Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Milling”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,585 records · Page 88

Performance Improvement of Friction Stir Welds by Better Surface Finish

The as-welded friction stir weld has a cross section that may act as a stress concentrator. The geometry associated with the stress concentration may reduce the weld strength and it makes the weld challenging to inspect with ultrasound. In some cases, the geometry leads to false positive nondestructive evaluation (NDE) indications and, in many cases, it requires manual blending to facilitate the inspection. This study will measure the stress concentration effect and develop an improved phased array ultrasound testing (PAUT) technique for friction stir welding. Post-welding, the friction stir weld (FSW) tool would be fitted with an end mill that would machine the weld smooth, trimmed shaved. This would eliminate the need for manual weld preparation for ultrasonic inspections. Manual surface preparation is a hand operation that varies widely depending on the person preparing the welds. Shaving is a process that can be automated and tightly controlled.

Russell, Sam↗

Post-Flight Assessment of Avcoat Thermal Protection System for the Exploration Flight Test-1

On December 5, 2014 NASA conducted the first flight test of its next generation human-class Orion spacecraft. The flight was called the Exploration Flight Test -1 (EFT-1) which lasted for 4 hours and culminated into a re-entry trajectory at 9 km/s. This flight test of the 5-meter Orion Crew Module demonstrated various sub-systems including the Avcoat ablative thermal protection system (TPS) on the heat shield. The Avcoat TPS had been developed from the Apollo-era recipe with a few key modifications. The engineering for thermal sizing was supported by modeling, analysis, and ground tests in arc jet facilities. This paper will describe a postlfight analysis plan and present results from post-recovery inspections, data analysis from embedded sensors, TPS sample extraction and characterization in the laboratory. After the recovery of the vehicle, a full photographic survey and surface scans of the TPS were performed. The recovered vehicle showed physical evidence of flow disturbances, varying degrees of surface roughness, and excessive recession downstream of compression pads. The TPS recession was measured at more than 200 locations of interest on the Avcoat surface. The heat shield was then processed for sample extraction prior to TPS removal using the 7-Axis Milling machine at Marshall Space Flight Center. Around 182 rectangular TPS samples were extracted for subsequent analysis and investigation. The final paper will also present results of sample analysis. The planned investigation includes sidewall imaging, followed by image analysis to characterize TPS response by quantifying different layers in the char and pyrolysis zones. A full postmortem of the instrumentation and sensor ports will also be performed to confirm no adverse effects due to the sensors themselves. A subset of the samples will undergo structural testing and perform detailed characterization of any cracks and integrity of gore seams. Finally, the material will be characterized with layer-by-layer density measurements and SEM investigations to evaluate material morphology at microstructural level including identification of elements and compounds.

Aerothermodynamics↗

Rapid Fabrication Techniques for Liquid Rocket Channel Wall Nozzles

The functions of a regeneratively-cooled nozzle are to (1) expand combustion gases to increase exhaust gas velocity while, (2) maintaining adequate wall temperatures to prevent structural failure, and (3) transfer heat from the hot gases to the coolant fluid to promote injector performance and stability. Regeneratively-cooled nozzles are grouped into two categories: tube-wall nozzles and channel wall nozzles. A channel wall nozzle is designed with an internal liner containing a series of integral coolant channels that are closed out with an external jacket. Manifolds are attached at each end of the nozzle to distribute coolant to and away from the channels. A variety of manufacturing techniques have been explored for channel wall nozzles, including state of the art laser-welded closeouts and pressure-assisted braze closeouts. This paper discusses techniques that NASA MSFC is evaluating for rapid fabrication of channel wall nozzles that address liner fabrication, slotting techniques and liner closeout techniques. Techniques being evaluated for liner fabrication include large-scale additive manufacturing of freeform-deposition structures to create the liner blanks. Abrasive water jet milling is being evaluated for cutting the complex coolant channel geometries. Techniques being considered for rapid closeout of the slotted liners include freeform deposition, explosive bonding and Cold Spray. Each of these techniques, development work and results are discussed in further detail in this paper.

