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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 NTRS2007

Development of Natural Flaw Samples for Evaluating Nondestructive Testing Methods for Foam Thermal Protection Systems

Low density polyurethane foam has been an important insulation material for space launch vehicles for several decades. The potential for damage from foam breaking away from the NASA External Tank was not realized until the foam impacts on the Columbia Orbiter vehicle caused damage to its Leading Edge thermal protection systems (TPS). Development of improved inspection techniques on the foam TPS is necessary to prevent similar occurrences in the future. Foamed panels with drilled holes for volumetric flaws and Teflon inserts to simulate debonded conditions have been used to evaluate and calibrate nondestructive testing (NDT) methods. Unfortunately the symmetric edges and dissimilar materials used in the preparation of these simulated flaws provide an artificially large signal while very little signal is generated from the actual defects themselves. In other words, the same signal are not generated from the artificial defects in the foam test panels as produced when inspecting natural defect in the ET foam TPS. A project to create more realistic voids similar to what actually occurs during manufacturing operations was began in order to improve detection of critical voids during inspections. This presentation describes approaches taken to create more natural voids in foam TPS in order to provide a more realistic evaluation of what the NDT methods can detect. These flaw creation techniques were developed with both sprayed foam and poured foam used for insulation on the External Tank. Test panels with simulated defects have been used to evaluate NDT methods for the inspection of the External Tank. A comparison of images between natural flaws and machined flaws generated from backscatter x-ray radiography, x-ray laminography, terahertz imaging and millimeter wave imaging show significant differences in identifying defect regions.

Workman, Gary L.↗
NASA NTRS2008

Micro-Vibration Measurements on Thermally Loaded Multi-Layer Insulation Samples in Vacuum

Some scientific missions require to an extreme extent the absence of any on-board microvibration. Recent projects dedicated to measuring the Earth's gravity field and modeling the geoid with extremely high accuracy are examples. Their missions demand for extremely low micro-vibration environment on orbit for: (1) Not disturbing the measurement of earth gravity effects with the installed gradiometer or (2) Even not damaging the very high sensitive instruments. Based on evidence from ongoing missions multi-layer insulation (MLI) type thermal control blankets have been identified as a structural element of spacecrafts which might deform under temperature variations being caused by varying solar irradiation in orbit. Any such deformation exerts tiny forces which may cause small reactions resulting in micro-vibrations, in particular by exciting the spacecraft eigenmodes. The principle of the test set-up for the micro-vibration test was as follows. A real side wall panel of the spacecraft (size about 0.25 m2) was low-frequency suspended in a thermal vacuum chamber. On the one side of this panel, the MLI samples were fixed by using the standard methods. In front of the MLI, an IR-rig was installed which provided actively controlled IR-radiation power of about 6 kW/m2 in order to heat the MLI surface. The cooling was passive using the shroud temperature at a chamber pressure <1E-5mbar. The resulting micro-vibrations due to MLI motion in the heating and the cooling phase were measured via seismic accelerometers which were rigidly mounted to the panel. Video recording was used to correlate micro-vibration events to any visual MLI motion. Different MLI sample types were subjected to various thermal cycles in a temperature range between -60 C to +80 C. In this paper, the experience on these micro-vibration measurements will be presented and the conclusions for future applications will be discussed

Deutsch, Georg↗
NASA NTRS2015

Advanced Booster Composite Case/Polybenzimidazole Nitrile Butadiene Rubber Insulation Development

The NASA Engineering and Safety Center (NESC) was requested to examine processing sensitivities (e.g., cure temperature control/variance, debonds, density variations) of polybenzimidazole nitrile butadiene rubber (PBI-NBR) insulation, case fiber, and resin systems and to evaluate nondestructive evaluation (NDE) and damage tolerance methods/models required to support human-rated composite motor cases. The proposed use of composite motor cases in Blocks IA and II was expected to increase performance capability through optimizing operating pressure and increasing propellant mass fraction. This assessment was to support the evaluation of risk reduction for large booster component development/fabrication, NDE of low mass-to-strength ratio material structures, and solid booster propellant formulation as requested in the Space Launch System NASA Research Announcement for Advanced Booster Engineering Demonstration and/or Risk Reduction. Composite case materials and high-energy propellants represent an enabling capability in the Agency's ability to provide affordable, high-performing advanced booster concepts. The NESC team was requested to provide an assessment of co- and multiple-cure processing of composite case and PBI-NBR insulation materials and evaluation of high-energy propellant formulations.

