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NASA NTRS2018

Sonic Boom Prediction and Mitigation using Three-Dimensional Earth Effects

As the industry progresses towards realizing a commercial supersonic aircraft, the push to reduce noise from sonic boom has intensified. This emphasizes the need to better understand and accurately model the underlying physics and seek ways to reduce modeling gaps in the calculation of sonic boom noise metrics. To answer this need, sonic boom prediction capability of the atmospheric propagation tool sBOOM is enhanced to include three-dimensional Earth effects during propagation. The discrete adjoint capability under three-dimensional effects is also enhanced to be helpful in design optimization. The differences in ground signatures, noise metrics, and carpet widths are compared against results obtained using flat Earth approximation and discussed. Finally, the developed capability is used in CFD based shape optimization to demonstrate the differences in aircraft outer mold line when ellipsoidal Earth effects during shape optimization for sonic boom mitigation.

Rallabhandi, Sriram K.↗

NASA NTRS2015

Development of an Ablative 3D Quartz / Cyanate Ester Composite for the Orion Spacecraft Compression Pad

With the successful flight test of the Orion Multipurpose Crew Vehicle last December, NASA is well on its way to sending humans into deep space with the goal of putting astronauts on Mars in the 2030s. Orion will receive some upgrades for its next launch in 2018 including a newly developed 3D Quartz Cyanate Ester composite material for the compression pad. The compression pads are 10-inches in diameter and 3-inches thick. The pucks are at 4 locations in the heat shield that serve as a part of the mechanism for holding the Crew and Service modules together during most mission phases prior to separation followed by Earth re-entry. Thus the compression pad has structural, aerothermal and thermal protection requirements.This paper describes the approach used for developing the new 3D composite, including continuous 3D weaving on an automated loom followed by resin transfer molding. Mechanical, thermal and arc jet testing of the 3D composite are also described.

Feldman, Jay↗

NASA NTRS2018

Evaluations of Candidate Materials for Advanced Space-Rated Vacuum Seals to Explore Space Environment Exposure Limits

For many materials used in space hardware, the environment in which they need to operate is harsher than the environment on earth. Exposure to vacuum conditions, atomic oxygen, and ultraviolet radiation can be detrimental, so testing of space hardware in simulated space environments is required. This is especially true for elastomeric components such as seals. NASA is developing advanced space-rated vacuum seals in support of future space exploration missions. These seals must exhibit extremely low leak rates to ensure that astronauts have sufficient breathable air during extended-duration missions. In some applications the seals are not mated during portions of the mission and are left uncovered and exposed to the conditions in space for prolonged periods of time prior to mating. Space-rated vacuum seals are often made of silicone because of the material's wide operating temperature range and ability to be molded or extruded into various shapes and cross sections. One approach being considered to achieve improved performance is to add titanium dioxide to the silicone material to make it more resistant to damage from ultraviolet radiation. In this study, seals made of the baseline material with and without 1.5 percent titanium dioxide additive (by weight) were exposed to atomic oxygen and increasing levels of ultraviolet radiation and then leak tested. Test results revealed that seals made of the new material could withstand longer exposures while still satisfying the leak rate requirement even under worst-case conditions of partial compression at the extremes of the anticipated operating temperature range.

Seals↗

NASA NTRS2018

Evaluations of Candidate Materials for Advanced Space-Rated Vacuum Seals to Explore Space Environment Exposure Limits

For many materials used in space hardware, the environment in which they need to operate is harsher than the environment on earth. Exposure to vacuum conditions, atomic oxygen, and ultraviolet radiation can be detrimental, so testing of space hardware in simulated space environments is required. This is especially true for elastomeric components such as seals. NASA is developing advanced space-rated vacuum seals in support of future space exploration missions. These seals must exhibit extremely low leak rates to ensure that astronauts have sufficient breathable air during extended-duration missions. In some applications the seals are not mated during portions of the mission and are left uncovered and exposed to the conditions in space for prolonged periods of time prior to mating. Space-rated vacuum seals are often made of silicone because of the material's wide operating temperature range and ability to be molded or extruded into various shapes and cross sections. One approach being considered to achieve improved performance is to add titanium dioxide to the silicone material to make it more resistant to damage from ultraviolet radiation. In this study, seals made of the baseline material with and without 1.5% titanium dioxide additive (by weight) were exposed to atomic oxygen and increasing levels of ultraviolet radiation and then leak tested. Test results revealed that seals made of the new material could withstand longer exposures while still satisfying the leak rate requirement even under worst-case conditions of partial compression at the extremes of the anticipated operating temperature range.