Gradl, Paul R.↗

Mechanical Prototyping and Manufacturing Internship

The internship was located at the Johnson Space Center (JSC) Innovation Design Center (IDC), which is a facility where the JSC workforce can meet and conduct hands-on innovative design, fabrication, evaluation, and testing of ideas and concepts relevant to NASA's mission. The tasks of the internship included mechanical prototyping design and manufacturing projects in service of research and development as well as assisting the users of the IDC in completing their manufacturing projects. The first project was to manufacture hatch mechanisms for a team in the Systems Engineering and Project Advancement Program (SETMAP) hexacopter competition. These mechanisms were intended to improve the performance of the servomotors and offer an access point that would also seal to prevent cross-contamination. I also assisted other teams as they were constructing and modifying their hexacopters. The success of this competition demonstrated a proof of concept for aerial reconnaissance and sample return to be potentially used in future NASA missions. I also worked with Dr. Kumar Krishen to prototype an improved thermos and a novel, portable solar array. Computer-aided design (CAD) software was used to model the parts for both of these projects. Then, 3D printing as well as conventional techniques were used to produce the parts. These prototypes were then subjected to trials to determine the success of the designs. The solar array is intended to work in a cluster that is easy to set up and take down and doesn't require powered servomechanisms. It could be used terrestrially in areas not serviced by power grids. Both projects improve planetary exploration capabilities to future astronauts. Other projects included manufacturing custom rail brackets for EG-2, assisting engineers working on underwater instrument and tool cases for the NEEMO project, and helping to create mock-up parts for Space Center Houston. The use of the IDC enabled efficient completion of these projects at significantly reduced cost. I acquired and improved manufacturing and prototyping skills during my tour including learning about a CAD (Computer-Aided Design) program called Creo (Creo Parametric; design software), gaining valuable conventional machining experience with lathes, CNC (Computer Numerical Control) milling machines and various other tools, and improving my engineering project communication and collaboration skills. The internship also allowed me to better understand operations at NASA. I plan to work in the aerospace industry or do academic research benefitting space science and exploration, and this internship experience will enable me to have insight into manufacturing processes for research and development.

Grenfell, Peter↗

A Brief Description of My Projects

My internship was in the IDC which consist of a machine shop and an array of design space. During my tour I worked on a wide variety of projects some of which included design, research, machining and fabrication. I gained further knowledge on some machines that I have had prior experience on such as the lathe and Hurco CNC machines. The first thing we did was complete our checkout in the machine shop which went pretty well, since I was already familiar with most of the machines. I also did a couple of practice parts on some of the machines, I made a name block on the CNC machine and I also used the vertical milling machine to complete this project. One of the other projects that I did was machine a hammer with my initials with the use of the lathe and CNC machine, this project took much longer since I had to set up a cylindrical piece on the CNC machine. The first project that I began work on was the Systems Engineering & Management Advancement Program (SEPMAP) Hexacopter project and helped them to assemble and modify one of their particle capture doors on their boxes. After a while we ended up helping them make a hinge and holes to reduce the weight of their design. We helped the NASA Extreme Environment Mission Operations (NEEMO) team a bit with some of their name tags and assembly of some of their underwater parts. One of the more challenging projects was a rail that came in with a rather weirdly drawn part. The biggest project that I worked on was the solar array project. Which consisted of a variety of machining and 3D printing and it took me about 3 different times of re-designing to come up with a final prototype. Along with this project I also had to complete a project in which I had to modify a thermos. This was rather simple since I just had to draw up a part and print it out on the 3D printer. I also learned how to use Pro E/Creo parametric to design a square block and print it on the 3D Printer. All of these projects increased my experience on all of the machines and equipment that I used. I also got to tweak my design skills and better understand how to modify my designs and how to improve those specific designs.

Barnes, Tobin↗

Primitive Liquid Water of the Solar System in an Aqueous Altered Carbonaceous Chondrite

Non-destructive 3D observations of the aqueous altered CM chondrite Sutter's Mill using scanning imaging x-ray microscopy (SIXM) showed that some of calcite and enstatite grains contain two-phase inclusion, which is most probably composed of liquid water and bubbles. This water should be primitive water responsible for aqueous alteration in an asteroid in the early solar system.