Gentz, Steve↗
NASA NTRS1985

Foam Insulation for Cryogenic Flowlines

Welded stainless-steel vacuum jackets on cryogenic ducts replaced by plastic foam-insulation jackets that weigh 12 percent less. Foam insulation has 85 percent of insulating ability of stainless-steel jacketing enclosing vacuum of 10 microns of mercury. Foam insulation easier to install than vacuum jacket. Moreover, foam less sensitive to damage and requires minimal maintenance. Resists vibration and expected to have service life of at least 10 years.

Sonju, T. R.↗
NASA NTRS2009

Further Analysis of MISSE Polymeric Materials at MSFC

Many different spacecraft materials were flown as part of the Materials on International Space Station Experiment (MISSE). MISSE was exposed to the low Earth orbital environment of atomic oxygen, ultraviolet radiation, thermal cycling, and hard vacuum. A number of polymer samples did not survive the atomic oxygen attack. Mass and thickness loss measurements indicate the durability of the remaining polymeric materials to withstand the space environment. Results from the one-year exposure on MISSE-3 and MISSE-4 are compared to those from the four-year exposure on MISSE-1 and MISSE-2. Solar absorptance and infrared emittance measurements are given for thermal control materials. Transmission measurements are given where appropriate. A wide variety of polymeric materials were flown on MISSE, ranging from extremely thin films for solar sails to bulk materials. Some of the candidate solar sail materials were flown underneath magnesium fluoride windows to eliminate atomic oxygen effects and allow the study of ultraviolet radiation damage. Exposed seal materials include Viton , silicone, and fluorosilicone. Multi-layer insulation materials were flown, including atomic oxygen-resistant polymers. Also flown were candidate inflatable materials for a High Altitude Airship or inflatable lunar habitat. Polymer materials being flown on MISSE-6 are discussed.

Finckenor, Miria M.↗
NASA NTRS1972

Nuclear radiation problems, unmanned thermionic reactor ion propulsion spacecraft

A nuclear thermionic reactor as the electric power source for an electric propulsion spacecraft introduces a nuclear radiation environment that affects the spacecraft configuration, the use and location of electrical insulators and the science experiments. The spacecraft is conceptually configured to minimize the nuclear shield weight by: (1) a large length to diameter spacecraft; (2) eliminating piping penetrations through the shield; and (3) using the mercury propellant as gamma shield. Since the alumina material is damaged by the high nuclear radiation environment in the reactor it is desirable to locate the alumina insulator outside the reflector or develop a more radiation resistant insulator.

Mondt, J. F.↗
NASA NTRS1991

Empirical predictions of hypervelocity impact damage to the space station

A family of user-friendly, DOS PC based, Microsoft BASIC programs written to provide spacecraft designers with empirical predictions of space debris damage to orbiting spacecraft is described. The spacecraft wall configuration is assumed to consist of multilayer insulation (MLI) placed between a Whipple style bumper and the pressure wall. Predictions are based on data sets of experimental results obtained from simulating debris impacts on spacecraft using light gas guns on Earth. A module of the program facilitates the creation of the data base of experimental results that are used by the damage prediction modules of the code. The user has the choice of three different prediction modules to predict damage to the bumper, the MLI, and the pressure wall. One prediction module is based on fitting low order polynomials through subsets of the experimental data. Another prediction module fits functions based on nondimensional parameters through the data. The last prediction technique is a unique approach that is based on weighting the experimental data according to the distance from the design point.

Rule, W. K.↗
NASA NTRS2017

Self-Healable Electrical Insulation for High Voltage Applications

Polymeric aircraft electrical insulation normally degrades by partial discharge with increasing voltage, which causes excessive localized Joule heating in the material and ultimately leads to dielectric failure of the insulator through thermal breakdown. Developing self-healing insulation could be a viable option to mitigate permanent mechanical degradation, thus increasing the longevity of the insulation. Instead of relying on catalyst and monomer-filled microcapsules to crack, flow, and cure at the damaged sites described in well-published mechanisms, establishment of ionic crosslinks could allow for multiple healing events to occur with the added benefit of achieving full recovery strength under certain thermal environments. This could be possible if the operating temperature of the insulator is the same as or close to the temperature where ionic crosslinks are formed. Surlyn, a commercial material with ionic crosslinks, was investigated as a candidate self-healing insulator based off prior demonstrations of self-healing behavior. Thin films of varying thicknesses were investigated and the effects of thickness on the dielectric strength were evaluated and compared to representative polymer insulators. The effects of thermal conditioning on the recovery strength and healing were observed as a function of time following dielectric breakdown. Moisture absorption was also studied to determine if moisture absorption rates in Surlyn were lower than that of common polyimides.

