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NASA NTRS1989

Flight experiment of thermal energy storage

Thermal energy storage (TES) enables a solar dynamic system to deliver constant electric power through periods of sun and shade. Brayton and Stirling power systems under current considerations for missions in the near future require working fluid temperatures in the 1100 to 1300+ K range. TES materials that meet these requirements fall into the fluoride family of salts. These salts store energy as a heat of fusion, thereby transferring heat to the fluid at constant temperature during shade. The principal feature of fluorides that must be taken into account is the change in volume that occurs with melting and freezing. Salts shrink as they solidify, a change reaching 30 percent for some salts. The location of voids that form as result of the shrinkage is critical when the solar dynamic system reemerges into the sun. Hot spots can develop in the TES container or the container can become distorted if the melting salt cannot expand elsewhere. Analysis of the transient, two-phase phenomenon is being incorporated into a three-dimensional computer code. The code is capable of analysis under microgravity as well as 1 g. The objective of the flight program is to verify the predictions of the code, particularly of the void location and its effect on containment temperature. The four experimental packages comprising the program will be the first tests of melting and freezing conducted under microgravity. Each test package will be installed in a Getaway Special container to be carried by the shuttle. The package will be self-contained and independent of shuttle operations other than the initial opening of the container lid and the final closing of the lid. Upon the return of the test package from flight, the TES container will be radiographed and finally partitioned to examine the exact location and shape of the void. Visual inspection of the void and the temperature data during flight will constitute the bases for code verification.

Namkoong, David↗

NASA NTRSDate not supplied

Additive Manufacturing and Experimental Characterization of Nickel-Titanium Shape-Memory Alloy Wick Structures and Heat Pipes for Spacecraft Thermal Control

Shape memory alloys (SMA), such as those based on nickel-titanium (NiTi), are increasingly being applied as multifunctional spacecraft components. For thermal management applications, NiTi flow tubing hinges and self-deploying loop heat pipes have been demonstrated. Emerging additive manufacturing (AM) processes are enabling more complex SMA devices than can be formed from conventional plain wire, tubing, and sheet stock materials. This paper presents our progress toward applying powder bed fusion AM to producing porous NiTi wicks and NiTi-H2O heat pipes, which could be embedded in thermally deploying radiators for spacecraft thermal management. AM near-equiatomic NiTi (55.1 wt% Ni) porous wick specimens were produced with a range of deposition parameters. Transient acetone rate-of-rise experiments were performed to estimate wick permeability (K) and average pore radius (r_pore) values and identify parameter sets with high capillary performance. Surface treatments were evaluated to achieve hydrophilic wick structures. Evaluated treatments included chemical oxide growth with H2O2, oxide and sodium titanate growth with NaOH solution, and ultrasonic cleaning with specialty detergents that can remove hydrocarbon contaminants. The most durable hydrophilic surface conditions were obtained with the NaOH treatment. High performing wick deposition parameters were used to produce a full AM NiTi heat pipe, which was treated with NaOH solution to activate the wick. This heat pipe was operated on a test stand in the inverted configuration (upper evaporator and lower condenser), and demonstrated stable nearly isothermal operation for 150 hrs.

Thermal management↗

NASA NTRSDate not supplied

Additive Manufacturing and Experimental Characterization of Nickel-Titanium Shape-Memory Alloy Wick Structures and Heat Pipes for Spacecraft Thermal Control

Thermal management↗

NASA NTRSDate not supplied

Manufacture, Characterization, and Fusion Welding of Thermoplastic Composites for Space Applications

The goals of NASA’s Thermoplastic Development for Exploration Applications (TDEA) Project include and assessment of thermoplastic composite joints for space structures by developing and maturing design capabilities, analysis tools and techniques, and manufacturing processes for thermoplastic composites. Through this effort the TDEA project will expand NASA’s in-house thermoplastic composite manufacturing capabilities, develop an understanding of advanced thermoplastic joining techniques relevant to space environments, evaluate the feasibility of reconfigurable composite structures, and advance structural analysis capabilities, including failure prediction of thermoplastic composites including joints. This presentation will provide an overview of the materials and manufacturing effort within the TDEA project. Three semi-crystalline and one amorphous thermoplastic composite system were selected for initial screening and provided an opportunity to gain manufacturing experience across a range of processing temperatures, rheological behavior, and composite properties. Equivalency to the National Center for Advanced Materials Performance (NCAMP) test report for Toray’s TC1225 material was established to provide confidence in in-house manufacturing and material properties were generated through baseline mechanical tests for each material. Material characterization data was generated for a subset of materials to (1) provide data for analysis and model development and (2) generate thermal, rheological and conductivity data across relevant temperatures. A key objective of the TDEA project is evaluation of thermoplastic composite joining processes suitable for in-space operations. This presentation will outline the project’s progress in fusion bonding candidate materials by common welding techniques to assess the quality, reproducibility and strength of the bond, as well as identify limitations to in-space manufacturing. The feasibility of joint disassembly and reassembly will be discussed.