Tsuchiyama, A.↗

Manufacturing Process Developments for Regeneratively-Cooled Channel Wall Rocket Nozzles

Regeneratively cooled channel wall nozzles incorporate a series of integral coolant channels to contain the coolant to maintain adequate wall temperatures and expand hot gas providing engine thrust and specific impulse. NASA has been evaluating manufacturing techniques targeting large scale channel wall nozzles to support affordability of current and future liquid rocket engine nozzles and thrust chamber assemblies. The development of these large scale manufacturing techniques focus on the liner formation, channel slotting with advanced abrasive water-jet milling techniques and closeout of the coolant channels to replace or augment other cost reduction techniques being evaluated for nozzles. NASA is developing a series of channel closeout techniques including large scale additive manufacturing laser deposition and explosively bonded closeouts. A series of subscale nozzles were completed evaluating these processes. Fabrication of mechanical test and metallography samples, in addition to subscale hardware has focused on Inconel 625, 300 series stainless, aluminum alloys as well as other candidate materials. Evaluations of these techniques are demonstrating potential for significant cost reductions for large scale nozzles and chambers. Hot fire testing is planned using these techniques in the future.

Gradl, Paul↗

Distinct Chlorine Isotopic Reservoirs on Mars: Implications for Character, Extent and Relative Timing of Crustal Interaction with Mantle-Derived Magmas, Evolution of the Martian Atmosphere, and the Building Blocks of an Early Mars

The style, magnitude, timing, and mixing components involved in the interaction between mantle derived Martian magmas and Martian crust have long been a point of debate. Understanding this process is fundamental to deciphering the composition of the Martian crust and its interaction with the atmosphere, the compositional diversity and oxygen fugacity variations in the Martian mantle, the bulk composition of Mars and the materials from which it accreted, and the noble gas composition of Mars and the Sun. Recent studies of the chlorine isotopic composition of Martian meteorites imply that although the variation in delta (sup 37) Cl is limited (total range of approximately14 per mille), there appears to be distinct signatures for the Martian crust and mantle. However, there are potential issues with this interpretation. New Cl isotope data from the SAM (Sample Analysis at Mars) instrument on the Mars Science Lab indicate a very wide range of Cl isotopic compositions on the Martian surface. Recent measurements by [10] duplicated the results of [7,8], but placed them within the context of SAM surface data. In addition, Martian meteorite Chassigny contains trapped noble gases with isotopic ratios similar to solar abundance, and has long been considered a pristine, mantle derived sample. However, previous studies of apatite in Chassigny indicate that crustal fluids have interacted with regions interstitial to the cumulus olivine. The initial Cl isotope measurements of apatite in Chassigny suggest an addition of crustal component to this lithology, apparently contradicting the rare gas data. Here, we examine the Cl isotopic composition of multiple generations and textures of apatite in Chassigny to extricate the crustal and mantle components in this meteorite and to reveal the style and timing of the addition of crustal components to mantle-derived magmas. These data reveal distinct Martian Cl sources whose signatures have their origins linked to both the early Solar System and the evolving Martian atmosphere.

Shearer, C. K.↗

Ion Microprobe Measurements of Comet Dust and Implications for Models of Oxygen Isotope Heterogeneity in the Solar System

