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All sourcesNASA NTRSDOE OSTI
NASA NTRS2013

TPSAS-NF1676L-16762-DND

Multi-Mission Earth Entry Vehicles (MMEEVs) are blunt-body vehicles designed with the purpose of transporting payloads from outer space to the surface of the Earth. To achieve high-reliability and minimum weight, MMEEVs avoid use of limited-reliability systems, such as parachutes and retro-rockets, instead using built-in impact attenuators to absorb energy remaining at impact to meet landing loads requirements. In the current effort, two different Rohacell foams were tested to determine their thermal conductivity in support of MMEEV design applications. These applications include thermal insulation during atmospheric entry, impact attenuation, and post-impact thermal insulation. Results indicate that for these closed-cell foams, the effect of impact is limited on thermal conductivity due to the venting of the virgin material gas and subsequent ambient air replacement. In addition, thermal conductivity results indicate a variation with temperature and are higher than manufacturer's specifications.

Lou Glaab↗
NASA NTRSDate not supplied

Corrugated Rollable Tubular Booms

A promising candidate for a new class of deployable composite boom is the COrrugated ROllable TUbular Boom (COROTUB), which is to be employed on future large space structures by the National Aeronautics and Space Administration (NASA). This is due to its two corrugated thin-shells forming a closed-section,which yields high bending and torsion stiffness, allowing for high dimensional stability. The corrugation geometry that dictates the boom cross-section shape is completely defined by closed-form analytical equations given a set of key input parameters available to the designer. Parametric studies changing two geometric variables are used to evaluate which parameters most influence the cross-section’s area moment of inertia and torsional constant. The number of corrugations, flattened height of the boom, and concave and convex corrugation radii are varied to study the complete boom design space. Deeper corrugations increase the local buckling loads (crimpling) of the thin-shell boom but reduce the area moment of inertia and therefore the global Euler buckling load of the compressive member,and thus a fine balance is sought. Finite element analyses of pure bending and compression load cases for 1.22 m boom specimens were carried out to study this design trade-off in detail. Based on previous work, several thin-ply composite laminates have been selected for the different shells that form the cross-section. Feasible boom designs with a maximized stiffness and load-carrying capacity will be manufactured to study their rollability and for experimental characterization. Structural characterization tests and additional numerical analyses will provide guidelines towards future corrugated boom designs and adequate boundary conditions to maximize the boom bending strength.

Deployable Booms↗
NASA NTRS2007

Food Supplement Reduces Fat, Improves Flavor

Diversified Services Corporation, seeking to develop a new nutritional fat replacement and flavor enhancement product, took advantage of the NASA Glenn Garrett Morgan Commercialization Initiative (GMCI) for technology acquisition and development and introductions to potential customers and strategic partners. Having developed and commercialized the product, named Nurtigras, the company is now marketing it through its subsidiary, H.F. Food Technologies Inc. The Nutrigras fat substitute is available in liquid, gel, or dry form and can be easily customized to the specific needs of the food manufacturer. It is primarily intended for use as a partial replacement for animal fat in beef patties and other normally high-fat meat products, and can also be used in soups, sauces, bakery items, and desserts. In addition to the nutritional benefits, the fat replacement costs less than the food it replaces, and as such can help manufacturers reduce material costs. In precooked products, Nutrigras can increase moisture content and thereby increase product yield. The company has been able to repay the help provided by NASA by contributing to the Space Agency's astronaut diet-the Nutrigras fat substitute can be used as a flavor enhancer and shelf-life extender for food on the ISS.

Source record↗
NASA NTRS1988

Effects of variables upon pyrotechnically induced shock response spectra, part 2

Throughout the aerospace industry, large variations of 50 percent (6 dB) or more in shock response spectra (SRS) derived from pyrotechnic separation events continue to be reported from actual spaceflight data and from laboratory tests. As a result of these variations, NASA funded a research program for 1984 through 1986. The purpose of the 1984 through 1986 project was to analyze variations in pyrotechnically induced SRS and to determine if and to what degree manufacturing and assembly variables and tolerances, distance from the shock source, data acquisition instrumentation, and shock energy propagation affect the SRS. Sixty-four free-free boundary plate tests were performed. NASA funded an additional study for 1987 through 1988. This paper is a summary of the additional study. The purpose was to evaluate shock dissipation through various spacecraft structural joint types, to evaluate shock variation for various manufacturing and assembly variables on clamped boundary test plates, and to verify data correction techniques. Five clamped boundary plate tests investigated manufacturing and assembly variables and mass loading effects. Six free-free boundary plate tests investigated shock dissipation across spacecraft joint structures.

