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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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All sourcesNASA NTRSDOE OSTI
NASA NTRS1993

Effect of tow alignment on the mechanical performance of 3D woven textile composites

Three-dimensional (3D) woven preforms are currently being considered for use as primary structural components. Lack of technology to properly manufacture, characterize and predict mechanical properties, and predict damage mechanisms leading to failure are problems facing designers of textile composite materials. Two material systems with identical specifications but different manufacturing approaches are investigated. One manufacturing approach resulted in an irregular (nonuniform) preform geometry. The other approach yielded the expected preform geometry (uniform). The objectives are to compare the mechanical properties of the uniform and nonuniform angle interlock 3D weave constructions. The effect of adding layers of laminated tape to the outer surfaces of the textile preform is also examined. Damage mechanisms are investigated and test methods are evaluated.

Norman, Timothy L.↗
NASA NTRS2016

Experimental Investigation of Subsonic Turbulent Boundary Layer Flow Over a Wall-Mounted Axisymmetric Hill

An important goal for modern fluid mechanics experiments is to provide datasets which present a challenge for Computational Fluid Dynamics simulations to reproduce. Such "CFD validation experiments" should be well-characterized and well-documented, and should investigate flows which are difficult for CFD to calculate. It is also often convenient for the experiment to be challenging for CFD in some aspects while simple in others. This report is part of the continuing documentation of a series of experiments conducted to characterize the flow around an axisymmetric, modified-cosine-shaped, wall-mounted hill named "FAITH" (Fundamental Aero Investigates The Hill). Computation of this flow is easy in some ways - subsonic flow over a simple shape - while being complex in others - separated flow and boundary layer interactions. The primary set of experiments were performed on a 15.2 cm high, 45.7 cm base diameter machined aluminum model that was tested at mean speeds of 50 m/s (Reynolds Number based on height = 500,000). The ratio of model height to boundary later height was approximately 3. The flow was characterized using surface oil flow visualization, Cobra probe to determine point-wise steady and unsteady 3D velocities, Particle Image Velocimetry (PIV) to determine 3D velocities and turbulence statistics along specified planes, Pressure Sensitive Paint (PSP) to determine mean surface pressures, and Fringe Imaging Skin Friction (FISF) to determine surface skin friction magnitude and direction. A set of pathfinder experiments were also performed in a water channel on a smaller scale (5.1 cm high, 15.2 cm base diameter) sintered nylon model. The water channel test was conducted at a mean test section speed of 3 cm/s (Reynolds Number of 1500), but at the same ratio of model height to boundary layer thickness. Dye injection from both the model and an upstream rake was used to visualize the flow. This report summarizes the experimental set-up, techniques used, and data acquired. It also describes some details of the dataset that is being constructed for use by other researchers, especially the CFD community.

fluid machanics cfd validation wind tunnel↗
NASA NTRSDate not supplied

Multi-Scale Thermo-Mechanical Modeling of Porous 3D Woven TPS Materials

This work summarizes the process to compute and analyze the thermal conductivity and mechanical properties of 3D woven TPS materials such as 3MDCP (3D Mid-Density Carbon-Phenolic). The PuMA software, developed at NASA Ames, was used to characterize different 3MDCP samples from their constituents' data, averaging their thermal conductivity and elastic properties in the three main directions to obtain their effective orthotropic thermo-mechanical properties. This was performed in multiple steps: firstly, TPS samples were digitally reconstructed using micro computed tomography (µCT) and their constituents were segmented; then, the porous matrix phase was analyzed at the micro-scale and these results were used, along with the fibers’ constituents information, to model the tows at the meso-scale; finally, results from the constituents were homogenized and used to model the thermo-mechanical behavior of the unit cell at the macro-scale. Additionally, to gain a better understanding of the tows’ morphology and distribution of the carbon-phenolic blended fibers, microscopy images of the tows’ cross-section were segmented using deep learning techniques and analyzed with PuMA. This workflow can be applied to any TPS material to computationally obtain its thermo-mechanical properties, enabling more informed TPS design and manufacturing choices.

