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At least 1,513 records · Page 84

High-performance, flexible, deployable array development for space applications

Flexible, deployable arrays are an attractive alternative to conventional solar arrays for near-term and future space power applications, particularly due to their potential for high specific power and low storage volume. Combined with low-cost flexible thin-film photovoltaics, these arrays have the potential to become an enabling or an enhancing technology for many missions. In order to expedite the acceptance of thin-film photovoltaics for space applications, however, parallel development of flexible photovoltaics and the corresponding deployable structure is essential. Many innovative technologies must be incorporated in these arrays to ensure a significant performance increase over conventional technologies. For example, innovative mechanisms which employ shape memory alloys for storage latches, deployment mechanisms, and array positioning gimbals can be incorporated into flexible array design with significant improvement in the areas of cost, weight, and reliability. This paper discusses recent activities at Martin Marietta regarding the development of flexible, deployable solar array technology. Particular emphasis is placed on the novel use of shape memory alloys for lightweight deployment elements to improve the overall specific power of the array. Array performance projections with flexible thin-film copper-indium-diselenide (CIS) are presented, and government-sponsored solar array programs recently initiated at Martin Marietta through NASA and Air Force Phillips Laboratory are discussed.

Gehling, Russell N.↗

Development of Metallic Thermal Protection Systems for the Reusable Launch Vehicle

A reusable Thermal Protection System (TPS) that is not only lightweight, but durable, operable and cost effective is one of the technologies required by the Reusable Launch Vehicle (RLV) to achieve the goal of drastically reducing the cost of delivering payload to orbit. Metallic TPS is one of the systems being developed to meet this challenge. Current efforts involve improving the superalloy honeycomb TPS concept, which consists of a foil-gage metallic box encapsulating a low density fibrous insulation, and evaluating it for RLV requirements. The superalloy honeycomb TPS concept is mechanically attached to the vehicle structure. Improvements include more efficient internal insulation, a simpler, lighter weight configuration, and a quick-release fastener system for easier installation and removal. Evaluation includes thermal and structural analysis, fabrication and testing of both coupons and TPS panels under conditions simulating RLV environments. Coupons of metallic honeycomb sandwich, representative of the outer TPS surface, were subjected to low speed impact, hypervelocity impact, and rain erosion testing as well as subsequent arcjet exposure. Arrays of TPS panels have been subjected to radiant heating in a thermal/vacuum facility, aerodynamic heating in an arcjet facility and acoustic loading.

Blosser, Max L.↗

Materials Testing on the DC-X and DC-XA

Flight testing of thermal protection materials has been carried out over a two year period on the base heat shield of the Delta Clipper (DC-X and DC-XA), as well on a body flap. The purpose was to use the vehicle as a test bed for materials and more efficient repair or maintenance processes which would be potentially useful for application on new entry vehicles (i.e., X-33, RLV, planetary probes), as well as on the existing space shuttle orbiters. Panels containing Thermal Protection Systems (TPS) and/or structural materials were constructed either at NASA Ames Research Center or at McDonnell Douglas Aerospace (MDA) and attached between two of the four thrusters in the base heat shield of the DC-X or DC-XA. Three different panels were flown on DC-X flights 6, 7, and 8. A total of 7 panels were flown on DC-XA flights 1, 2, and 3. The panels constructed at Ames contained a variety of ceramic TPS including flexible blankets, tiles with high emissivity coatings, lightweight ceramic ablators and other ceramic composites. The MDS test panels consisted primarily of a variety of metallic composites. This report focuses on the ceramic TPS test results.