thermoplastic composite↗

NASA NTRS1983

New techniques for fusion bonding and replication for large glass reflectors

Lightweight, space-deployable glass honeycomb telescope primary mirror structures are produced by a novel method which involves the heating to softening temperature of many borosilicate or silica glass tube sections that are packed to form a honeycomb matrix and filled with a high expansion coefficient refractory sand. The close packed tubes yield a hexagonal-cell honeycomb. Attention is given to the results of an experiment in which a highly refractory master was used to shape a honeycomb of less refractory glass, employing a 1-micron thick, vacuum-deposited gold coating as a parting layer between the two.

Angel, J. R. P.↗

NASA NTRS1988

Economic geology of lunar Helium-3

Economic geology evaluation of lunar He-3 should answer the question: Can lunar He-3 be sold on Earth with sufficient profit margins and low enough risk to attract capital investment in the enterprise. Concepts that relate to economic geology of recovering He-3 from the lunar maria are not new to human experience. A parametric cost and technology evaluation scheme, based on existing and future data, is required to qualitatively and quantitatively assess the comprehensive economic feasibility and return on investment of He-3 recovery from the lunar maria. There are also many political issues which must be considered as a result of nuclear fusion and lunar mining.

Schmitt, Harrison H.↗

NASA NTRS1991

Heat sink effects in variable polarity plasma arc welding

The Space Shuttle External Tank is fabricated by the variable polarity plasma arc (VPPA) welding process. In VPPA welding, a noble gas, usually argon, is directed through an arc to emerge from the torch as a hot plasma jet. This jet is surrounded by a shielding gas, usually helium, to protect the weld from contamination with air. The high velocity, hot plasma jet completely penetrates the workpiece (resembling a line heat source) when operated in the 'keyhole' mode. The metal melts on touching the side of the jet, as the torch travels in the perpendicular direction to the direction of the jet, and melted metal moves around the plasma jet in the keyhole forming a puddle which solidifies behind the jet. Heat sink effects are observed when there are irregularities in the workpiece configuration, especially, if these irregularities are close to the weld bead. These heat sinks affect the geometry of the weld bead, i.e., in extreme cases they could cause defects such as incomplete fusion. Also, different fixtures seem to have varying heat sink effects. The objective of this research is to study the effect of irregularities in workpiece configuration and fixture differences (heat sink effects) on the weld bead geometry with the ultimate objective to compensate for the heat sink effects and achieve a perfect weld. Experiments were performed on different workpiece geometries and compared to approximate models.

Abdelmessih, Amanie N.↗

NASA NTRS2003

Large-Eddy Simulation of Conductive Flows at Low Magnetic Reynolds Number

In this paper we study the LES method with dynamic procedure in the context of conductive flows subject to an applied external magnetic field at low magnetic Reynolds number R(sub m). These kind of flows are encountered in many industrial applications. For example, in the steel industry, applied magnetic fields can be used to damp turbulence in the casting process. In nuclear fusion devices (Tokamaks), liquid-lithium flows are used as coolant blankets and interact with the surrounding magnetic field that drives and confines the fusion plasma. Also, in experimental facilities investigating the dynamo effect, the flow consists of liquid-sodium for which the Prandtl number and, as a consequence, the magnetic Reynolds number is low. Our attention is focused here on the case of homogeneous (initially isotropic) decaying turbulence. The numerical simulations performed mimic the thought experiment described in Moffatt in which an initially homogeneous isotropic conductive flow is suddenly subjected to an applied magnetic field and freely decays without any forcing. Note that this flow was first studied numerically by Schumann. It is well known that in that case, extra damping of turbulence occurs due to the Joule effect and that the flow tends to become progressively independent of the coordinate along the direction of the magnetic field. Our comparison of filtered direct numerical simulation (DNS) predictions and LES predictions show that the dynamic Smagorinsky model enables one to capture successfully the flow with LES, and that it automatically incorporates the effect of the magnetic field on the turbulence. Our paper is organized as follows. In the next section we summarize the LES approach in the case of MHD turbulence at low R(sub m) and recall the definition of the dynamic Smagorinsky model. In Sec. 3 we describe the parameters of the numerical experiments performed and the code used. Section 4 is devoted to the comparison of filtered DNS results and LES results. Conclusions are presented in Sec. 5.