Ultraviolet radiation↗

NASA NTRS2015

Development of an Ablative 3D Quartz / Cyanate Ester Composite for the Orion Spacecraft Compression Pad

With the successful flight test of the Orion Multipurpose Crew Vehicle last December, NASA is well on its way to sending humans into deep space with the ultimate goal of putting astronauts on Mars in the 2030s. Orion will receive some upgrades for its next launch in 2018 including a newly developed 3D quartz / cyanate ester composite material for the compression pad. Multiple pad locations in the heat shield serve as a part of the mechanism for holding the Crew and Service Modules together during most mission phases prior to separation followed by Earth re-entry of the Crew Module. Thus the compression pad must survive structural and aerothermal loads, and protect the adjascent structure and heat shield materials from over-heating.This paper describes the approach used for developing the new 3D composite, including continuous 3D weaving on an automated loom followed by resin transfer molding. Mechanical, thermal, arc jet ,and stress relaxation testing of the 3D composite are also described.

Feldman, Jay D.↗

NASA NTRS2018

2.5/3D Daisy Chain Reliability Evaluation

The objective of this task is to evaluate thermal cycle behavior of advanced 2.5/3D electronics — commercial-off the-shelf (COTS) —packages of different configurations assembled onto printed circuit boards (PCBs). Three key approaches were considered for evaluation. The first approach focused on the through-mold via (TMV™) technology at assembly level. The second approach focused on evaluation of 2.5D (also known as, System in Package (SiP)) in fine pitch ball grid array (FPGA). The third approach focused on evaluation of through-silicone-via (TSV) technologies. This report presents the test results for TMV™ and SiP packaging technologies and reliability, and it also provides lessons learned on quality assurance methods. Specifically, the report presents the test matrix for various 3D TMV™ packaging assembly configurations and reliability characterizations performed under two accelerated thermal cycling (ATC) and accelerated thermal shock cycling (ATSC) conditions. The ATC and ATSC were performed in the range of –55°C to 125°C and –100°C to 100°C, respectively. The report also includes assembly of a SiP— a 60-mm fine-pitch ball-grid array (FPGA) interposer with an IC at the center and six chip-scale package (CSP) daisy chains at the periphery—with package assembly characterizations. After assembly, the daisy chains were subjected to ATCs in the range of –40°C to 125°C for reliability evaluation. Finally, for both TMV™ and SiP packaging configurations, characterizations results by X-ray, optical imaging, and daisy-chain resistance evaluations were also presented.

Ghaffarian, Reza↗

NASA NTRS2017

Surface Characterization of Carbon Fiber Reinforced Polymers by Picosecond Laser Induced Breakdown Spectroscopy

Adhesive bonding of composite materials requires reliable monitoring and detection of surface contaminants as part of a vigorous quality control process to assure robust and durable bonded structures. Surface treatment and effective monitoring prior to bonding are essential in order to obtain a surface which is free from contaminants that may lead to inferior bond quality. In this study, the focus is to advance the laser induced breakdown spectroscopy (LIBS) technique by using pulse energies below 100 μJ (μLIBS) for the detection of low levels of silicone contaminants in carbon fiber reinforced polymer (CFRP) composites. Various CFRP surface conditions were investigated by LIBS using ∼10 ps, 355 nm laser pulses with pulse energies below 30 μJ. Time-resolved analysis was conducted to optimize the gate delay and gate width for the detection of the C I emission line at 247.9 nm to monitor the epoxy resin matrix of CFRP composites and the Si I emission line at 288.2 nm for detection of silicone contaminants in CFRP. To study the surface sensitivity to silicone contamination, CFRP surfaces were coated with polydimethylsiloxane (PDMS), the active ingredient in many mold release agents. The presence of PDMS was studied by inspecting the Si I emission lines at 251.6 nm and 288.2 nm. The measured PDMS areal densities ranged from 0.15 to 2 μg/cm(sup 2). LIBS measurements were performed before and after laser surface ablation. The results demonstrate the successful detection of PDMS thin layers on CFRP using picosecond μLIBS.