Smith, Dane↗

Evaluation of Design Concepts for Collapsible Cryogenic Storage Vessels

Future long-duration missions to Mars using in situ resource production to obtain oxygen from the Martian atmosphere for use as a propellant or for life support will require long term oxygen storage facilities. This report describes preliminary analysis of design concepts for lightweight, collapsible liquid oxygen storage tanks to be used on the surface of Mars. With storage at relatively low pressures, an inflatable tank concept in which the cryogen is stored within a fiber-reinforced Teflon FEP bladder is an efficient approach. The technology required for such a tank is well-developed through similar previous applications in positive expulsion bladders for zero-g liquid fuel rocket tanks and inflatable space habitat technology, though the liquid oxygen environment presents unique challenges. The weight of the proposed structure is largely dominated by the support structure needed to hold the tank off the ground and permit a vacuum insulation space to be maintained around the tank. In addition to the inflatable tank concept, telescoping tank concepts are studied. For a telescoping tank, the greatest difficulty is in making effective joints and seals. The use of shape memory alloy to produce a passive clamping ring is evaluated. Although the telescoping tank concepts are a viable option, it appears that inflatable tank concepts will be more efficient and are recommended.

Fleming, David C.↗

Novel High Efficient Organic Photovoltaic Materials: Final Summary of Research

The objectives and goals of this project were to investigate and develop high efficient, lightweight, and cost effective materials for potential photovoltaic applications, such as solar energy conversion or photo detector devices. Specifically, as described in the original project proposal, the target material to be developed was a block copolymer system containing an electron donating (or p-type) conjugated polymer block coupled to an electron withdrawing (or n-type) conjugated polymer block through a non-conjugated bridge unit. Due to several special requirements of the targeted block copolymer systems, such as electron donating and withdrawing substituents, conjugated block structures, processing requirement, stability requirement, size controllability, phase separation and self ordering requirement, etc., many traditional or commonly used block copolymer synthetic schemes are not suitable for this system. Therefore, the investigation and development of applicable and effective synthetic protocols became the most critical and challenging part of this project. During the entire project period, and despite the lack of a proposed synthetic polymer postdoctoral research associate due to severe shortage of qualified personnel in the field, several important accomplishments were achieved in this project and are briefly listed and elaborated. A more detailed research and experimental data is listed in the Appendix.

Sun, Sam↗

Bio-inspired strategies for next-generation perovskite solar mobile power sources

Smart electronic devices are becoming ubiquitous due to many appealing attributes including portability, long operational time, rechargeability and compatibility with the user-desired form factor. Integration of mobile power sources (MPS) based on photovoltaic technologies with smart electronics will continue to drive improved sustainability and independence. With high efficiency, low cost, flexibility and lightweight features, halide perovskite photovoltaics have become promising candidates for MPS. Realization of these photovoltaic MPS (PV-MPS) with unconventionally extraordinary attributes requires new ‘out-of-box’ designs. Natural materials have provided promising designing solutions to engineer properties under a broad range of boundary conditions, ranging from molecules, proteins, cells, tissues, apparatus to systems in animals, plants, and humans optimized through billions of years of evolution. Applying bio-inspired strategies in PV-MPS could be biomolecular modification on crystallization at the atomic/meso-scale, bio-structural duplication at the device/system level and bio-mimicking at the functional level to render efficient charge delivery, energy transport/utilization, as well as stronger resistance against environmental stimuli (e.g., self-healing and self-cleaning). In this paper, we discuss the bio-inspired/-mimetic structures, experimental models, and working principles, with the goal of revealing physics and bio-microstructures relevant for PV-MPS. Here the emphasis is on identifying the strategies and material designs towards improvement of the performance of emerging halide perovskite PVs and strategizing their bridge to future MPS.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Non-Invasive Tension Measurement Devices for Parachute Cordage

The need for lightweight and non-intrusive tension measurements has arisen alongside the development of high-fidelity computer models of textile and fluid dynamics. In order to validate these computer models, data must be gathered in the operational environment without altering the design, construction, or performance of the test article. Current measurement device designs rely on severing a cord and breaking the load path to introduce a load cell. These load cells are very reliable, but introduce an area of high stiffness in the load path, directly affecting the structural response, adding excessive weight, and possibly altering the dynamics of the parachute during a test. To capture the required data for analysis validation without affecting the response of the system, non-invasive measurement devices have been developed and tested by NASA. These tension measurement devices offer minimal impact to the mass, form, fit, and function of the test article, while providing reliable, axial tension measurements for parachute cordage.