Multi-Scale↗
NASA NTRS1990

Distributed deformation and block rotation in 3D

The authors address how block rotation and complex distributed deformation in the Earth's shallow crust may be explained within a stationary regional stress field. Distributed deformation is characterized by domains of sub-parallel fault-bounded blocks. In response to the contemporaneous activity of neighboring domains some domains rotate, as suggested by both structural and paleomagnetic evidence. Rotations within domains are achieved through the contemporaneous slip and rotation of the faults and of the blocks they bound. Thus, in regions of distributed deformation, faults must remain active in spite of their poor orientation in the stress field. The authors developed a model that tracks the orientation of blocks and their bounding faults during rotation in a 3D stress field. In the model, the effective stress magnitudes of the principal stresses (sigma sub 1, sigma sub 2, and sigma sub 3) are controlled by the orientation of fault sets in each domain. Therefore, adjacent fault sets with differing orientations may be active and may display differing faulting styles, and a given set of faults may change its style of motion as it rotates within a stationary stress regime. The style of faulting predicted by the model depends on a dimensionless parameter phi = (sigma sub 2 - sigma sub 3)/(sigma sub 1 - sigma sub 3). Thus, the authors present a model for complex distributed deformation and complex offset history requiring neither geographical nor temporal changes in the stress regime. They apply the model to the Western Transverse Range domain of southern California. There, it is mechanically feasible for blocks and faults to have experienced up to 75 degrees of clockwise rotation in a phi = 0.1 strike-slip stress regime. The results of the model suggest that this domain may first have accommodated deformation along preexisting NNE-SSW faults, reactivated as normal faults. After rotation, these same faults became strike-slip in nature.

Scotti, Oona↗
NASA NTRS2020

Characterization of SiC/SiC Composites Subjected to Sequential Tensile Creep and Dwell Fatigue in Air under Thermal Gradient Conditions

Uncoated SiC/SiC composites, with 2D and 3D fiber architectures, were investigated under steady state thermal gradient conditions with sequential tensile creep and dwell fatigue. Melt infiltration (MI), chemical vapor infiltration (CVI), polymer impregnation and pyrolysis (PIP), and hybrid (CVI and PIP) techniques were used to fabricate ceramic matrix composites (CMCs) with a 2D balanced fiber architecture. CMCs with 3D fiber weaves were also fabricated using MI and hybrid methods. Steady state through the thickness thermal gradients were generated for the tensile specimens using laser heating on the front (hot side) and forced air cooling on the back (cold side). Hot side and cold side temperatures of 2400 and 2200 °F, respectively, were used for testing CMCs fabricated with the MI process, whereas hot side and cold side temperatures of 2700 and 2400 °F, respectively, were used for CMCs fabricated with CVI, PIP, and hybrid processes. Each CMC specimen was initially tested under tensile creep at 69 MPa (10 ksi) for 80 hours, which was then followed by tensile dwell fatigue testing at a maximum stress of 69 MPa (10 ksi) for another 80 hours for a total of 160 hours. This type of sequential tensile creep followed by tensile dwell fatigue testing was performed to ascertain the integrity of uncoated CMCs under steady state thermal gradient conditions. Tensile creep and dwell fatigue test results, generated under steady state thermal gradient conditions on different types of SiC/SiC composites, are compared with corresponding creep behaviors observed under isothermal conditions to determine the influence of both monotonic creep (static fatigue) and dwell fatigue on accumulated strains and deformation behaviors of the CMCs.

