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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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At least 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
NASA NTRS1981

Porous tooling process for manufacture of graphite/polyimide composites

A porous tooling system was selected for the processing of Graphite/PMR-15 Polyimide laminates in thickness up to 3.2 mm. (0.125 inch). This tool system must have a reasonable strength, permeability dimensional stability, and thermal conductivity to accomplish curing at 600 F and 200 psi and 200 psi autoclave temperature and pressure. A permeability measuring apparatus was constructed and permeability vs. casting water level determined to produce tools at three different permeability levels. On these tools, laminates of 5, 11, and 22 plies (.027, .060, and 0.121 inch) were produced and evaluated by ultrasonic, mechanical, and thermal tests to determine the effect of the tool permeability on the cured laminates. All tools produced acceptable laminates at 5 and 11 plies but only the highest permeability produced acceptable clear ultrasonic C-Scans. Recommendations are made for future investigations of design geometry, and strengthening techniques for porous ceramic tooling.

Smiser, L. W.↗
NASA NTRS1972

Development of dispersion-strengthened Ni-Cr-ThO2 alloys for the space shuttle thermal protection system.

An improved manufacturing process has been developed for TD-NiCr that provides sheet of improved quality, better gage control, and reproducible properties. A standard manufacturing process has been developed for the alternate alloy, DS-NiCr, produced by pack-chromizing Ni-2ThO2 sheet. Extension of forming and joining technology for TD-NiCr is in process. Formability criteria are being established for basic sheet forming processes related to the manufacture of Shuttle TPS panels. They include brake forming, corrugation forming, joggling, dimpling, and beading. Joining processes applicable to TPS panels are being optimized with emphasis on establishment of joint efficiencies. Resistance spot welding (fusion and solid state), resistance seam welding, solid-state diffusion welding, and brazing are included in the joining programs. Development of improved manufacturing technology for TD-NiCr fasteners is also being accomplished. Mechanical and physical properties of TD-NiCr are being characterized to provide design-allowable data.

Blankenship, C. P.↗
NASA NTRS1973

Materials processing in zero gravity

Manufacturing processes which are expected to show drastic changes in a space environment due to the absence of earth gravity are classified according to (1) buoyancy and thermal convection sensitive processes and (2) processes where molecular forces like cohesion and adhesion remain as the relatively strongest and hence controlling factors. Some specific process demonstration experiments carried out during the Apollo 14 mission and in the Skylab program are described. These include chemical separation by electrophoresis, the M551 metals melting experiment, the M552 exothermic brazing experiment, the M553 sphere forming experiment, the M554 composite casting experiment, and the M555 gallium arsenide crystal growth experiment.

Wuenscher, H. F.↗
NASA NTRS1977

Project STOP (Spectral Thermal Optimization Program)

The spectral thermal optimization of solar cell configurations for various solar panel applications is considered. The method of optimization depends upon varying the solar cell configuration's optical characteristics to minimize panel temperatures, maximize power output and decrease the power delta from beginning of life to end of life. Four areas of primary investigation are: (1) testing and evaluation of ultraviolet resistant coverslide adhesives, primarily FEP as an adhesive; (2) examination of solar cell absolute spectral response and corresponding cell manufacturing processes that affect it; (3) experimental work with solar cell manufacturing processes that vary cell reflectance (solar absorptance); and (4) experimental and theoretical studies with various coverslide filter designs, mainly a red rejection filter. The Hughes' solar array prediction program has been modified to aid in evaluating the effect of each of the above four areas on the output of a solar panel in orbit.

Goldhammer, L. J.↗
NASA NTRS2017

Cleaning and Cleanliness Measurement of Additive Manufactured Parts

Additive Manufacturing processes allow for the manufacture of complex three dimensional components that otherwise could not be manufactured. Post treatment processes require the removal of any remnant bulk powder that may become entrapped within small cavities and channels within a component. This project focuses on several gross cleaning methods and the verification metrics associated with additive manufactured parts for oxygen propulsion usage.