Smith, James Lee↗
NASA NTRSDate not supplied

Print-Consistency and Process-Interaction for Inkjet-Printed Copper on Flexible Substrate

Printed electronics is a fastest growing and emerging technology that have shown much potential in several industries including automotive, wearables, healthcare, and aerospace. Its applications can be found not only in flexible but also in large area electronics. The technology provides an effective and convenient method to additively deposit conductive and insulating materials on any type of substrate. Comparing with traditional manufacturing processes, which involves chemical etching, this technology also comes to be relatively environmental friendly. Despite its status, it is not without its challenges. Starting from the material being compatible in the printer equipment to the point of achieving fine resolutions, and with excellent properties are some of the challenges that printed electronics face. Among the myriad of printing technologies such as Aerosol Jet, micro-dispensing, gravure printing, screen printing, Inkjet printing, Inkjet has gained much attention due to its low-cost, low material consumption, and roll-to-roll capability for mass manufacturing. The technology has been widely used in home and office, but recently gained interest in printed electronics in a research and development setting. Conductive materials used in Inkjet printing generally comprises of metal Nanoparticles that need to be thermally sintered for it to be conductive. The preferred metal of choice has been mostly silver due to its excellent electrical properties and ease in sintering. However, silver comes to be expensive than its counterpart copper. Since copper is prone to oxidation, much focus has been given towards photonic sintering that involves sudden burst of pulsed light at certain energy to sinter the copper Nanoparticles. With this technique, only the printed material gets sintered in a matter of seconds without having a great impact on its substrate, due to which it is also preferred in low temperature applications. With all the knowledge, there is still a large gap in the process side with copper where it is important to look how the print process affects the resolution of the print along with the effect of post-print processes on electrical and mechanical properties. In this paper, a copper Inkjet ink is utilized for understanding the effect of Inkjet print parameters on the ejected droplet and its resolution. Post-print process is also quantified using a photonic sintering equipment for excellent electrical and mechanical properties. To demonstrate the complete process, commercial-off-the-shelf components will also be mounted on the additively printed pads via Inkjet. Statistically, control charting technique will be utilized to understand the capability of the Inkjet process.

printed electronics↗
NASA NTRSDate not supplied

Thermoplastic Composite Aircraft Manufacturing Model

A manufacturing process to produce 80 single aisle sized thermoplastic composite aircraft a month is presented. Within the Hi-Rate Composite Aircraft Manufacturing (HiCAM) program a baseline aircraft fuselage was designed and modeled based on the Boeing 787 one-piece barrel build, but scaled down to a single aisle aircraft. Key Performance Parameters (KPPs) of recurring cost, non-recurring cost, and weight are calculated from the model. The outcome of this simulation indicated a prohibitively high non-recurring cost, so the thermoplastic team modeled the manufacturing flow for a panelized fuselage concept. The minimum success criteria is a 30% cost reduction and less than two percent increase in weight compared to the baseline aircraft. Automated Fiber Placement (AFP) is used to layup skins, stamp forming is used to make body frames, stringers, and passenger door surround parts. In the model, Co-Fusion was used to consolidate the skin while simultaneously welding on stringers to make stiffened panels. Additional welding technologies were considered to minimize fastener use and a vertical build concept was used for final assembly to reduce factory size. This manufacturing concept for a thermoplastic aircraft indicated a 39% cost and 12% weight savings compared to the baseline. Additional trade studies were conducted using Northrop Grumman’s Automated Stiffener Forming technology to make stringers and stamp forming instead of AFP to make skins.