Kalluri, Sreeramesh↗
NASA NTRS2012

Paramyxovirus Infection Mimics In Vivo Cellular Dynamics in Three-Demensional Human Bronchio-Epithelial Tissue-Like Assemblies

Respiratory syncytial virus and parainfluenza virus cause severe respiratory disease, especially in infants, children and the elderly. An in vitro model that accurately mimics infection of the human respiratory epithelium (HRE) would facilitate vaccine development greatly. Monolayer cultures traditionally used to study these viruses do not accurately and precisely differentiate the replication efficiencies of wild type and attenuated viruses. Therefore, we engineered novel three-dimensional (3D) tissue-like assemblies (TLAs) of human broncho-epithelial (HBE) cells to produce a more physiologically relevant in vitro model of the HRE. TLAs resemble HRE structurally and by expression of differentiated epithelial cell markers. Most significantly, wild type viruses exhibited a clear growth advantage over attenuated strains in TLAs unlike monolayer cultures. In addition, the TLAs responded to virus infection by secreting pro-inflammatory mediators similar to the respiratory epithelia of infected children. These characteristics make the TLA model a valuable platform technology to develop and evaluate live, attenuated respiratory virus vaccine candidates for human use. Respiratory virus diseases, the most frequent and least preventable of all infectious diseases, range in severity from the common cold to severe bronchiolitis and pneumonia . Two paramyxoviruses, respiratory syncytial virus (RSV) and parainfluenza virus type 3 (PIV3), are responsible for a majority of the most severe respiratory diseases of infants and young children. RSV causes 70% of all bronchiolitis cases and is a major cause of morbidity and mortality worldwide, especially in infants. PIV3 causes 10-15% of bronchiolitis and pneumonia during infancy, second only to RSV, and 40% of croup in infants To date, licensed vaccines are not available to prevent these respiratory diseases. At present, traditional monkey kidney (Vero and LLC-MK2) and human (HEp-2) tissue culture cells and small animal models (mouse, cotton rat, guinea pig, ferret, and hamster) fail to accurately imitate viral replication and human disease states (8). Lacking an authentic model has impeded the development and evaluation of live, attenuated vaccine candidates. Development of a physiologically relevant in vitro tissue culture model that reproduces characteristics of the HRE, the primary target of RSV and PIV3, would aid in predicting clinical attenuation and safety of vaccine candidates. Successful tissue engineering of a 3D human intestinal model using novel NASA technology inspired the development of a tri-culture 3D model for the HRE. Sequential layering of primary mesenchymal cells (comprised of normal human fibroblasts and endothelial cells) followed by BEAS-2B epithelial cells derived from human bronchi and tracheae were recapitulated on Cultisphere and/or cytodex3 microcarriers in cylindrical vessels that rotate horizontally creating an organized epithelial structure. Horizontal rotation randomizes the gravity vector modeling aspects of microgravity. Mesenchymal and epithelial cells grown under these conditions reproduce the structural organization, multi-cellular complexity, and differentiation state of the HRE. The opportunity to study respiratory viruses in a nasal epithelium model is invaluable because the most promising respiratory virus vaccine candidates are live attenuated viruses for intranasal administration. Here we characterize the interactions of respiratory viruses and epithelial cells grown under modeled microgravity in comparison to gravity-ladened monolayers. 3D HBE TLAs and traditional monolayers (2D) are infected at 35 C, the upper temperature of the upper HRE, to simulate in vivo infection conditions. Growth kinetics of wild type (wt) RSV and PIV3 viruses were compared in 2D and 3D cells to that of strains attenuated in humans or rhesus macaques. This novel 3D HBE model also offers an opportunity to study whether the epithelial cell function, especially in host defenses recapitulated by mimicking the structural organization of the HRE. In vivo, airway epithelial cells play a significant and dynamic role in host defense by blocking paracellular permeability and modulating airway function through cellular interactions or tight junctions. As regulators of the innate immune response, epithelial cells constitutively express cytokines, chemokines, and colony stimulating factors including RANTES, IL-8, IL-6, GM-CSF, and G-CSF for proactive host defense. In response to viral infection, epithelial cells induce potent immuno-modulatory and pro-inflammatory cytokines that recruit phagocytic and inflammatory cells to clear the virus and enhance protection. Although disease pathogenesis is classically attributed to the cytopathic effects of the pathogen, severe disease states associated with RSV and PIV3 are attributed to the inflammatory response, especially in infants. RSV is a potent inducer of cytokines and pro-inflammatory mediators in epithelial cells in vivo. A differentiated human epithelial model independent of the complete functional immune system will help elucidate the role of epithelial cells in respiratory disease. We reported here, virus and host cell interactions in 3D HBE TLAs are similar to that in vivo. Because the epithelial cell organization of the TLAs impacts not only the expression of airway epithelial characteristics, but also cellular communication, the TLAs represent a more physiologically relevant model of the HRE than BEAS-2B or other non-tumour monolayer models of respiratory disease. As a result, wild type respiratory viruses have a clear growth advantage over attenuated viruses in TLAs unlike traditional monolayers. In addition, the TLAs respond to wild type virus infection by secreting pro-inflammatory mediators characteristic of infected HRE. TLAs expressing microbial defense mechanisms provide an excellent model to study the interactions of respiratory pathogens with their host and to identify the innate immunity mediators. Therefore, 3D HBE TLAs offer advantages for the study of respiratory viruses and the development of viral vaccine candidates.