Litteken, Douglas A.↗

High strength films from oriented, hydrogen-bonded “graphamid” 2D polymer molecular ensembles

The linear polymer poly(p-phenylene terephthalamide), better known by its tradename Kevlar, is an icon of modern materials science due to its remarkable strength, stiffness, and environmental resistance. Here, we propose a new two-dimensional (2D) polymer, “graphamid”, that closely resembles Kevlar in chemical structure, but is mechanically advantaged by virtue of its 2D structure. Using atomistic calculations, we show that graphamid comprises covalently-bonded sheets bridged by a high population of strong intermolecular hydrogen bonds. Molecular and micromechanical calculations predict that these strong intermolecular interactions allow stiff, high strength (6–8GPa), and tough films from ensembles of finite graphamid molecules. In contrast, traditional 2D materials like graphene have weak intermolecular interactions, leading to ensembles of low strength (0.1–0.5GPa) and brittle fracture behavior. These results suggest that hydrogen-bonded 2D polymers like graphamid would be transformative in enabling scalable, lightweight, high performance polymer films of unprecedented mechanical performance.

36 MATERIALS SCIENCE↗

Lightweight Materials for Automotive Application: An Assessment of Material Production Data for Magnesium and Carbon Fiber

The use of lightweight materials in vehicle components, also known as “lightweighting,” can result in automobile weight reduction, which improves vehicle fuel economy and generally its environmental footprint. Materials often used for vehicle lightweighting include aluminum, magnesium, and polymers reinforced with either glass or carbon fiber. However, because alternative materials typically used for vehicle lightweighting require more energy to make on a per part basis than the material being replaced (often steel or iron), the fuel efficiency improvement induced by a weight reduction is partially offset by an increased energy for the vehicle material production. To adequately quantify this tradeoff, reliable and current values for life-cycle production energy are needed for both conventional and alternative materials. Our focus here is on the production of two such alternative materials: magnesium and carbon fibers. Both these materials are low density solids with good structural properties. These properties have enabled their use in applications where weight is an issue, not only for automobiles but also for aerospace applications. This report addresses the predominant production methods for these materials and includes a tabulation of available material and energy input data necessary to make them. The life cycle inventory (LCI) information presented herein represents a process chain analysis (PCA) approach to life cycle assessment (LCA) and is intended for evaluation as updated materials production data for magnesium and carbon fiber for inclusion into the Greenhouse gases, Regulated Emissions, and Energy use in Transportation model (GREET2_2012). The summary life-cycle metrics used to characterize the cradle-to-gate environmental performance of these materials are the cumulative energy demand (CED) and greenhouse gas emissions (GHG) per kilogram of material.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

First-principles investigation of phase stability in the Mg-Sc binary alloy

The recent discovery of shape memory behavior in Mg-Sc alloys has opened the door to the possibility of lightweight shape memory alloys. Very little is known, however, about martensitic phase transformations or about equilibrium phase stability in this alloy system. In this paper we report on a first-principles statistical mechanics study of zero Kelvin and finite temperature phase stability of hcp, bcc, and fcc based phases in the Mg-Sc binary. Our calculations reveal a rich array of phase transitions among the different low-temperature ordered and high-temperature disordered phases. Ground state orderings on hcp, bcc, and fcc belong to families of hierarchical structures containing rods of scandium atoms assembled in layers that repeat periodically. Both fcc and bcc are found to undergo a series of second-order phase transformations with increasing temperature until they completely disorder. A high degree of degeneracy is predicted at low and high temperatures among hcp, bcc, and fcc, a property that is likely to play an important role in the shape memory effects observed in this alloy.