Mitchell, Mark A.↗
NASA NTRS1986

Oxide-dispersion-strengthened turbine blades, volume 1

The objective of Project 4 was to develop a high-temperature, uncooled gas turbine blade using MA6000 alloy. The program objectives were achieved. Production scale up of the MA6000 alloy was achieved with a fair degree of tolerance to nonoptimum processing. The blade manufacturing process was also optimized. The mechanical, environmental, and physical property evaluations of MA6000 were conducted. The ultimate tensile strength, to about 704 C (130 F), is higher than DS MAR-M 247 but with a corresponding lower tensile elongation. Also, above 982 C (180 F) MA6000 tensile strength does not decrease as rapidly as MAR-M 247 because the ODS mechanism still remains active. Based on oxidation resistance and diffusional stability considerations, NiCrAlY coatings are recommended. CoCrAly coating should be applied on top of a thin NiCrAlY coating. Vibration tests, whirlpit tests, and a high-rotor-rig test were conducted to ensure successful completion of the engine test of the MA6000 TFE731 high pressure turbine blades. The results of these tests were acceptable. In production quantities, the cost of the Project 4 MA6000 blade is estimated to be about twice that of a cast DS MAR-M 247 blade.

Millan, P. P., Jr.↗
NASA NTRS1987

Oxide-dispersion-strengthened turbine blades. Volume 2

The overall objective of Project 4 was to develop and test a high-temperature, uncooled gas turbine blade using MA6000 alloy. Production scale up of the MA6000 alloy was achieved with a fair degree of tolerance to non-optimum processing. The blade manufacturing process was also optimized. The mechanical, environmental, and physical property evaluations of MA6000 were conducted. The ultimate tensile strength, to about 704 C (1300 F), is higher than DS MAR-M 247 but with a corresponding lower tensile elongation. Also, above 982 C (1800 F) MA6000 tensile strength does not decrease as rapidly as MAR-M 247 because the ODS mechanism still remains active. Based on oxidation resistance and diffusional stability considerations, NiCrAlY coatings are recommended. CoCrAlY coating should be applied on top of a thin NiCrAlY coating if hot corrosion is expected. Vibration, whirlpit, and high-rotor-rig tests were conducted to ensure successful completion of the engine test of the MA6000 TFE731 high pressure turbine blades. Test results were acceptable. In production quantities, the cost of the Project 4 MA6000 blade is estimated to be twice that of a cast DS MAR-M 247 blade.

Millan, P. P., Jr.↗
NASA NTRS1989

Nickel-hydrogen capacity loss on storage

A controlled experiment evaluating the capacity loss experienced by nickel electrodes stored under various conditions of temperature, hydrogen pressure, and electrolyte concentration was conducted using nickel electrodes from four different manufacturers. It was found that capacity loss varied with respect to hydrogen pressure, and storage temperature as well as with respect to electrode manufacturing processes. Impedance characteristics were monitored and found to be indicative of electrode manufacturing processes and capacity loss. Cell testing to evaluate state-of-charge effects on capacity loss were inconclusive as no loss was sustained by the cells tested in this experiment.

Manzo, Michelle A.↗
NASA NTRS1990

Nickel-hydrogen capacity loss on storage

A controlled experiment evaluating the capacity loss experienced by nickel electrodes stored under various conditions of temperature, hydrogen pressure, and electrolyte concentration was conducted using nickel electrodes from four different manufacturers. It was found that capacity loss varied with regard to hydrogen pressure and storage temperature, as well as with regard to electrode manufacturing processes. Impedance characteristics were monitored and found to be indicative of electrode manufacturing processes and capacity loss. Cell testing to evaluate state-of-charge effects on capacity loss were inconclusive as no loss was sustained by the cells tested in this experiment.

Manzo, Michelle A.↗
NASA NTRS1991

Manufacturing with the Sun

Concentrated solar radiation is now a viable alternative source for many advanced manufacturing processes. Researchers at the National Renewable Energy Laboratory (NREL) have demonstrated the feasibility of processes such as solar induced surface transformation of materials (SISTM), solar based manufacturing, and solar pumped lasers. Researchers are also using sunlight to decontaminate water and soils polluted with organic compounds; these techniques could provide manufacturers with innovative alternatives to traditional methods of waste management. The solar technology that is now being integrated into today's manufacturing processes offer greater potential for tomorrow, especially as applied to the radiation abundant environment available in space and on the lunar surface.