Deatly, Anne M.↗
NASA NTRS1999

An overview of vertebrate mineralization with emphasis on collagen-mineral interaction

The nucleation, growth, and development of mineral crystals through their interaction principally with collagen in normal bone and calcifying tendon have been elaborated by applying a number of different techniques for analysis of the inorganic and organic constituents of these tissues. The methods have included conventional and high voltage electron microscopy, electron diffraction, microscopic tomography and 3D image reconstruction, and atomic force microscopy. This summary presents results of these studies that have now characterized the size, shape, and aspects of the chemical nature of the crystals as well as their orientation, alignment, location, and distribution with respect to collagen. These data have provided the means for understanding more completely the formation and strength of the collagen-mineral composite present in most vertebrate calcifying tissues and, from that information, a basis for the adaptation of such tissues under mechanical constraints. In the context of the latter point, other data are given showing effects on collagen in bone cell cultures subjected to the unloading parameters of spaceflight. Implications of these results may be particularly relevant to explaining loss of bone by humans and other vertebrate animals during missions in space, during situations of extended fracture healing, long-term bedrest, physical immobilization, and related conditions. In a broader sense, the data speak to the response of bone and mineralized vertebrate tissues to changes in gravitational loading and applied mechanical forces in general.

Non-NASA Center↗
NASA NTRS2011

VESGEN Mapping of Bioactive Protection against Intestinal Inflammation: Application to Human Spaceflight and ISS Experiments

Challenges to successful space exploration and colonization include adverse physiological reactions to micro gravity and space radiation factors. Constant remodeling of the microvasculature is critical for tissue preservation, wound healing, and recovery after ischemia. Regulation of the vascular system in the intestine is particularly important to enable nutrient absorption while maintaining barrier function and mucosal defense against micro biota. Although tremendous progress has been made in understanding the molecular circuits regulating neovascularization, our knowledge of the adaptations of the vascular system to environmental challenges in the intestine remains incomplete. This is in part because of the lack of methods to observe and quantify the complex processes associated with vascular responses in vivo. Developed by GRC as a mature beta version, pre-release research software, VESsel GENeration Analysis (VESGEN) maps and quantifies the fractal-based complexity of vascular branching for novel insights into the cytokine, transgenic and therapeutic regulation of angiogenesis, lymphangiogenesis and microvascular remodeling. Here we demonstrate that VESGEN can be used to characterize the dynamic vascular responses to acute intestinal inflammation and mucosal recovery from in vivo confocal microscopic 3D image series. We induced transient intestinal inflammation in mice by DSS treatment and investigated whether the ability of the pro biotic yeast Saccharomyces boulardii (Sb) to protect against intestinal inflammation was due to regulation of vascular remodeling. A primary characteristic of inflammation is excessive neovascularization (angiogenesis) resulting in fragile vessels prone to bleeding. Morphological parameters for triplicate specimens revealed that Sb treatment greatly reduced the inflammatory response of vascular networks by an average of 78%. This resulted from Sb inhibition of vascular endothelial growth factor receptor signaling, a major angiogenesis signaling pathway. It needs to be determined whether pro biotic yeast represents a promising approach to GI protection in space. GRC performed only the VESGEN post-testing analysis.