36 MATERIALS SCIENCE↗

Rollable Thin-Shell Nanolaminate Mirrors

A class of lightweight, deployable, thin-shell, curved mirrors with built-in precise-shape-control actuators is being developed for high-resolution scientific imaging. This technology incorporates a combination of advanced design concepts in actuation and membrane optics that, heretofore, have been considered as separate innovations. These mirrors are conceived to be stowed compactly in a launch shroud and transported aboard spacecraft, then deployed in outer space to required precise shapes at much larger dimensions (diameters of the order of meters or tens of meters). A typical shell rollable mirror structure would include: (1) a flexible single- or multiple-layer face sheet that would include an integrated reflective surface layer that would constitute the mirror; (2) structural supports in the form of stiffeners made of a shape-memory alloy (SMA); and (3) piezoelectric actuators. The actuators, together with an electronic control subsystem, would implement a concept of hierarchical distributed control, in which (1) the SMA actuators would be used for global shape control and would generate the large deformations needed for the deployment process and (2) the piezoelectric actuators would generate smaller deformations and would be used primarily to effect fine local control of the shape of the mirror.

Hickey, Gregory↗

Lightweight Thrust Chamber Assemblies using Multi-Alloy Additive Manufacturing and Composite Overwrap

Additive Manufacturing (AM) has brought significant design and fabrication opportunities for complex components with internal features such as liquid rocket engine thrust chambers not previously possible. This technology allows for significant cost savings and schedule reductions in addition to new performance optimization through weight reduction and increased margins. Specific to regeneratively-cooled combustion chambers and nozzles for liquid rocket engines, additive manufacturing offers the ability to form the complex internal coolant channels and the closeout of the channels to contain the high pressure liquid propellants with a single operation. Much of additive manufacturing development has focused on monolithic alloys using Laser Powder Bed Fusion (L-PBF), which do not allow for complete optimization of the structure. The National Aeronautics and Space Administration (NASA) completed feasibility of an AM bimetallic L-PBF GRCop-84 copper-alloy combustion chamber with an AM electron beam freeform Inconel 625 structural jacket under the Low Cost Upper Stage Propulsion (LCUSP) Project. A follow-on project called Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) is under development to further expand large-scale multi-alloy thrust chambers while maturing composite overwrap technology for significant weight savings opportunities. The RAMPT project has three primary objectives: 1) Advancing blown powder Directed Energy Deposition (DED) to fabricate integral-channel large scale nozzles, 2) Develop composite overwrap technology to reduce weight and provide structural capability for thrust chamber assemblies, and 3) Develop bimetallic and multi-metallic additively manufactured radial and axial joints to optimize material performance. In addition to these primary manufacturing developments, analytical modeling efforts compliment the process development to simulate the AM processes to reduce build failures and distortions. The RAMPT project is also maturing the supply chain for various manufacturing processes described above in addition to L-PBF of GRCop-42. This paper will present an overview of the RAMPT project, the process development and hardware progress to date, material and hot-fire testing results, along with future developments.

Additive Manufacturing↗

Unitized Regenerative Fuel Cell System Gas Storage/Radiator Development

The ancillary components for Unitized Regenerative Fuel Cell (URFC) Energy Storage System are being developed at the NASA Glenn Research Center. This URFC system is unique in that it uses the surface area of the hydrogen and oxygen storage tanks as radiating heat surfaces for overall thermal control of the system. The waste heat generated by the URFC stack during charging and discharging is transferred from the cell stack to the surface of each tank by loop heat pipes. The heat pipes are coiled around each tank and covered with a thin layer of thermally conductive layer of carbon composite. The thin layer of carbon composite acts as a fin structure that spreads the heat away from the heat pipe and across the entire tank surface. Two different sized commercial grade composite tanks were constructed with integral heat pipes and tested in a thermal vacuum chamber to examine the feasibility of using the storage tanks as system radiators. The storage radiators were subjected to different steady-state heat loads and varying heat load profiles. The surface emissivity and specific heat capacity of each tank were calculated. The results were incorporated into a model that simulates the performance of similar radiators using lightweight, space rated carbon composite tanks.