electrical insulation↗
NASA NTRS1980

Thermal performance of a mechanically attached ablator tile for on-orbit repair of shuttle TPS

The reusable surface insulation (RSI) material used in the shuttle thermal protection system is susceptible to damage. If any RSI tiles are damaged or lost during ascent, they must be repaired or replaced prior to entry. One approach to replacing a damaged or missing RSI tile consists of mechanically attaching a tile of ablation material in the place of the RSI tile. The thermal performance of this type of repair tile was evaluated in a simulated entry heating environment. The test specimen consisted of the ablator repair tile mechanically fastened to the strain isolation pad and surrounded by RSI tiles. The evaluation of the thermal performance was based on temperature response, surface integrity, and predicted flight performance. When the ablator tile protruded 1/8 inch above the surrounding RSI tiles, the forward facing steps caused significant inflow of hot gas down the ablator RSI joints and this inflow caused greatly increased back surface temperatures.

Thompkins, S. S.↗
NASA NTRS1997

Laser Shearographic Inspection for Debonds in Sprayed On Foam Insulation (SOFI)

Preliminary results of shearographic inspections of the test panels simulating the Space Shuttle's external tank (ET) spray on foam insulation (SOFI) are presented. Debonding of SOFI may introduce flight debris that may damage the orbiter's thermal protection system (TPS) exposing the orbiter (as well as the ET) to thermal loading. It is estimated that 90 percent of the TPS damage on the orbiter's 'belly' results from debonded SOFI during ascent. A series of test panels were fabricated, with programmed debonds of different geometries and sizes, to determine the sensitivity of shearography as a function of debond size, SOFI thickness,'and vacuum excitation. Results show that a Probability of Detection (POD) of 0.95 or better can be expected for debonds with a diameter equal to the SOFI thickness as less than 0.4-psi pressure reduction. More testing will be required to validate the laser shearography imaging process for certifying its use in nondestructive evaluation (NDE) of Space Shuttle space flight components.

Adams, F. W.↗
NASA NTRS2004

Tethers as Debris: Simulating Impacts of Tether Fragments on Shuttle Tiles

The SPHC hydrodynamic code was used to simulate impacts of Kevlar and aluminum projectiles on a model of the LI-900 type insulating tiles used on Space Shuffle Orbiters The intent was to examine likely damage that such tiles might experience if impacted by orbital debris consisting of tether fragments. Projectile speeds ranged from 300 meters per second to 10 kilometers per second. Damage is characterized by penetration depth, tile surface-hole diameter, tile body-cavity diameter, coating fracture diameter, tether and cavity wall material phases, and deformation of the aluminum backwall.

Evans, Steven W.↗
NASA NTRS2013

Electrodynamic Dust Shield Demonstrator

The objective of the project was to design and manufacture a device to demonstrate a new technology developed by NASA's Electrostatics and Surface Physics Laboratory. The technology itself is a system which uses magnetic principles to remove regolith dust from its surface. This project was to create an enclosure that will be used to demonstrate the effectiveness of the invention to The Office of the Chief Technologist. ONE of the most important challenges of space exploration is actually caused by something very small and seemingly insignificant. Dust in space, most notably on the moon and Mars, has caused many unforeseen issues. Dirt and dust on Earth, while a nuisance, can be easily cleaned and kept at bay. However, there is considerably less weathering and erosion in space. As a result, the microscopic particles are extremely rough and abrasive. They are also electrostatically charged, so they cling to everything they make contact with. This was first noted to be a major problem during the Apollo missions. Dust would stick to the spacesuits, and could not be wiped off as predicted. Dust was brought back into the spacecraft, and was even inhaled by astronauts. This is a major health hazard. Atmospheric storms and other events can also cause dust to coat surfaces of spacecraft. This can cause abrasive damage to the craft. The coating can also reduce the effectiveness of thermal insulation and solar panels.' A group of engineers at Kennedy Space Center's Electrostatics and Surface Physics Laboratory have developed a new technology, called the Electrodynamic Dust Shield, to help alleviate these problems. It is based off of the electric curtain concept developed at NASA in 1967. "The EDS is an active dust mitigation technology that uses traveling electric fields to transport electrostatically charged dust particles along surfaces. To generate the traveling electric fields, the EDS consists of a multilayer dielectric coating with an embedded thin electrode grid running a multiphase low frequency AC signal. Electrostatically charged particles, such as those encountered on the moon, Mars, or an asteroid, are carried along by the traveling field due to the action of Coulomb and dielectrophoretic forces."2 The technical details have been described in a separate article. This document details the design and construction process of a small demonstration unit. Once finished, this device will go to the Office of the ChiefTechnologist at NASA headquarters, where it will be used to familiarize the public with the technology. 1 NASA KSC FO Intern, Prototype Development Laboratory, Kennedy Space Center, University of Central Florida Kennedy Space