Parsons-Wingerter, P. A.↗
NASA NTRSDate not supplied

Fast Assessment of Metal Performance through Dislocation Physics and Machine Learning

The microstructure of metals is key to their mechanical properties. The types, density, composition and morphology of crystal defects all have pronounced impact on the properties. Changes to the microstructure occurring during processing and use can be very striking. The emerging technology additive manufacturing (AM) has the potential to improve performance by allowing optimized designs, but the process and environments can lead to unusual microscale features whose properties must be understood and characterized to enable higher technological readiness levels and application. Experimentally, an extensive evaluation of mechanical properties of 3D printed metals is a challenge, and anomalous effects related to the AM process add complexity. We present a new machine learning (ML) model predicting mechanical response based on dislocation mediated plasticity simulations. A large set of 3D discrete dislocation dynamics simulations with wide ranges of loading conditions is transformed to preprocessed data ready for training with the ML model. The trained model can predict the mechanical response of Mo30W for a given microstructure evolution, providing key information essential for optimization of AM processing.

Jaehyun Cho↗
NASA NTRSDate not supplied

Fast Assessment of Metal Performance through Dislocation Physics and Machine Learning

The microstructure of metals is key to their mechanical properties. The types, density, composition and morphology of crystal defects all have pronounced impact on the properties. Changes to the microstructure occurring during processing and use can be very striking. The emerging technology additive manufacturing (AM) has the potential to improve performance by allowing optimized designs, but the process and environments can lead to unusual microscale features whose properties must be understood and characterized to enable higher technological readiness levels and application. Experimentally, an extensive evaluation of mechanical properties of 3D printed metals is a challenge, and anomalous effects related to the AM process add complexity. We present a new machine learning (ML) model predicting mechanical response based on dislocation mediated plasticity simulations. A large set of 3D discrete dislocation dynamics simulations with wide ranges of loading conditions is transformed to preprocessed data ready for training with the ML model. The trained model can predict the mechanical response of Mo30W for a given microstructure evolution, providing key information essential for optimization of AM processing.

Jaehyun Cho↗
NASA NTRS2022

The TRAPPIST-1 Habitable Atmosphere Intercomparison (THAI). Part III: Simulated Observables - The Return of the Spectrum

The TRAPPIST-1 Habitable Atmosphere Intercomparison (THAI) is a community project that aims to quantify how differences in general circulation models (GCMs) could impact the climate prediction for TRAPPIST-le and, subsequently its atmospheric characterization in transit. Four GCMs have participated in THAI so far: ExoCAM, LMD-Generic, ROCKE-3D and the UM. This paper, focused on the simulated observations, is the third part of a trilogy, following the analysis of two land planet scenarios (part I) and two aquaplanet scenarios (part II). Here, we show a robust agreement between the simulated spectra and the number of transits estimated to detect the land planet atmospheres. For the cloudy aquaplanet ones, a 5-σ detection of CO2 could be achieved in about 10 transits if the atmosphere contains at least 1 bar of CO2. That number can vary by 41- 56% depending on the GCM used to predict the terminator profiles, principally due to differences in the cloud deck altitude, with ExoCAM and LMD-G producing higher clouds than ROCKE-3D and UM. Therefore, for the first time, this work provides "GCM uncertainty error bars" of ~ 50% that need to be considered in future analyses of transmission spectra. We also analyzed the inter-transit variability induced by weather patterns and changes of terminator cloudiness between transits. Its magnitude differs significantly between the GCMs but its impact on the transmission spectra is within the measurement uncertainties. THAI has demonstrated the importance of model intercomparison for exoplanets and also paved the way for a larger project to develop an intercomparison meta-framework, namely the Climates Using Interactive Suites of Intercomparisons Nested for Exoplanet Studies (CUISINES).