Jakupca, Ian↗

A 100 kW-Class Technology Demonstrator for Space Solar Power

A first step in the development of solar power from space is the flight demonstration of critical technologies. These fundamental technologies include efficient solar power collection and generation, power management and distribution, and thermal management. In addition, the integration and utilization of these technologies into a viable satellite bus could provide an energy-rich platform for a portfolio of payload experiments such as wireless power transmission (WPT). This paper presents the preliminary design of a concept for a 100 kW-class free-flying platform suitable for flight demonstration of technology experiments. Recent space solar power (SSP) studies by NASA have taken a stepping stones approach that lead to the gigawatt systems necessary to cost-effectively deliver power from space. These steps start with a 100 kW-class satellite, leading to a 500 kW and then a 1 MW-class platform. Later steps develop a 100 MW bus that could eventually lead to a 1-2 GW pilot plant for SSP. Our studies have shown that a modular approach is cost effective. Modular designs include individual laser-power-beaming satellites that fly in constellations or that are autonomously assembled into larger structures at geosynchronous orbit (GEO). Microwave power-beamed approaches are also modularized into large numbers of identical units of solar arrays, power converters, or supporting structures for arrays and microwave transmitting antennas. A cost-effective approach to launching these modular units is to use existing Earth-to-orbit (ETO) launch systems, in which the modules are dropped into low Earth orbit (LEO) and then the modules perform their own orbit transfer to GEO using expendable solar arrays to power solar electric thrusters. At GEO, the modules either rendezvous and are assembled robotically into larger platforms, or are deployed into constellations of identical laser power-beaming satellites. Since solar electric propulsion by the modules is cost-effective for both self-transport of the modules from LEO to GEO, and for on-orbit stationkeeping and repositioning capability during the satellite’s lifetime, this technology is also critical in technology development for SSP. The 100 kW-class technology demonstrator will utilize advanced solar power collection and generation technologies, power management and distribution, advanced thermal management, and solar electric propulsion. State-of-the-art solar concentrators, highly efficient multi-junction solar cells, integrated thermal management on the arrays, and innovative deployable structure design and packaging make the 100 kW satellite feasible for launch on one existing launch vehicle. Early SSP studies showed that a major percentage of the on-orbit mass for power-beaming satellites was from massive power converters at the solar arrays, at the bus, at the power transmitter, or at combinations of these locations. Higher voltage mays and power management and distribution (PMAD) systems reduce or eliminate the need for many of these massive power converters, and could enable direct-drive of high-voltage solar electric thrusters. Lightweight, highly efficient thermal management systems are a critical technology that must be developed and flown for SSP feasibility. Large amounts of power on satellites imply that large amounts of waste heat will need to be managed. In addition, several of the more innovative lightweight configurations proposed for SSP satellites take advantage of solar concentrators that are intractable without advanced thermal management technologies for the solar arrays. These thermal management systems include efficient interfaces with the WPT systems or other high-power technology experiments, lightweight deployable radiators that can be easily integrated into satellite buses, and efficient reliable thermal distribution systems that can pipe heat from the technology experiments to the radiators. In addition to demonstrating the integration and use of these mission-critical technologies, the 100 kw-class satellite will provide a large experiment deck for a portfolio of technology experiments. Current plans for this technology demonstrator allow 2000 kg of payload capability and up to 100 kW of power. The technology experiments could include one or more wireless power transmission demonstrations, either to the Earth’s surface or to a suitable space-based receiver. Technology experiments to quantify the on-orbit performance of critical technologies for SSP or space exploration are welcomed. In addition, the technology experiments provide an opportunity for international cooperation, to advance technology readiness levels of SSP technologies that require flight demonstration. This paper will present the preliminary design for a 100 kW solar-powered satellite and a variety of technology experiments that may be suitable for flight demonstration. In addition, a space-to-Earth-surface WPT experiment will be discussed.