Stankie, Charles G.↗
NASA NTRSDate not supplied

Short Circuiting the Controller – Missteps in Maintenance and Inspection of Process and Wiring in STS-93

The primary objective of the Space Transportation System mission 93 (STS-93) was to deploy the Chandra X-Ray Observatory. Chandra, the world's most powerful X-Ray telescope, allowed scientists from around the world to study some of the most distant and dynamic objects in the universe. Stripped of nearly 7,000 pounds of its own gear to make room for the payload, the orbiter assigned to this mission was Space Shuttle Columbia. Prior to STS-93, Columbia had flown 25 flights and was NASA's oldest and heaviest orbiter. On July 23, 1999, after two prior launch scrubs, Eileen Collins and her crew of four launched from Kennedy Space Center. About five seconds after launch, Mission Control at Johnson Space Center detected a voltage drop on one of Columbia's electrical buses. As a result of this power fluctuation, a primary and back-up Main Engine controller dropped offline. Given design redundancy, the two remaining controllers supported all three engines. If there had been any other AC bus issues, one engine of the three on the Orbiter would have shut down. The redundant set of digital computer units in each engine controller saved Columbia and her crew from a very risky contingency abort. Post-flight inspection revealed soot on a screw head and a hole in an adjacent Kapton insulated wire. The single strand of polyimide wire was located nearly half-way down the payload bay. The Shuttle Independent Assessment Team (SIAT) reported that the wire had rubbed and chaffed against a burred screw head. The burr was later determined to be the result of overtightening of the screw by a technician during a maintenance refurbishment. Alone, the burr may not have been problematic, but later, during another ground processing event, possibly years after, someone inadvertently stepped on the wiring harness. With the pressure and motion of unintended contact, some of the Kapton insulation rubbed off against the burred screw head. The SIAT suspected the wire damage was pre-existing and was caused 4 or 5 years prior to the flight. Finally, the intense vibrations during the launch sequence allowed contact between the exposed conductor and exposed metal area on the burred screw head, resulting in the arcing and shorting of the wire. Due to the quick turnaround times of Space Shuttle Orbiters, wiring issues caused from multiple maintenance events were often overlooked. Additionally, failing to incorporate thorough and early inclusion of human systems integration (HSI) applications as a crucial part of the decision process can result in these types of misshaps. In order to reduce human error associated with integrated manufacturing, maintenance, refurbishment and flight preparations, wire inspection criteria should be refined and standardized, visual inspection processes should be quantified, and technicians should be certified by specially trained instructors. This case, among many others, unveils why human error management and development of safety metrics is a vital piece in the development of complex systems, and why it should be supported aggressively and implemented program wide.

Human Systems Integration↗
NASA NTRS2009

NASA Tech Briefs, March 2009

Topics covered include: Improved Instrument for Detecting Water and Ice in Soil; Real-Time Detection of Dust Devils from Pressure Readings; Determining Surface Roughness in Urban Areas Using Lidar Data; DSN Data Visualization Suite; Hamming and Accumulator Codes Concatenated with MPSK or QAM; Wide-Angle-Scanning Reflectarray Antennas Actuated by MEMS; Biasable Subharmonic Membrane Mixer for 520 to 600 GHz; Hardware Implementation of Serially Concatenated PPM Decoder; Symbolic Processing Combined with Model-Based Reasoning; Presentation Extensions of the SOAP; Spreadsheets for Analyzing and Optimizing Space Missions; Processing Ocean Images to Detect Large Drift Nets; Alternative Packaging for Back-Illuminated Imagers; Diamond Machining of an Off-Axis Biconic Aspherical Mirror; Laser Ablation Increases PEM/Catalyst Interfacial Area; Damage Detection and Self-Repair in Inflatable/Deployable Structures; Polyimide/Glass Composite High-Temperature Insulation; Nanocomposite Strain Gauges Having Small TCRs; Quick-Connect Windowed Non-Stick Penetrator Tips for Rapid Sampling; Modeling Unsteady Cavitation and Dynamic Loads in Turbopumps; Continuous-Flow System Produces Medical-Grade Water; Discrimination of Spore-Forming Bacilli Using spoIVA; nBn Infrared Detector Containing Graded Absorption Layer; Atomic References for Measuring Small Accelerations; Ultra-Broad-Band Optical Parametric Amplifier or Oscillator; Particle-Image Velocimeter Having Large Depth of Field; Enhancing SERS by Means of Supramolecular Charge Transfer; Improving 3D Wavelet-Based Compression of Hyperspectral Images; Improved Signal Chains for Readout of CMOS Imagers; SOI CMOS Imager with Suppression of Cross-Talk; Error-Rate Bounds for Coded PPM on a Poisson Channel; Biomorphic Multi-Agent Architecture for Persistent Computing; and Using Covariance Analysis to Assess Pointing Performance.