Rodolfo Ledesma↗

NASA NTRS2018

Challenges and Opportunities for Subsonic Transport X-Plane Acoustic Flight Research

Aircraft system noise aspects of experimental aircraft acoustic flight research are analyzed. Experimental aircraft are seen as a key development step toward the introduction of a full scale low noise subsonic transport in the future, especially when considering an unconventional aircraft configuration integrating a range of advanced noise reduction technologies. Possible design scenarios for an experimental aircraft are considered where the scale of the experimental aircraft relative to the future, full scale aircraft is likely a major cost driver. Aircraft system noise predictions are presented for a NASA modeled Mid- Fuselage Nacelle subsonic transport concept. The predictions are made for the total airframe system noise at 100, 50, 25, and 12.5% scale of the full scale, future version of the concept, both without and then with a set of noise reduction technologies. The noise reduction technologies include the dual use fairing of the Krueger flap, the continuous mold line for the trailing edge high lift flap, and the pod gear concept for the main gear. The predictions are treated as simulations of flight test measurements of an experimental aircraft that are then processed to full scale as flight data would be. The analysis shows that the combined impact of frequency shift, atmospheric absorption, and background noise cutoff is to establish a realistic upper limit on useful frequency from the experimental aircraft noise. The implications for instrumentation requirements are also noted for high frequency, as well as for the challenge of identifying sources that are reduced significantly by the proposed noise reduction technologies. For the experimental acoustic flight research to be most useful for the objectives of improving the prediction of the future full scale aircraft, it is indicated that the scale should be above 75%. As the demonstrator scale approaches 50%, the limitations become more severe for direct impact to the prediction of the full scale future concept.

Thomas, Russell H.↗

NASA NTRS2019

Space PV Concentrators for Outer Planet and Near-Sun Missions, Using Ultra-Light Fresnel Lenses Made with Vanishing Tools

Working under a NASA-funded Small Business Innovation Research (SBIR) program, our team has made additional progress in the development of space photovoltaic concentrators for outer planet and near-sun missions. One noteworthy innovation is in the scalable method of producing the ultra-light Fresnel lenses which provide the optical concentration of sunlight for both point-focus and line-focus concentrators. The new method uses “vanishing” lens molding tools. The paper will present the latest advances in this technology.

O'neill, Mark↗

NASA NTRS2019

The 3D Printing of Polyimide Aerogels

Polyimide aerogels are a nanoporous material made by extracting the liquid portion of a wet gel and replacing it with air, while still maintaining the porous solid internal architecture. This results in a material with extremely low densities, low thermal conductivities, high internal surfaces areas, and low dielectric constants. Currently, complex aerogel forms are not possible, since they require molds in order to be shaped. To overcome this challenge, we are attempting to use various additive manufacturing techniques to produce complex architectures. Three different approaches are being studied to accomplish this. One is to print using a viscous wet gel and have the structure solidify at the end of the print, another is to use a mixing tip, where a less viscous gel and the final chemical that causes gelation will be mixed as it is printing, allowing it to gel layer by layer, and the third is to use a UV curable aerogel with a UV light following behind to solidify the gel as it prints. To have these approaches be successful, the printing parameters and the aerogel's chemical formulation need to be optimized. The more harmonious these two factors can be made, the more defined and complex the resulting structure can be. Preliminary results show that 3D printing polyimide aerogels are a viable option, but further optimization must occur for reliable printing.

Nosel, Theresa↗

NASA NTRS2019

Space PV Concentrators for Outer Planet and Near-Sun Missions, Using Ultra-Light Fresnel Lenses Made with Vanishing Tools

At the past four PVSCs [1-4], our team has presented recent advances in our space photovoltaic concentrator technology. In the past year, under a NASA-funded Small Business Innovation Research (SBIR) program, our team has made additional progress in the development of space photovoltaic concentrators for outer planet and near-sun missions. One noteworthy innovation is in the scalable method of producing the ultra-light Fresnel lenses which provide the optical concentration of sunlight for both point-focus and line-focus concentrators. The new method uses "vanishing" lens molding tools. The paper will present the latest advances in this technology.