Exoplanet atmospheres↗
NASA NTRSDate not supplied

Additive Manufacturing and Working Fluid Characterization of Ceramic Heat Pipes

In this work, additively manufactured aluminum nitride (AlN) ceramic heat pipes are developed to improve spacecraft heat rejection capabilities beyond the current state-of-the-art metal systems. Printed AlN parts are characterized via SEM, EDS, X-ray diffraction, optical profilometry, thermal conductivity, and emissivity testing. AlN 3D-printed parts are also tested for compatibility with aluminum bromide, aluminum chloride, and iodine, among other proposed working fluids at 500-600 K in vacuum.

Thermal management↗
NASA NTRS2024

Metal Extraction from Trash via Trash-to-Gas Processing for Use in 3D Printing

This work synergized state-of-the-art trash-to-gas (TtG) and in-space manufacturing (ISM) technologies to successfully extract metals from astronaut waste items for use in 3D printing. This was accomplished by isolating pure aluminum (Al 1235) from astronaut multilayer food packaging via TtG processing, cleaning the extracted aluminum, and preparing it for compatibility with the bound metal deposition (BMD) 3D printing process. A suite of material analyses was performed on the extracted aluminum product to fully characterize the key properties linked to effective additive manufacturing, including particle size distribution, oxygen content quantitation, and elemental composition. Metal extraction from Lunar and Martian regolith has become a significant area of interest for the in-situ resource utilization (ISRU) community to produce metallic equipment for various mission scenarios. However, the extraction of metals from astronaut waste streams has yet to be investigated. This project demonstrated an end-to-end waste metallic reuse process which may garner considerable metal production that would otherwise be disposed of.

Ray Pitts↗
NASA NTRSDate not supplied

Multi-Scale Thermo-Mechanical Modeling of Porous 3D Woven TPS Materials

This work summarizes the process to compute and analyze the thermal conductivity and mechanical properties of 3D woven TPS materials such as 3MDCP (3D Mid-Density Carbon-Phenolic). The PuMA [1,2] software, developed at NASA Ames, was used to characterize different 3MDCP samples from their constituents' data, averaging their thermal conductivity and elastic properties in the three main directions to obtain their effective orthotropic thermo-mechanical properties. This was performed in multiple steps: firstly, TPS samples were digitally reconstructed using micro computed tomography (µCT) and their constituents were segmented; then, the porous matrix phase was analyzed at the micro-scale and these results were used, along with the fibers’ constituents information, to model the tows at the meso-scale; finally, results from the constituents were homogenized and used to model the thermo-mechanical behavior of the unit cell at the macro-scale. Additionally, to gain a better understanding of the tows’ morphology and distribution of the carbon-phenolic blended fibers, microscopy images of the tows’ cross-section were segmented using deep learning techniques and analyzed with PuMA. This workflow can be applied to any TPS material to computationally obtain its thermo-mechanical properties, enabling more informed TPS design and manufacturing choices.