thermoplastic composites↗
NASA NTRS2003

Environmentally Safer, Less Toxic Fire-Extinguishing Agents

Fire-extinguishing agents comprising microscopic drops of water microencapsulated in flame-retardant polymers have been proposed as effective, less toxic, non-ozone-depleting, non-globalwarming alternatives to prior fire-extinguishing agents. Among the prior fire-extinguishing agents are halons (various halocarbon fluids), which are toxic and contribute both to depletion of upperatmospheric ozone and to global warming. Other prior fire-extinguishing agents are less toxic and less environmentally harmful but, in comparison with halons, are significantly less effective in extinguishing fires. The proposal to formulate new waterbased agents is based on recent success in the use of water mist as a fire-suppression agent. Water suppresses a flame by reducing the flame temperature and the concentration of oxygen available for the combustion process. The temperature is reduced because the water droplets in the mist absorb latent heat of vaporization as they evaporate. The concentration of oxygen is reduced because the newly generated water vapor displaces air. Unfortunately, water mists are difficult to produce in confined spaces and can evaporate before they reach the bases of flames. The proposal addresses both of these issues: The proposed fire-extinguishing agents would be manufactured in microencapsulated form in advance, eliminating the problem of generating mists in confined spaces. Because of the microencapsulation, the droplets would not evaporate until exposed directly to the heat of flames. In addition, the proposal calls for the introduction of free radicals that would inhibit the propagation of the chemical reactions of the combustion reactions. Manufacturing of a fire-extinguishing agent according to the proposal would begin with the formulation of a suitable polymer (e.g., a polybromostyrene) that would contribute free radicals to the combustion process. The polymer would be dissolved in a suitable hydrocarbon liquid (e.g., toluene). Water would be dispersed in the polymer/toluene solution, then another hydrocarbon liquid (e.g., hexane) that is not a solvent for the polymer would be added to the mixture to make the dissolved polymer precipitate onto the water droplets. The resulting polymer-coated droplets would be removed from the coating mixture by filtration, dried, and stored for use.

Parrish, Clyde F.↗
NASA NTRS2004

CMC Property Variability and Life Prediction Methods for Turbine Engine Component Application

The ever increasing need for lower density and higher temperature-capable materials for aircraft engines has led to the development of Ceramic Matrix Composites (CMCs). Today's aircraft engines operate with >3000"F gas temperatures at the entrance to the turbine section, but unless heavily cooled, metallic components cannot operate above approx.2000 F. CMCs attempt to push component capability to nearly 2700 F with much less cooling, which can help improve engine efficiency and performance in terms of better fuel efficiency, higher thrust, and reduced emissions. The NASA Glenn Research Center has been researching the benefits of the SiC/SiC CMC for engine applications. A CMC is made up of a matrix material, fibers, and an interphase, which is a protective coating over the fibers. There are several methods or architectures in which the orientation of the fibers can be manipulated to achieve a particular material property objective as well as a particular component geometric shape and size. The required shape manipulation can be a limiting factor in the design and performance of the component if there is a lack of bending capability of the fiber as making the fiber more flexible typically sacrifices strength and other fiber properties. Various analysis codes are available (pcGINA, CEMCAN) that can predict the effective Young's Moduli, thermal conductivities, coefficients of thermal expansion (CTE), and various other properties of a CMC. There are also various analysis codes (NASAlife) that can be used to predict the life of CMCs under expected engine service conditions. The objective of this summer study is to utilize and optimize these codes for examining the tradeoffs between CMC properties and the complex fiber architectures that will be needed for several different component designs. For example, for the pcGINA code, there are six variations of architecture available. Depending on which architecture is analyzed, the user is able to specify the fiber tow size, tow spacing, weave parameter, and angle of orientation of fibers. By holding the volume fraction of the fibers constant, variations in tow spacing can be explored for different architectures. The CMC material properties are usually calculated assuming the component is manufactured perfectly. However, this is typically not the case so that a quantification of the material property variability is needed to account for processing and/or manufacturing imperfections. The overall inputs and outputs are presented using a regression software to rapidly investigate the tradeoffs associated with fiber architecture, material properties, and ultimately cost. This information is then propagated through lifing models and Larson-Miller data to assess timehemperature-dependent CMC strength. In addition, a first order cost estimation will be quantified from a current qualitative perspective. This cost estimation includes the manufacturing challenges, such as tooling, as well as the component cost for a particular application. Ultimately, a cost to performance ratio should be established that compares the effectiveness of CMCs to their current rival, nickel superalloys.