Source record↗
NASA NTRS2008

Extreme High and Low Temperature Operation of the Silicon-On-Insulator Type CHT-OPA Operational Amplifier

A new operational amplifier chip based on silicon-on-insulator technology was evaluated for potential use in extreme temperature environments. The CHT-OPA device is a low power, precision operational amplifier with rail-to-rail output swing capability, and it is rated for operation between -55 C and +225 C. A unity gain inverting circuit was constructed utilizing the CHT-OPA chip and a few passive components. The circuit was evaluated in the temperature range from -190 C to +200 C in terms of signal gain and phase shift, and supply current. The investigations were carried out to determine suitability of this device for use in space exploration missions and aeronautic applications under wide temperature incursion. Re-restart capability at extreme temperatures, i.e. power switched on while the device was soaked at extreme temperatures, was also investigated. In addition, the effects of thermal cycling under a wide temperature range on the operation of this high performance amplifier were determined. The results from this work indicate that this silicon-on-insulator amplifier chip maintained very good operation between +200 C and -190 C. The limited thermal cycling had no effect on the performance of the amplifier, and it was able to re-start at both -190 C and +200 C. In addition, no physical degradation or packaging damage was introduced due to either extreme temperature exposure or thermal cycling. The good performance demonstrated by this silicon-on-insulator operational amplifier renders it a potential candidate for use in space exploration missions or other environments under extreme temperatures. Additional and more comprehensive characterization is, however, required to establish the reliability and suitability of such devices for long term use in extreme temperature applications.

Patterson, Richard↗
NASA NTRS1988

In-flight rain damage tests of the shuttle thermal protection system

NASA conducted in-flight rain damage tests of the Shuttle thermal protection system (TPS). Most of the tests were conducted on an F-104 aircraft at the Dryden Flight Research Facility of NASA's Ames Research Center, although some tests were conducted by NOAA on a WP-3D aircraft off the eastern coast of southern Florida. The TPS components tested included LI900 and LI2200 tiles, advanced flexible reusable surface insulation, reinforced carbon-carbon, and an advanced tufi tile. The objective of the test was to define the damage threshold of various thermal protection materials during flight through rain. The test hardware, test technique, and results from both F-104 and WP-3D aircraft are described. Results have shown that damage can occur to the Shuttle TPS during flight in rain.

Meyer, Robert R., Jr.↗
NASA NTRS2013

Method of Fault Detection and Rerouting

A system and method for detecting damage in an electrical wire, including delivering at least one test electrical signal to an outer electrically conductive material in a continuous or non-continuous layer covering an electrically insulative material layer that covers an electrically conductive wire core. Detecting the test electrical signals in the outer conductive material layer to obtain data that is processed to identify damage in the outer electrically conductive material layer.

Medelius, Pedro J.↗
NASA NTRS1982

Starprobe thermal shield system design concepts

The mission goals, flight trajectory, and material durability requirements for the NASA Starprobe spacecraft are reviewed. The spacecraft will use a Jovian gravity assist to pass within four solar radii of the sun to study fields and particles near the sun, perform experiments dealing with relativity and gravity, and observe the structure of the solar atmosphere from the photosphere to the corona. Constraints on the system size and mass design are given, and the system is noted to be required to withstand 2500 K at perihelion, thermally insulate the instrument payload, have a tube for optical measurements, and provide protection from meteorite damage. A secondary shield is also required to dispense thermal radiation that passes the primary shield and could endanger the payload. Design options are discussed, along with temperature control requirements and a conical carbon-carbon primary shield with mass-loss rate characteristics sufficient to meet a 2.5 mg/sec criterion.

Maag, C. R.↗