Murphy, Lawrence M.↗
NASA NTRS1994

Knowledge-Based Manufacturing and Structural Design for a High Speed Civil Transport

The aerospace industry is currently addressing the problem of integrating manufacturing and design. To address the difficulties associated with using many conventional procedural techniques and algorithms, one feasible way to integrate the two concepts is with the development of an appropriate Knowledge-Based System (KBS). The authors present their reasons for selecting a KBS to integrate design and manufacturing. A methodology for an aircraft producibility assessment is proposed, utilizing a KBS for manufacturing process selection, that addresses both procedural and heuristic aspects of designing and manufacturing of a High Speed Civil Transport (HSCT) wing. A cost model is discussed that would allow system level trades utilizing information describing the material characteristics as well as the manufacturing process selections. Statements of future work conclude the paper.

Marx, William J.↗
NASA NTRS2000

Novel Vibration Damping of Ceramic Matrix Composite Turbine Blades Developed for RLV Applications

The Reusable Launch Vehicle (RLV) represents the next generation of space transportation for the U.S. space program. The goal for this vehicle is to lower launch costs by an order of magnitude from $10,000/lb to $1,000/lb. Such a large cost reduction will require a highly efficient operation, which naturally will require highly efficient engines. The RS-2200 Linear Aerospike Engine is being considered as the main powerplant for the RLV. Strong, lightweight, temperature-resistant ceramic matrix composite (CMC) materials such as C/SiC are critical to the development of the RS-2200. Preliminary engine designs subject turbopump components to extremely high frequency dynamic excitation, and ceramic matrix composite materials are typically lightly damped, making them vulnerable to high-cycle fatigue. The combination of low damping and high-frequency excitation creates the need for enhanced damping. Thus, the goal of this project has been to develop well-damped C/SiC turbine components for use in the RLV. Foster-Miller and Boeing Rocketdyne have been using an innovative, low-cost process to develop light, strong, highly damped turbopump components for the RS-2200 under NASA s Small Business Innovation Research (SBIR) program. The NASA Glenn Research Center at Lewis Field is managing this work. The process combines three-dimensionally braided fiber reinforcement with a pre-ceramic polymer. The three-dimensional reinforcement significantly improves the structure over conventional two-dimensional laminates, including high through-the-thickness strength and stiffness. Phase I of the project successfully applied the Foster-Miller pre-ceramic polymer infiltration and pyrolysis (PIP) process to the manufacture of dynamic specimens representative of engine components. An important aspect of the program has been the development of the manufacturing process. Results show that the three-dimensionally braided carbon-fiber reinforcement provides good processability and good mechanical stiffness and strength in comparison to materials produced with competing processes as shown in the graphs.

Min, James B.↗
NASA NTRS2012

The Multiple Use Plug Hybrid for NanoSats (MUPHyN) Miniature Thruster

The Multiple Use Plug Hybrid (for) Nanosats is a prototype thruster is being developed to fill a niche application for NanoSat-scale spacecraft propulsion. When fully developed, the MUPHyN thruster will provide an effective and low-risk propulsive capability that could enable multiple NanoSats to be independently re-positioned after deployment from a parent launch vehicle. Because the environmentally benign, chemically-stable propellants are mixed only within the combustion chamber after ignition and the flow rate of the fuel is determined by a pyrolysis mechanism that is nearly independent of pressure or fuel grain defects, the system is inherently safe and can be piggy-backed near a secondary payload with little or no overall mission risk increase to the primary payload. The MUPHyN thruster uses safe-handling and inexpensive nitrous oxide (N2O) and acrylonitrile-butadiene-styrene (ABS) as propellants. Fused Deposition Modeling (FDM), a direct digital manufacturing process, is used to fabricate short-form-factor solid fuel grains with multiple helical combustion ports from ABS thermoplastic. This manufacturing process allows for the rapid development and manufacture of complex fuel grain geometries that are not possible to extrude or cast using conventional methods. This technology enables the construction of fuel grains with length-to-diameter ratios appropriate for incorporation into CubeSats while maintaining high surface areas and regression rates that allow the system to maintain a near optimal oxidizer to fuel ratio. The MUPHyN system provides attitude control torques by using secondary-injection thrust vectoring on a truncated aerospike nozzle. This configuration allows large impulse delta V burns and small impulse attitude control firings to be performed with the same system. To ensure survivability during extend duration burns, the MUPHyN incorporates a novel regenerative cooling design where the N2O oxidizer flows through a cooling path embedded in the aerospike nozzle before being injected into the combustion chamber near the nozzle base.