Cheplak, Matthew L.↗
NASA NTRSDate not supplied

Thermoplastic Aircraft Manufacturing Model

A manufacturing process to produce 80 single aisle sized thermoplastic composite aircraft a month is presented. Within the Hi-Rate Composite Aircraft Manufacturing (HiCAM) program a baseline aircraft fuselage was designed and modeled based on the Boeing 787 one-piece barrel build, but scaled down to a single aisle aircraft. Key Performance Parameters (KPPs) of recurring cost, non-recurring cost, and weight are calculated from the model. The outcome of this simulation indicated a prohibitively high non-recurring cost, so the thermoplastic team modeled the manufacturing flow for a panelized fuselage concept. The minimum success criteria is a 30% cost reduction and less than two percent increase in weight compared to the baseline aircraft. Automated Fiber Placement (AFP) is used to layup skins, stamp forming is used to make body frames, stringers, and passenger door surround parts. In the model, Co-Fusion was used to consolidate the skin while simultaneously welding on stringers to make stiffened panels. Additional welding technologies were considered to minimize fastener use and a vertical build concept was used for final assembly to reduce factory size. This manufacturing concept for a thermoplastic aircraft indicated a 39% cost and 12% weight savings compared to the baseline. Additional trade studies were conducted using Northrop Grumman’s Automated Stiffener Forming technology to make stringers and stamp forming instead of AFP to make skins.

thermoplastic composites↗
NASA NTRS2026

AC and DC Fault Management for Megawatt Electrified Aircraft Electrical Powertrains Task 3: Lifetime and Reliability of Electrical Insulators

This research project was a collaborative investigation between researchers at the RTX Technology Research Center (RTRC) and the University of Texas at Austin and made a significant contribution to enabling electric aircraft. The transport of electric power between the points of generation and use requires power cables. These cables must be smaller, lighter and provide a more predictable life than power cables used in stationary applications. Consequently, this investigation provided heretofore unavailable information supporting the safety and reliability of smaller lighter power cables for electrified aircraft. In addition, the research identified key additional engineering data needed to support quantitative reliability assessments. Important advances included: • Demonstrated that at least one manufacturer can make a novel, smaller, lighter power cable that is free from serious defects. • Developed and published an appropriate analytical construct to describe the life of this novel cable. This is a necessary step for use in aviation where the understanding of remaining life is critical. • Demonstrated thermal-mechanical aging that suggested 1000+ flights before the thermal-mechanical processes produced defects large enough that the defect growth was accelerated electrically. • Showed that electrical aging took place at two rates. The first possibly lasting weeks to months and the second possibly days to weeks. If robust, this provides a good diagnostic for cable replacement. • Demonstrated that the traditional electrical testing of cable materials using manufactured voids can be misleading due to the size of the voids. Emerging laser drilling technology permitted demonstration that the physics of failure in realistically small voids is different from that in the unrealistically large voids used in earlier research, which is very important for high-quality, high-performance, small aircraft cables. Although this project represents a significant contribution to the specifics of cable aging in the aircraft environment, important additional research remains to be completed, including: • Non-uniform thermal cycling by applying the heat from the center conductor to maximize thermal stress next to the core area where the electric gradient is the strongest. This builds on the uniform thermal cycling that has been completed. • The augmentation of the thermal-mechanical failure rate by electrical processes. Better understanding of these time constants strongly affects the ability to predict life. • Termination design: Terminations provide not only electrical reflection potential, but a location for a series arc fault and an area where ozone can diffuse into the center conductor and negatively affect cable insulation. • The abrasion and ozone resistance of the cable jacket. • Pressure cycling as an accelerant of thermal, mechanical, and/or electrical aging. • Possible methods for online PD detection and offline PD localization

model↗
NASA NTRS1982

Experience and assessment of the DOE-NASA Mod-1 2000-Kilowatt wind turbine generator at Boone, North Carolina