O'Neill, Mark↗

NASA NTRS2020

Effects of Texture and Silica Content on Crack Growth in Boron Nitrides

Boron nitride is used in applications such as crucibles for melting and casting glasses and metals, insulators for furnaces, molds for hot pressing, and neutron absorbers. Historically, various grades of hot pressed hexagonal boron nitride (BN) have been used. This study investigates the fracture toughness and slow crack growth parameters of several commercially available BN grades. Prior work revealed that some grades of BN absorb water and change strength, thus presenting a philosophical conundrum on crack growth test methods. The grades selected for this study are of interest because their available billet size is sufficient for large components, or because they have heritage in specific applications. Ultimately, the data will be used to perform material selection, system design and reliability analyses of components of interest. Boron nitrides exhibit limited slow crack growth in humidity, with an orientation dependence due to crystallographic texture: orientations with van der Waal bonds are insensitive to water whereas those with covalent bonds are sensitive. Fracture toughness is low, around that of glass, and is also a function of orientation (bond type), with fracture occurring more readily along van der Waal bonds between hexagonal BN platelets than at covalent bonds across platelets. Silica additions toughen BN, but increase slow crack growth susceptibility.

Salem, Jonathan A.↗

NASA NTRS2020

Human Mars Entry, Descent, and Landing Architecture Study: Phase 3 Summary

Over the past four years, NASA has directed the Entry, Descent and Landing Architecture Study (EDLAS) to evaluate candidate technologies to deliver human-scale vehicles (carrying 20t payloads) to the surface of Mars. The study focused on two vehicles in Phase 3 (during 2018 and 2019), one low and one mid lift-to-drag (L/D) vehicle. This paper summarizes updates to the structural and aeroshell outer mold line design for the mid-L/D Mars entry lander vehicle that occurred during EDLAS Phase 3. The design efforts used parametric optimization to arrive at a solution for total vehicle primary and secondary structure mass, and vehicle center-of-gravity location. Additionally, the end of Phase 2 provided an updated surface payload manifest that required three 22 t landers. This paper also summarizes the results of the packaging feasibility study of the updated payload configurations for those three reference missions. The study verified an arrangement of the payload elements within the mid-L/D vehicle that satisfied the center of gravity location limitations for flight.

Calderon, Damien↗

NASA NTRS2018

Effectiveness of Surface Treatment Techniques for Composite Bonding with Different Contamination Levels

Various surface treatment techniques have been developed to promote adhesive bond performance for composite structural components in aerospace applications. The condition of the pre-bond surface is critical to achieving desirable bond quality. Contamination on bonding surfaces is well recognized as a major threat to ultimate bond performance. Variation in contamination level has brought additional challenges into manufacturing process control. High fidelity surface treatment techniques are required for effective removal of contaminants over a wide range of contamination levels. In this study, a common contaminant, i.e. silicone mold release, was introduced to pre-bond composite surfaces with different concentrations. Plasma and laser surface treatment techniques were performed and their effectiveness in restoring and enhancing desirable bond quality was investigated. Surface characterization techniques, including water contact angle goniometry, Fourier transform infrared spectroscopy and X-ray photoelectron spectroscopy, were conducted to assess the condition of contaminated surfaces and the improvement induced by plasma and laser surface treatments. Failure modes from a customized double cantilever beam test were investigated before and after surface treatments. Fundamental mechanisms of plasma and laser surface treatments on the composite bonding surfaces were also investigated.

Fang, Xiaomei↗

NASA NTRS2018

Determination of Trace Silicone Contamination on Composites by Quantitative XPS and LIBS

Surface treatment and surface characterization techniques are critical to ensure that adherends are chemically activated and free of contaminants prior to adhesive bonding. Silicone contamination from mold-release agents and other sources can interfere with interfacial bonding, decreasing the durability and performance of bonded composite structures. Tools and methods are needed that can be used in a production environment to reliably detect low levels of contaminants in a rapid, simple, and cost-effective manner to improve bond reliability. In this work, surface characterization of carbon fiber reinforced polymer (CFRP) composites was performed using laser induced breakdown spectroscopy (LIBS) and the results were compared with those obtained from X-ray photoelectron spectroscopy (XPS). The objective was to investigate the ability to quantify the surface species measured by LIBS since it offers many advantages over XPS in terms of ease of use, sample preparation, and real-time results. The as-processed CFRP panels had trace surface silicone contamination from the fabrication process, the source of which was not investigated. The composites were laser treated at select average laser power levels, resulting in varying levels of contamination reduction. The Si atomic percentage measurements using XPS were conducted both before and after laser ablation. The XPS results were compared with those obtained from LIBS to assess the reliability of each technique for surface contaminant characterization. The results showed an excellent correlation in Si atomic concentration between the two techniques.