The oxygen isotopic compositions of anhydrous minerals in carbonaceous chondrites reflect mixing between a O-16-rich and O-17, O18-rich reservoir. The UV photodissociation of CO (i.e. selfshielding) has been proposed as a mass-independent mechanism for producing these isotopically distinct reservoirs. Self-shielding models predict the composition for the CO gas reservoir to be O-16-rich, and that the accreting primordial dust was in isotopic equilibrium with the gaseous reservoir [1, 2]. Self-shielding also predicts that cometary water, presumed to represent the O-17, O-18-rich reservoir, should be enriched in O-17 and O-18, with compositions of 200 -1000per mille, and that the interaction with this O-17, O-18-rich H2O reservoir altered the compositions of the primordial dust toward planetary values. The bulk composition of the solar nebula, which may be an approximation to the 16O-rich gaseous reservoir, has been constrained by the Genesis results [3]. However, material representing the O-17, O-18-rich end-member is rare [4], and dust representing the original accreting primordial dust has been challenging to conclusively identify in current collections. Anhydrous dust from comets, which accreted in the distal cold regions of the nebula at temperatures below approximately 30K, may provide the best opportunity to measure the oxygen isotope composition of primordial dust. Chondritic porous interplanetary dust particles (CP-IDPs) have been suggested as having cometary origins [5]; however, until direct comparisons with dust from a known comet parent body were made, link between CP-IDPs and comets remained circumstantial. Oxygen isotope analyses of particles from comet 81P/Wild 2 collected by NASA's Stardust mission have revealed surprising similarities to minerals in carbonaceous chondrites which have been interpreted as evidence for large scale radial migration of dust components from the inner solar nebula to the accretion regions of Jupiter- family comets [6]. These studies have been largely focused on the coarse-grained terminal particles extracted from aerogel collectors; hypervelocity capture into aerogel resulted in fine-grained material that was melted and intimately mixed with the SiO2 capture medium. Hypervelocity impacts into Al foils surrounding the aerogel tiles produced impact craters that captured material from the impactor without significant oxygen contamination, allowing for analysis of both the coarse and fine-grained components of the Wild 2 dust. To date, no particles with definitive hydrated mineralogy have been observed in Stardust samples, though this may be a result of alteration due to hypervelocity capture. High-carbon hydrated CS-IDPs have been suggested as resulting from the aqueous alteration of CP-IDPs [7], and may retain evidence for interaction with O-17, O-18-enriched "cometary" water predicted by CO self-shielding. Here we present results of oxygen isotope measurements of twelve Stardust foil craters and four C-rich hydrated IDPs [8, 9], and discuss implications for models of oxygen isotope heterogeneity in the early solar system.

Snead, C. J.↗

Fabrication of X-ray Microcalorimeter Focal Planes Composed of Two Distinct Pixel Types

We develop superconducting transition-edge sensor (TES) microcalorimeter focal planes for versatility in meeting the specifications of X-ray imaging spectrometers, including high count rate, high energy resolution, and large field of view. In particular, a focal plane composed of two subarrays: one of fine pitch, high count-rate devices and the other of slower, larger pixels with similar energy resolution, offers promise for the next generation of astrophysics instruments, such as the X-ray Integral Field Unit Instrument on the European Space Agencys ATHENA mission. We have based the subarrays of our current design on successful pixel designs that have been demonstrated separately. Pixels with an all-gold X-ray absorber on 50 and 75 micron pitch, where the Mo/Au TES sits atop a thick metal heatsinking layer, have shown high resolution and can accommodate high count rates. The demonstrated larger pixels use a silicon nitride membrane for thermal isolation, thinner Au, and an added bismuth layer in a 250-sq micron absorber. To tune the parameters of each subarray requires merging the fabrication processes of the two detector types. We present the fabrication process for dual production of different X-ray absorbers on the same substrate, thick Au on the small pixels and thinner Au with a Bi capping layer on the larger pixels to tune their heat capacities. The process requires multiple electroplating and etching steps, but the absorbers are defined in a single-ion milling step. We demonstrate methods for integrating the heatsinking of the two types of pixel into the same focal plane consistent with the requirements for each subarray, including the limiting of thermal crosstalk. We also discuss fabrication process modifications for tuning the intrinsic transition temperature (T(sub c)) of the bilayers for the different device types through variation of the bilayer thicknesses. The latest results on these 'hybrid' arrays will be presented.