The Mod 1 program objectives are defined. The Mod 1 wind turbine is described. In addition to the steel blade operated on the wind turbine, a composite blade was designed and manufactured. During the early phase of the manufacturing cycle of Mod 1A configuration was designed that identified concepts such as partial span control, a soft tower, and upwind teetered rotors that were incorporated in second and third generation industry designs. The Mod 1 electrical system performed as designed, with voltage flicker characteristics within acceptable utility limits. Power output versus wind speed equaled or exceeded design predictions. The wind turbine control system was operated successfully at the site and remotely from the utility dispatcher's office. During wind turbine operations, television interference was experienced by the local residents. As a consequence, operations were restricted. Although not implemented, two potential solutions were identified. In addition to television interference, a few local residents complained bout objectionable sound, particularly the 'thump' as the blade passed behind the tower. To eliminate objections, the sound generation level was reduced by 10 dB by reducing the rotor speed from 35 rpm to 23 rpm. Bolts in the drive train fractured. A solution was identified but not implemented. The public reaction toward the Mod 1 wind turbine program was overwhelmingly favorable.

Collins, J. L.↗
NASA NTRS1971

Development of dispersion strengthened nickel-chromium alloy (Ni-Cr-Th-O2) sheet for space shuttle vehicles, part 1

A dispersion-strengthened alloy, TD nickel chromium (TDNiCr) is being developed for use on the thermal protection system of the space shuttle at temperatures up to 1204 C(2200 F). Manufacturing processes were developed for the fabrication of sheet and foil to specifications. The addition of aluminum to the basic TDNiCr composition provides outstanding oxidation resistance up to 1260 C(2300 F); aluminum levels of 2 to 4% are considered optimum for space shuttle application.

Klingler, L. J.↗
NASA NTRS1972

Reference data for thermocouple materials below the ice point.

Standard thermoelectric data have been determined for four thermocouple combinations used below the ice point: commercial types E, K, and T and the special combination of KP vs Au-0.07 at.% Fe. Power series coefficients necessary to generate E = f(T) data for these combinations are given. In addition, extensive tests were carried out to ascertain the variability between materials from different manufacturers. Typical wires processed for low-temperature usage often have slightly thermoelectric properties (up to 1%) from those, nominally identical, wires made for high-temperature applications. Generally, type E is the most satisfactory standardized commercial combination. The Au-0.07 at.% Fe material has been examined in particular detail, because it is not yet an ISA standard material. It has excellent sensitivity in the liquid helium/liquid hydrogen temperature range and a nearly linear thermovoltage at higher temperatures.

Sparks, L. L.↗
NASA NTRS1979

Combined pressure and temperature distortion effects on internal flow of a turbofan engine

An additional data base for improving and verifying a computer simulation developed by an engine manufacturer was obtained. The multisegment parallel compressor simulation was designed to predict the effects of steady-state circumferential inlet total-pressure and total-temperature distortions on the flows into and through a turbofan compression system. It also predicts the degree of distortion that will result in surge of the compressor. The effect of combined 180 deg square-wave distortion patterns of total pressure and total temperature in various relative positions is reported. The observed effects of the combined distortion on a unitary bypass ratio turbofan engine are presented in terms of total and static pressure profiles and total temperature profiles at stations ahead of the inlet guide vanes as well as through the fan-compressor system. These observed profiles are compared with those predicted by the complex multisegment model. The effects of relative position of the two components comprising the combined distortion on the degree resulting in surge are discussed. Certain relative positions required less combined distortion than either a temperature or pressure distortion by itself.

Braithwaite, W. M.↗
NASA NTRS1996

Analysis of Measurements for Solid State Lidar Development

A Detector Characterization Facility (DCF), capable of measuring 2-micron detection devices and evaluating heterodyne receivers, was developed at the Marshall Space Flight Center. The DCF is capable of providing all the necessary detection parameters for design, development, and calibration of coherent and incoherent solid state laser radar (lidar) systems. The coherent lidars in particular require an accurate knowledge of detector heterodyne quantum efficient, nonlinearity properties, and voltage-current relationship as a function of applied optical power. At present, no detector manufacturer provides these qualities or adequately characterizes their detectors for heterodyne detection operation. In addition, the detector characterization facility measures the detectors DC and AC quantum efficiencies noise equivalent power and frequency response up to several GHz. The DCF is also capable of evaluating various heterodyne detection schemes such as balanced detectors and fiber optic interferometers. The design and analyses of measurements for the DCF were preformed over the previous year and a detailed description of its design and capabilities was provided in the NASA report NAS8-38609/DO77. It should also be noted that the DCF design was further improved to allow for the characterization of diffractive andholographical optical elements and other critical components of coherent lidar systems.