Multi-Scale↗
NASA NTRS2022

The TRAPPIST-1 Habitable Atmosphere Intercomparison (THAI). Part II: Moist Cases - The Two Waterworlds

To identify promising exoplanets for atmospheric characterization and to make the best use of observational data, a thorough understanding of their atmospheres is needed. 3D general circulation models (GCMs) are one of the most comprehensive tools available for this task and will be used to interpret observations of temperate rocky exoplanets. Due to parameterization choices made in GCMs, they can produce different results, even for the same planet. Employing four widely-used exoplanetary GCMs - ExoCAM, LMD-G, ROCKE-3D and the UM - we continue the TRAPPIST-1 Habitable Atmosphere Intercomparison by modeling aquaplanet climates of TRAPPIST-le with a moist atmosphere dominated by either nitrogen or carbon dioxide. Although the GCMs disagree on the details of the simulated regimes, they all predict a temperate climate with neither of the two cases pushed out of the habitable state. Nevertheless, the inter-model spread in the global mean surface temperature is non-negligible: 14 K and 24 K in the nitrogen and carbon dioxide dominated case, respectively. We find substantial inter-model differences in moist variables, with the smallest amount of clouds in LMDGeneric and the largest in ROCKE-3D. ExoCAM predicts the warmest climate for both cases and thus has the highest water vapor content and the largest amount and variability of cloud condensate. The UM tends to produce colder conditions, especially in the nitrogen-dominated case due to a strong negative cloud radiative effect on the day side of TRAPPIST-le. Our study highlights various biases of GCMs and emphasizes the importance of not relying solely on one model to understand exoplanet climates.

TRAPPIST↗
NASA NTRSDate not supplied

Development of Additive Manufacturing Technologies for 3D Printing of Spacecraft Heat Shields

Introduction: Ablative heat shields are an enabling technology for entry into planetary atmospheres. From the PICA heatshields used for several Mars rovers to the carbon phenolic material used for Galileo’s Jupiter entry probe, the heat shield manages the heat load transferred to the payload, protecting the sensitive scientific instruments carried on entry probes. The Additive Manufacturing of Thermal Protection Systems (AMTPS) project, an Early Career Initiative (ECI) funded by NASA’s Space Technology Mission Directorate and led by NASA Johnson Space Center, seeks to develop materials and processes for 3D printing ablative heat shields for spacecraft. Current methods for producing ablative heat shields are extremely labor intensive and re-quire extensive hands-on processes and quality control characterization. Additive manufacturing (AM) offers the possibility of reduced production times, improved reliability, and enhanced performance via graded compositions. Costs will also be reduced by reducing the time and labor required for heat shield production. Direct integration of the heat shield onto the structure during processing simplifies integration and reduces risk. Material Development: A critical challenge for the project is development of a material system that can (1) be printed in a near-net shape process and (2) perform well as an ablator. Achieving printability requires the material to flow under applied pressure, but maintain its shape once extruded from the printer nozzle. Ablative performance is measured by a multitude of markers, including char yield, char strength, thermal conductivity, and recession rate. Furthermore, there are several mechanical and thermal property considerations for vehicle integration including coefficient of thermal expansion (CTE) and residual stress. AM technology will be leveraged to grade the material formulation and properties through the thickness of the heat shield, an architecture not possible with current manufacturing processes. To this end, “robust” material formulations have been pre-pared with higher density for use on the surface where most ablation will occur. “Insulative” material formulations, with lower density and lower thermal conductivity, are prepared for use in the depth of the heat shield. This graded architecture will re-duce the overall mass of the heat shield and reduce costs and/or increase scientific payload capacities. To achieve a material system with the required properties, multiple resins have been investigated in collaboration with NASA Ames Research Center. To tune printability and performance, resin additives were studied to improve flexibility of the cured material while maintaining acceptable ablative performance. Material coupons were printed and studied via a suite of mechanical and thermal characterization methods. Arc jet testing was conducted at NASA Ames Research Center to evaluate ablative performance and thermal protection under conditions expected in atmospheric entry. Manufacturing Scale-Up: A partnership with Oak Ridge National Laboratory (ORNL) aims to enable full-scale fabrication of a 3D printed heat shield. Leveraging expertise in manufacturing and 3D printing at ORNL, a mid-scale manufacturing demonstration unit will be built and tested, using a dual-layer ablative system printed directly onto the titanium structure. Work on robotic system integration is ongoing and efforts to scale up material mixing with a material compound will ensure accurate and homogenous composition. Flight Test: A hypersonic sub-orbital flight test will provide a rigorous test of material performance ranging from ablation, thermal management, and mechanical integrity. Design of the capsule has taken place in collaboration with the University of Kentucky. Data collected from the flight will inform future design efforts in material formulation, printing methodology, and heat shield-capsule integration.