Terms—Arrays↗

Organic Matter in Extraterrestrial Water-Bearing Salt Crystals

Introduction: Direct samples of early Solar System fluids are present in two thermally-metamorphosed ordinary chondrite regolith breccias (Monahans (1998) [H5] and Zag [H3-6]), which were found to contain brine-bearing halite (NaCl) crystals that have been added to the regolith of an S-type asteroid following asteroidal metamorphism [1, 2]. The brine-bearing halite grains were proposed to be formed on an icy C-type asteroids (possibly Ceres), and transferred to an S-type asteroid via cryovolcanic event(s) [3]. A unique aspect of these halites is that they contain abundant organic rich solid inclusions hosted within the halites alongside the water inclusions. Methods: We analyzed in detail the compositions of the organic solids and the amino acid content of the halite crystals with two-step laser desorption/laser ionization mass spectrometry (L(sup 2) MS), Raman spectroscopy, X-ray absorption near edge structure (XANES), nanoscale secondary ion mass spectrometry (NanoSIMS), and ultra-performance liquid chromatography fluorescence detection and quadrupole time of flight hybrid mass spectrometry (UPLC-FD/QToF-MS). Results and Discussion: The L(sup 2) MS results show signatures of low-mass polyaromatic hydro-carbons (PAHs) indicated by sequences of peaks separated by 14 atomic mass units (amu) due to successive addition of methylene (CH2) groups to the PAH skeletons [4]. Raman spectra of the micron-sized solid inclusions of the halites indicate the presence of abundant and highly variable organic matter that include a mixture of short-chain aliphatic compounds and macromolecular carbon. C-XANES analysis identified C-rich areas with peaks at 285.0 eV (aromatic C=C) and 286.6 eV (vinyl-keto C=O). However, there is no 1s-sigma* exciton peak (291.7 eV) that is indicative of the development of graphene structure [5], which suggests the organics were synthesized cold. Na-noSIMS analyses show C-rich and N-rich areas that exhibit similar isotopic values with that of the IOM in the unweathered CR chondrites and less metamorphosed meteorites [6], and are moderately enriched in N-15 (delta N-15 = 106.1-164.5 per mille). The total amino acid distribution and abundance of the Zag matrix (approximately 1,940 parts per billion [ppb]) is comparable to other ordinary chondrites (60-3,330 ppb) [7, 8]. While the Zag matrix is gamma-ABA and EACA-deficient, the halite is shown to exhibit an opposite trend and is almost depleted in amino acids. The striking difference in the amino acid contents between the halite and matrix indicates their separate synthetic origins. Conclusion: Abundant, primitive, and highly-diverse N-15-rich organic compounds were detected in brine-water bearing halite crystals that were synthesized on a cryovolcanically-active asteroid. Our study suggests that the asteroidal parent body where the halite precipitated, potentially Ceres, is a host to abundance large variety organic precursors. Insoluble organic matter and amino acids can be synthesized from similar organic precusors under hydrous conditions [9].We envision that similar organic synthetic processes could have occurred on Ceres that synthesized organic solids as well as biologically relevant molecules.

Chan, Q. H. S.↗

Hemispherical Optical Dome for Underwater Communication

For many years, acoustic systems have been used as the primary method for underwater communication; however, the data transfer rate of such systems is low because sound propagates slowly through the water. A higher throughput can be achieved using visible light to transmit data underwater. The first issue with using this approach is that there is generally a large loss of the light signal due to scattering and absorption in water even though there is an optimal wavelength for transmission in the blue or green wavelengths of the visible spectrum. The second issue is that a simple system consisting only of a highly directional source transmitter and small optical detector receiver has a very narrow field of view. The goal of this project is to improve an optical, underwater communication system by increasing the effective field of view of the receiving optics. To this end, we make two changes to the simple system: (1) An optical dome was added near the receiver. An array of lenses is placed radially on the surface of the dome, reminiscent of the compound eye of an insect. The lenses make the source and detector planes conjugate, and each lens adds a new region of the source plane to the instrument's total field of view. (2) The receiver was expanded to include multiple photodiodes. With these two changes, the receiver has much more tolerance to misalignments (in position and angle) of the transmitter.Two versions of the optical dome (with 6 and 8 diameters) were designed using the CREO CAD software and modeled using the CODE V optical design software. A series of these transparent hemispherical domes, with both design diameters, were manufactured using a 5-axis mill. The prototype was then retrofitted with lenses and compared with the computer-generated model to demonstrate the effectiveness of this solution. This work shows the dome design improves the optical field of view of the underwater communication system considerably. Furthermore, with the experimental test results, a geometric optimization model was derived providing insights to the design performance limits.