Ledesma, Rodolfo↗

NASA NTRSDate not supplied

Human Mars Entry, Descent, and Landing Architecture Study: Phase 3 Summary

Over the past four years, NASA has directed the Entry, Descent and Landing Architecture Study (EDLAS) team to evaluate candidate technologies to deliver human-scale vehicles (carrying 20t payloads) to a precise location on the surface of Mars. The study, which initially considered four candidate vehicles, narrowed the design space to focus on two vehicles in Phase 3, one low and one mid lift-to-drag vehicle. Key design challenges exist for both, and the purpose of the Phase 3 analysis was to identify specific technology investment areas and opportunities to mature the vehicle designs beyond simulations to include ground and flight tests. This paper summarizes the detailed analyses performed on the two vehicle configurations, including aerodynamic and propulsive interference effects during the powered flight phase, vehicle packaging, as well as outer mold line and parametric mass model upgrades. The analyses were used to update models in the vehicle performance simulations. The simulation results showing the impact of the Phase 3 analyses on vehicle performance are also presented. Finally, a summary of the technology investment recommendations, including opportunities to validate models using wind tunnel tests and evaluate technologies at the moon, are presented. This paper offers a systems level overview of the more detailed analysis that will be presented in this special session.

Alicia Dwyer Cianciolo↗

NASA NTRSDate not supplied

Solvent-Free Preparation of High Energy, Binder-Free Electrodes Enabled by Dry Compressible Holey Graphene

Graphene is an atomically thick sheet consisting of a graphitic carbon network with excellent mechanical strength, electrical and thermal conductivity, and chemical stability. Holey graphene, a structural derivative of graphene, has an array of through-the-thickness holes across the lateral surface of the nanosheet. The presence of these holes has minimal detrimental effect on the graphene properties and leads to enhanced performance in applications such as electronics, sensors, and energy storage. For example, these holes allow more facile cross-plane ion and gas transport than intact graphene, making holey graphene an ideal electrode material for electrochemical energy storage. This presentation will focus on the ability of holey graphene to be compression molded into robust articles or architectures under solvent-free conditions without the need for potentially parasitic binders. The unique dry compressibility of holey graphene has enabled facile fabrication of high mass loading electrodes with both high density and high porosity, which have found use in supercapacitors and various high-energy battery systems such as lithium-oxygen, lithium-sulfur, and lithium-selenium batteries.

Yi Lin↗

NASA NTRSDate not supplied

Long-term Engagement in Authentic Research with NASA (LEARN): Innovative Practices Suggested by a New Model for Teacher Research Experiences

NASA's LEARN Project is an innovative program that provides long-term immersion in the practice of atmospheric science for middle and high school in-service teachers. Working alongside NASA scientists and using authentic NASA Science Mission Directorate research data, teachers develop individual research topics of interest during two weeks in the summer while on-site at NASA Langley. With continued, intensive mentoring by NASA scientists, the teachers further develop their research throughout the academic year through virtual group meetings and data team meetings mirroring scientific collaborations. At the end of the first year, LEARN teachers present scientific posters. The LEARN experience has had such an impact that multiple teachers from the first two cohorts have elected to continue their research. The LEARN project evaluation has provided insights into particularly effective elements of this new approach. Findings indicate that teachers? perceptions of the scientific enterprise have changed, and that LEARN provided substantial resources to help them take real-world research to their students. This presentation will focus on key factors from LEARN?s implementation that inform best practices for the incorporation of authentic scientific research into teacher professional development experiences. We suggest that these factors should be considered in the development of other such experiences, including: (1) The involvement of a single scientist as both the project leader/manager and the project scientist, to ensure that the project can meet teachers? needs. (2) An emphasis on framing and approaching scientific research questions, so that teachers can learn to evaluate the feasibility of studies based on scope, scale, and availability of data. (3) Long term, ongoing relationships where teachers and scientists work as collaborators, beyond the workshop ?mold.? (4) A focus on meeting the needs of individual teachers, whether their needs relate to elements of research and analysis, or to their tight professional schedules. (5) Above all, flexibility and patience. LEARN builds relationships with teachers slowly, over a long period of time. In the middle, life often intervenes. LEARN has emphasized that teachers? success is more important than deadlines or following a rigid protocol.

M Pippin↗