Amzajerdian, Farzin↗
NASA NTRS2000

Impact of Parallel Computing on Large Scale Aeroelastic Computations

Aeroelasticity is computationally one of the most intensive fields in aerospace engineering. Though over the last three decades the computational speed of supercomputers have substantially increased, they are still inadequate for large scale aeroelastic computations using high fidelity flow and structural equations. In addition to reaching a saturation in computational speed because of changes in economics, computer manufactures are stopping the manufacturing of mainframe type supercomputers. This has led computational aeroelasticians to face the gigantic task of finding alternate approaches for fulfilling their needs. The alternate path to over come speed and availability limitations of mainframe type supercomputers is to use parallel computers. During this decade several different architectures have evolved. In FY92 the US Government started the High Performance Computing and Communication (HPCC) program. As a participant in this program NASA developed several parallel computational tools for aeroelastic applications. This talk describes the impact of those application tools on high fidelity based multidisciplinary analysis.

Guruswamy, Guru P.↗
NASA NTRS2011

Large Payload Transportation and Test Considerations

Ironically, the limiting factor to a national heavy lift strategy may not be the rocket technology needed to throw a heavy payload, but rather the terrestrial infrastructure - roads, bridges, airframes, and buildings - necessary to transport, acceptance test, and process large spacecraft. Failure to carefully consider how large spacecraft are designed, and where they are manufactured, tested, or launched, could result in unforeseen cost to modify/develop infrastructure, or incur additional risk due to increased handling or elimination of key verifications. During test and verification planning for the Altair project, a number of transportation and test issues related to the large payload diameter were identified. Although the entire Constellation Program - including Altair - was canceled in the 2011 NASA budget, issues identified by the Altair project serve as important lessons learned for future payloads that may be developed to support national "heavy lift" strategies. A feasibility study performed by the Constellation Ground Operations (CxGO) project found that neither the Altair Ascent nor Descent Stage would fit inside available transportation aircraft. Ground transportation of a payload this large over extended distances is generally not permitted by most states, so overland transportation alone would not have been an option. Limited ground transportation to the nearest waterway may be permitted, but water transportation could take as long as 66 days per production unit, depending on point of origin and acceptance test facility; transportation from the western United States would require transit through the Panama Canal to access the Kennedy Space Center launch site. Large payloads also pose acceptance test and ground processing challenges. Although propulsion, mechanical vibration, and reverberant acoustic test facilities at NASA s Plum Brook Station have been designed to accommodate large spacecraft, special handling and test work-arounds may be necessary, which could increase cost, schedule, and technical risk. Once at the launch site, there are no facilities currently capable of accommodating the combination of large payload size and hazardous processing (which includes hypergolic fuels, pyrotechnic devices, and high pressure gasses).

Rucker, Michelle A.↗
NASA NTRS2016

Key Elements of a Low Voltage, Ultracompact Plasma Spectrometer

Taking advantage of technological developments in wafer-scale processing over the past two decades, such as deep etching, 3-D chip stacking, and double-sided lithography, we have designed and fabricated the key elements of an ultracompact 1.5cm (exp 3)plasma spectrometer that requires only low-voltage power supplies, has no microchannel plates, and has a high aperture area to instrument volume ratio. The initial design of the instrument targets the measurement of charged particles in the 3-20keV range with a highly directional field of view and a 100 duty cycle; i.e., the entire energy range Is continuously measured. In addition to reducing mass, size, and voltage requirements, the new design will affect the manufacturing process of plasma spectrometers, enabling large quantities of identical instruments to be manufactured at low individual unit cost. Such a plasma spectrometer is ideal for heliophysics plasma investigations, particularly for small satellite and multispacecraft missions. Two key elements of the instrument have been fabricated: the collimator and the energy analyzer. An initial collimator transparency of 20 with 3deg x 3deg angular resolution was achieved. The targeted 40 collimator transparency appears readily achievable. The targeted energy analyzer scaling factor of 1875 was achieved; i.e.20 keV electrons were selected for only a 10.7V bias voltage in the energy analyzer.

Scime, E. E.↗