Design↗

Soil Moisture Active and Passive (SMAP) White-Painted Expanded Polystyrene (EPS) Radome Survivability Test

NASA's SMAP Mission launched in January 2015 into a 685 km near-polar, sun-synchronous orbit. The SMAP instrument architecture incorporates an L-band radar and radiometer which share a common feedhorn and mesh reflector. The instrument rotates about the nadir axis at approximately 15 rpm, thereby providing a conically scanning wide swath antenna beam that is capable of achieving global coverage within three days. The radiometer and its associated electronics have tight thermal stability requirements in order to meet the required surface emittance measurement precision from space. Maintaining the thermal stabilities is quite challenging because the radiometer is located on a spinning platform that can either be in full sunlight or eclipse, and thus exposed to a highly transient environment. Stability requirements were met by integrating a light-weight Expanded Polystyrene (EPS) radome into the design to prevent solar illumination of the feed horn interior. The radome was painted white since the thermo-optical properties of bare sunlit EPS degrade rapidly over the three-year mission. Milling of the EPS and solvent within the white paint created cavities on the EPS surface which may introduce localized hot spots possibly violating the EPS glass transition temperature of 96degC and leading to structural integrity concerns. A three-day thermal test was conducted in a vacuum chamber to verify survivability of the radome during a simulated non-spin fault condition at end of mission. A portable solar simulator illuminated the test article and the beam irradiance was kept nearly constant during the entire 50 hour test, except during the first hour which simulated the expected 79degC on-orbit surface temperature of the radome. The test article survived based on the established pass criteria for three separate metrics: dimensional, optical property, and color. If any hot spots exist locally, they did not cause any observable permanent deformation when compared to pre- and post-test images. The test results increase confidence that there is a high probability that the radome will survive the worst-case scenario of a no-spin fault condition at the end of mission.

Mikhaylov, Rebecca↗

Circadian and Fatigue Effects on the Dynamics of the Pupillary Light Reflex

The pupillary light reflex (PLR) is known to be driven by the photo-entrainment of intrinsically-photosensitive retinal ganglion cells. These ganglion cells are known to have retino-hypothalamic projections to the suprachiasmatic nuclei (SCN), which regulates circadian rhythms, and bilateral retinal projections to the pretectal area, which mediates the PLR (Dacey et al., 2005; Hattar et al., 2002, 2006). The magnitude of the PLR has previously been shown to show circadian variation (Mnch et al., 2012). In this study, we used a constant routine protocol (Mills et al., 1978) to examine circadian and fatigue effects on the dynamics of the PLR. We characterized the PLR (pupil size as a function of time) in response to a square-wave change in the luminance of a white display background, at ten different times over a single circadian cycle. Twelve subjects participated in three daytime baseline runs followed by 7 nighttime runs each separated by an hour (17 23 hours after awakening). The constriction and dilation phases of the PLR waveform were fit separately with a single exponential model (Longtin Milton, 1988; Milton Longtin, 1990) with time constants estimated using a least-squares method. The dilation time constant exhibited a distinct sinusoidal modulation across the circadian cycle and, after 23 hours of wakefulness, decreased on average by 82 ms (paired t-test, p 0.05) relative to baseline (mean: 543 ms). The constriction time constant however, did not show an overall decrease with increased wakefulness. We conclude that the dynamics of the PLR show circadian variation and that, in addition, the briskness of the dilation response to a step-decrease in luminance shows a homeostatic enhancement with increased wakefulness.