Connie Carrington↗

TransHab: NASA's Large-Scale Inflatable Spacecraft

TransHab is a, 27-foot diameter by 40-foot, lightweight inflatable habitation module for space applications. TransHab consists of a lightweight graphite-composite core, 11-foot diameter by 23-foot tall, surrounded by a 27-foot diameter inflatable shell. Originally envisioned to be the habitation module of an interplanetary transit vehicle, TransHab is currently being considered as a module for use on the International Space Station (ISS). During the past two years, several tests have been performed at the NASA/Johnson Space Center to demonstrate and prove the technologies required in building a large-scale inflatable habitation module. This paper discusses the results of these tests which including the following: 1) a structural integrity development test article hydJ"Ostatically tested to four times ambient pressure, 2) a full-scale development test article manufactured, assembled, folded and deployed at vacuum, and 3) extensive hypervelocity impact testing of the micro meteoroid and orbital debris protection system.

delaFuente, Horacio↗

WRF-ELM v1.0: a regional climate model to study land–atmosphere interactions over heterogeneous land use regions

Abstract. The Energy Exascale Earth System Model (E3SM) Land Model (ELM) is a state-of-the-art land surface model that simulates the intricate interactions between the terrestrial land surface and other components of the Earth system. Originating from the Community Land Model (CLM) version 4.5, ELM has been under active development, with added new features and functionality, including plant hydraulics, radiation–topography interaction, subsurface multiphase flow, and more explicit land use and management practices. This study integrates ELM v2.1 with the Weather Research and Forecasting (WRF; WRF-ELM) model through a modified Lightweight Infrastructure for Land Atmosphere Coupling (LILAC) framework, enabling affordable high-resolution regional modeling by leveraging ELM's innovative features alongside WRF's diverse atmospheric parameterization options. This framework includes a top-level driver for variable communication between WRF and ELM and Earth System Modeling Framework (ESMF) caps for the WRF atmospheric component and ELM workflow control, encompassing initialization, execution, and finalization. Importantly, this LILAC–ESMF framework demonstrates a more modular approach compared to previous coupling efforts between WRF and land surface models. It maintains the integrity of ELM's source code structure and facilitates the transfer of future developments in ELM to WRF-ELM. To test the ability of the coupled model to capture land–atmosphere interactions over regions with a variety of land uses and land covers, we conducted high-resolution (4 km) WRF-ELM ensemble simulations over the Great Lakes region (GLR) in the summer of 2018 and systematically compared the results against observations, reanalysis data, and WRF-CTSM (WRF coupled with the Community Terrestrial Systems Model). In general, the coupled WRF-ELM model has reasonably captured the spatial distribution of surface state variables and fluxes across the GLR, particularly over the natural vegetation areas. The evaluation results provide a baseline reference for further improvements in ELM in the regional application of high-resolution weather and climate predictions. Our work serves as an example to the model development community for expanding an advanced land surface model's capability to represent fully-coupled land–atmosphere interactions at fine spatial scales. The development and release of WRF-ELM marks a significant advancement for the ELM user community, providing opportunities for fine-scale regional representation, parameter calibration in coupled mode, and examination of new schemes with atmospheric feedback.

54 ENVIRONMENTAL SCIENCES↗

Ultrasonic Spectroscopy of Stainless Steel Sandwich Panels

Enhanced, lightweight material systems, such as 17-4PH stainless steel sandwich panels are being developed for use as fan blades and fan containment material systems for next generation engines. In order to improve the production for these systems, nondestructive evaluation (NDE) techniques, such as ultrasonic spectroscopy, are being utilized to evaluate the brazing quality between the 17-4PH stainless steel face plates and the 17-4PH stainless steel foam core. Based on NDE data, shear tests are performed on sections representing various levels of brazing quality from an initial batch of these sandwich structures. Metallographic characterization of brazing is done to corroborate NDE findings and the observed shear failure mechanisms.

Cosgriff, Laura M.↗

Stainless-Steel-Foam Structures Evaluated for Fan and Rotor Blades

The goal of this project is to use a sandwich structure design, consisting of two stainlesssteel face sheets and a stainless-steel-foam core, to fabricate engine fan and propeller blades. Current fan blades are constructed either of polymer matrix composites (PMCs) or hollow titanium alloys. The PMC blades are expensive and have poor impact resistance on their leading edges, thereby requiring a metallic leading edge to satisfy the Federal Aviation Administration s impact requirements relating to bird strikes. Hollow titanium blades cost more to fabricate because of the intrinsically difficult fabrication issues associated with titanium alloys. However, both these current concepts produce acceptable lightweight fan blades.

Lerch, Bradley A.↗