of various materials and components is complete. Sub=scale (short stack) system testing is complete. A full-scale demonstration unit is now under construction for testing in the second half of 1995. The full scale demonstration test will simulate environmental conditions of the operational system. This paper summarizes the results of the extensive short stack and endurance test programs, describes the plan for full-scale testing, and concludes with a brief discussion of future directions for this technology.

Gregg, Dane W.↗

NASA NTRS2014

Qualification of Coatings for Launch Facilities and Ground Support Equipment Through the NASA Corrosion Technology Laboratory

Corrosion protection at NASA's Kennedy Space Center is a high priority item. The launch facilities at the Kennedy Space Center are located approximately 1000 feet from the Atlantic Ocean where they are exposed to salt deposits, high humidity, high UV degradation, and acidic exhaust from solid rocket boosters. These assets are constructed from carbon steel, which requires a suitable coating to provide long-term protection to reduce corrosion and its associated costs.

Ground Support Equipment↗