additive manufacturing↗
NASA NTRS2015

An Imaging System for Satellite Hypervelocity Impact Debris Characterization

This paper discusses the design of an automated imaging system for size characterization of debris produced by the DebriSat hypervelocity impact test. The goal of the DebriSat project is to update satellite breakup models. A representative LEO satellite, DebriSat, was constructed and subjected to a hypervelocity impact test. The impact produced an estimated 85,000 debris fragments. The size distribution of these fragments is required to update the current satellite breakup models. An automated imaging system was developed for the size characterization of the debris fragments. The system uses images taken from various azimuth and elevation angles around the object to produce a 3D representation of the fragment via a space carving algorithm. The system consists of N point-and-shoot cameras attached to a rigid support structure that defines the elevation angle for each camera. The debris fragment is placed on a turntable that is incrementally rotated to desired azimuth angles. The number of images acquired can be varied based on the desired resolution. Appropriate background and lighting is used for ease of object detection. The system calibration and image acquisition process are automated to result in push-button operations. However, for quality assurance reasons, the system is semi-autonomous by design to ensure operator involvement. This paper describes the imaging system setup, calibration procedure, repeatability analysis, and the results of the debris characterization.

Moraguez, Matthew↗
NASA NTRS2001

Cloud Spatial Structure and 3D Radiative Transfer

Cloud radiative properties are sensitive to drop size and other parameters of cloud micro-structure, but also to cloud shape, spacing, and other parameters of cloud macro-structure, including internal fractal structure. New information on cloud structure is being derived from a variety of cloud radars and lidars. Ongoing field programs such as DoE/ARM are improving the measurement and modelling of physical and radiative properties of clouds. A parallel effort is underway to improve cloud remote sensing, especially from the new suite of EOS (Earth Observing System) instruments which are beginning to provide higher spectral, spatial resolution, and/or angular resolution. Key parameters for improving pixel-scale retrievals are cloud thickness and photon mean-free-path, which together determine the scale of "radiative smoothing" of cloud fluxes and radiances. This scale has been observed as a change in the spatial spectrum of Landsat cloud radiances, and was also recently found with the Goddard micropulse lidar, by searching for returns from directions nonparallel to the incident beam. "Offbeam" Lidar returns are now being used to estimate the cloud "radiative Green's function", (G). G depends on cloud thickness and may be used to retrieve that important quantity. G is also being applied to improving simple estimates of cloud radiative properties that are based on the "Independent Pixel Approximation" or IPA. This and other measurements of 3D transfer in clouds, coupled with Monte Carlo and other 3D transfer methods, are beginning to provide a better understanding of the dependence of radiation on cloud inhomogeneity, and to suggest new retrieval and parameterization algorithms which take account of cloud inhomogeneity. An international "Intercomparison of 3D Radiation Codes" or I3RC, program is underway to coordinate and evaluate the variety of 3D radiative transfer methods now available, and to make them more widely available. Information is on the Web at: http://climate.gsfc.nasa.gov/I3RC. Input consists of selected cloud fields derived from data sources such as radar, microwave and satellite, and from models involved in the GEWEX Cloud Systems Studies. Output is selected radiative quantities that characterize the large-scale properties of the fields of radiative fluxes and heating. Several example cloud fields will be used to illustrate the effects of cloud inhomogeneity and 3D radiation.

Cahalan, Robert F.↗