human performance↗

Hemispherical Optical Dome for Underwater Communication

For many years, acoustic systems have been used as the primary method for underwater communication; however, the data transfer rate of such systems is low because sound propagates slowly through the water. A higher throughput can be achieved using visible light to transmit data underwater. The first issue with using this approach is that there is generally a large loss of the light signal due to scattering and absorption in water even though there is an optimal wavelength for transmission in the blue or green wavelengths of the visible spectrum. The second issue is that a simple system consisting only of a highly directional source/transmitter and small optical detector/receiver has a very narrow field of view. The goal of this project is to improve an optical, underwater communication system by increasing the effective field of view of the receiving optics. To this end, we make two changes to the simple system: (1) An optical dome was added near the receiver. An array of lenses is placed radially on the surface of the dome, reminiscent of the compound eye of an insect. The lenses make the source and detector planes conjugate, and each lens adds a new region of the source plane to the instrument's total field of view. (2) The receiver was expanded to include multiple photodiodes. With these two changes, the receiver has much more tolerance to misalignments (in position and angle) of the transmitter.Two versions of the optical dome (with 6 and 8 diameters) were designed using the CREO CAD software and modeled using the CODE V optical design software. A series of these transparent hemispherical domes, with both design diameters, were manufactured using a 5-axis mill. The prototype was then retrofitted with lenses and compared with the computer-generated model to demonstrate the effectiveness of this solution. This work shows the dome design improves the optical field of view of the underwater communication system considerably. Furthermore, with the experimental test results, a geometric optimization model was derived providing insights to the design performance limits.

Underwater↗

Study of a Tricarbide Grooved Ring Fuel Element for Nuclear Thermal Propulsion

Deep space exploration, especially that of Mars, is on the horizon as the next big challenge for space exploration. Nuclear propulsion, through which high thrust and efficiency can be achieved, is a promising option for decreasing the cost and logistics of such a mission. Work on nu- clear thermal engines goes back to the days of the NERVA program. Currently, nuclear thermal propulsion is under development again in various forms to provide a superior propulsion system for deep space exploration. The authors have been working to develop a concept nuclear thermal engine that uses a grooved ring fuel element as an alternative to the traditional hexagonal rod design. The authors are also studying the use of carbide fuels. The concept was developed in order to increase surface area and heat transfer to the propellant. The use of carbides would also raise the operating temperature of the reactor. It is hoped that this could lead to a higher thrust to weight nuclear thermal engine. This paper describes the modeling of neutronics, heat transfer, and fluid dynamics of this alternative nuclear fuel element geometry. Fabrication experiments of grooved rings from carbide refractory metals are also presented along with material characterization and interactions with a hot hydrogen environment. Results of experiments and associated analysis are desired densities with some success in material distribution and reaching a solid solution. Future work is needed to improve distribution of material, minimize oxidation during the milling process, and de ne a fabrication process that will serve for constructing grooved ring fuel rods for large system tests.

Taylor, Brian↗

Study of a Tricarbide Grooved Ring Fuel Element for Nuclear Thermal Propulsion

Deep space exploration, especially that of Mars, is on the horizon as the next big challenge for space exploration. Nuclear propulsion, through which high thrust and efficiency can be achieved, is a promising option for decreasing the cost and logistics of such a mission. Work on nuclear thermal engines goes back to the days of the NERVA program. Currently, nuclear thermal propulsion is under development again in various forms to provide a superior propulsion system for deep space exploration. The authors have been working to develop a concept nuclear thermal engine that uses a grooved ring fuel element as an alternative to the traditional hexagonal rod design. The authors are also studying the use of carbide fuels. The concept was developed in order to increase surface area and heat transfer to the propellant. The use of carbides would also raise the operating temperature of the reactor. It is hoped that this could lead to a higher thrust to weight nuclear thermal engine. This paper describes the modeling of neutronics, heat transfer, and fluid dynamics of this alternative nuclear fuel element geometry. Fabrication experiments of grooved rings from carbide refractory metals are also presented along with material characterization and interactions with a hot hydrogen environment. Results of experiments and associated analysis are discussed. The authors demonstrated success in reaching desired densities with some success in material distribution and reaching a solid solution. Future work is needed to improve distribution of material, minimize oxidation during the milling process, and define a fabrication process that will serve for constructing grooved ring fuel rods for large system tests.

Taylor, Brian↗

Spring Internship 2018 at the Prototype Development Lab: A place of Dreamers and Makers

This paper covers the role of the design process and the methodology of creating a trophy during my Spring 2018 Internship at the Prototype Development Laboratory at the Kennedy Space Center. In the course of this project I used many new machines and materials while trying to deliver a professional product for a competition that invites college student teams from across the country. The machines covered in this paper include the wood chop saw, CNC mill, water jet, laser engraver, and the 3D printer. This paper also serves as an assembly guide for the trophy.

Rueda, Juan F.↗