Eilers, Shannon D.↗
NASA NTRS2016

In-Process Thermal Imaging of the Electron Beam Freeform Fabrication Process

Researchers at NASA Langley Research Center have been developing the Electron Beam Freeform Fabrication (EBF3) metal additive manufacturing process for the past 15 years. In this process, an electron beam is used as a heat source to create a small molten pool on a substrate into which wire is fed. The electron beam and wire feed assembly are translated with respect to the substrate to follow a predetermined tool path. This process is repeated in a layer-wise fashion to fabricate metal structural components. In-process imaging has been integrated into the EBF3 system using a near-infrared (NIR) camera. The images are processed to provide thermal and spatial measurements that have been incorporated into a closed-loop control system to maintain consistent thermal conditions throughout the build. Other information in the thermal images is being used to assess quality in real time by detecting flaws in prior layers of the deposit. NIR camera incorporation into the system has improved the consistency of the deposited material and provides the potential for real-time flaw detection which, ultimately, could lead to the manufacture of better, more reliable components using this additive manufacturing process.

Taminger, Karen M.↗
NASA NTRS2015

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

In a NASA Aeronautics Research Institute (NARI) sponsored program entitled "A Fully Non-Metallic Gas Turbine Engine Enabled by Additive Manufacturing," evaluation of emerging materials and additive manufacturing technologies was carried out. These technologies may enable fully non-metallic gas turbine engines in the future. This paper highlights the results of engine system trade studies which were carried out to estimate reduction in engine emissions and fuel burn enabled due to advanced materials and manufacturing processes. A number of key engine components were identified in which advanced materials and additive manufacturing processes would provide the most significant benefits to engine operation. In addition, feasibility of using additive manufacturing technologies to fabricate gas turbine engine components from polymer and ceramic matrix composite were demonstrated. A wide variety of prototype components (inlet guide vanes (IGV), acoustic liners, engine access door, were additively manufactured using high temperature polymer materials. Ceramic matrix composite components included first stage nozzle segments and high pressure turbine nozzle segments for a cooled doublet vane. In addition, IGVs and acoustic liners were tested in simulated engine conditions in test rigs. The test results are reported and discussed in detail.

Ceramic Matrix Composites↗
NASA NTRS2015

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

In a NASA Aeronautics Research Institute (NARI) sponsored program entitled "A Fully Non-Metallic Gas Turbine Engine Enabled by Additive Manufacturing", evaluation of emerging materials and additive manufacturing technologies was carried out. These technologies may enable fully non-metallic gas turbine engines in the future. This paper highlights the results of engine system trade studies which were carried out to estimate reduction in engine emissions and fuel burn enabled due to advanced materials and manufacturing processes. A number of key engine components were identified in which advanced materials and additive manufacturing processes would provide the most significant benefits to engine operation. In addition, feasibility of using additive manufacturing technologies to fabricate gas turbine engine components from polymer and ceramic matrix composite were demonstrated. A wide variety of prototype components (inlet guide vanes (IGV), acoustic liners, engine access door) were additively manufactured using high temperature polymer materials. Ceramic matrix composite components included first stage nozzle segments and high pressure turbine nozzle segments for a cooled doublet vane. In addition, IGVs and acoustic liners were tested in simulated engine conditions in test rigs. The test results are reported and discussed in detail.

Additive Manufacturing↗
NASA NTRS2022

Effects of Debulking on the Fiber Microstructure and Void Distribution in Carbon Fiber Reinforced Plastics

Carbon Fiber Reinforced Plastics (CFRPs) are widely used due to their high stiffness to weight ratios. A common process manufacturers use to increase the strength to weight ratio is debulking. Debulking is the process of compacting a dry fibrous reinforcement prior to resin infusion. This process is meant to decrease the average inter-fiber distance, effectively increasing the fiber volume fraction of the sample. While this process is widely understood macroscopically its effects on fibrous microstructures have not yet been well characterized. The aim of this work is to compare the microstructures of three CFRP laminates, varying only the debulking step in the manufacturing process. High resolution serial sections of all three laminates were taken for analysis. Using these scans, the fiber positions were reconstructed. Statistical descriptors such as local fiber and void volume fractions, fiber orientation, and void distribution and morphology were then generated for each sample. Fiber clusters present within the material were identified and analyzed for each level of debulking applied. Using these descriptors, the effects of debulking on the morphology and organization of the composite microstructure was evaluated.

carbon fiber↗