Knaepen, B.↗

NASA NTRS1993

Growth of binary organic NLO crystals: m.NA-p.NA and m.NA-CNA system

Experiments were carried out to grow 3.Nitroaniline (m.NA) crystals doped with 4.Nitroaniline (p.NA) and 2.chloro 4.Nitroaniline (CNA). The measured undercooling for m.NA, p.NA, and CNA were 0.21 tm K, 0.23 tm K, and 0.35 tm K respectively, where tm represents the melting temperature of the pure component. Because of the crystals' large heat of fusion and large undercooling, it was not possible to grow good quality crystals with low thermal gradients. In the conventional two-zone Bridgman furnace we had to raise the temperature of the hot zone above the decomposition temperature of CNA, p.NA, and m.NA to achieve the desired thermal gradient. To avoid decomposition, we used an unconventional Bridgman furnace. Two immiscible liquids, silicone oil and ethylene glycol, were used to build a special two-zone Bridgman furnace. A temperature gradient of 18 K/cm was achieved without exceeding the decomposition temperature of the crystal. The binary crystals, m.NA-p.NA and m.NA-CNA, were grown in centimeter size in this furnace. X-ray and optical characterization showed good optical quality.

Singh, N. B.↗

NASA NTRSDate not supplied

Robust Metal Additive Manufacturing Process Selection and Development for Aerospace Components

Metal additive manufacturing (AM) is a generic term that captures a variety of fabrication techniques. Each of these manufacturing process has unique advantages, applications for use, and challenges. The most common AM processes in use include Powder Bed Fusion (PBF) and Directed Energy Deposition (DED) as well as many solid state processes. While detailed research has been conducted among many of the processes including parameters and material properties, navigating which processes are best to select is difficult as it is based on component requirements. The focus of this presentation is to provide an overview of considerations for each of metal AM process selection for aerospace components based on various attributes. These attributes include geometric considerations, metallurgical characteristics, cost basis, post-processing and maturity of the processes. The data for these trade selections are based on studies that NASA as performed internally and with academic and industry partners. These studies include multiple AM build experiments to evaluate (1) geometric variations and constraints within the processes, (2) alloy characterization and mechanical testing, (3) pathfinder component development and hotfire evaluations, and (4) certification approaches. This presentation summarizes these results and meant to introduce various considerations when designing a metal AM component.

Additive Manufacturing↗

NASA NTRS1986

Physics through the 1990s: Atomic, molecular and optical physics

The volume presents a program of research initiatives in atomic, molecular, and optical physics. The current state of atomic, molecular, and optical physics in the US is examined with respect to demographics, education patterns, applications, and the US economy. Recommendations are made for each field, with discussions of their histories and the relevance of the research to government agencies. The section on atomic physics includes atomic theory, structure, and dynamics; accelerator-based atomic physics; and large facilities. The section on molecular physics includes spectroscopy, scattering theory and experiment, and the dynamics of chemical reactions. The section on optical physics discusses lasers, laser spectroscopy, and quantum optics and coherence. A section elucidates interfaces between the three fields and astrophysics, condensed matter physics, surface science, plasma physics, atmospheric physics, and nuclear physics. Another section shows applications of the three fields in ultra-precise measurements, fusion, national security, materials, medicine, and other topics.

Source record↗

NASA NTRS1992

Monolithic millimeter-wave diode array beam controllers: Theory and experiment

In the current work, multi-function beam control arrays have been fabricated and have successfully demonstrated amplitude control of transmitted beams in the W and D bands (75-170 GHz). While these arrays are designed to provide beam control under DC bias operation, new designs for high-speed electronic and optical control are under development. These arrays will fill a need for high-speed watt-level beam switches in pulsed reflectometer systems under development for magnetic fusion plasma diagnostics. A second experimental accomplishment of the current work is the demonstration in the 100-170 GHz (D band) frequency range of a new technique for the measurement of the transmission phase as well as amplitude. Transmission data can serve as a means to extract ('de-embed') the grid parameters; phase information provides more complete data to assist in this process. Additional functions of the array beam controller yet to be tested include electronically controlled steering and focusing of a reflected beam. These have application in the areas of millimeter-wave electronic scanning radar and reflectometry, respectively.

Sjogren, L. B.↗

NASA NTRS1987

Glass formation in microgravity

An account is given of containerless glass-forming experiments conducted aboard the Space Shuttle in 1985, using a single-axis acoustic levitator furnace apparatus. An attempt was made to obtain quantitative evidence for the suppression of heterogeneous nucleation/crystallization in containerless melts under microgravity conditions, as well as to study melt homogenization in the absence of gravity-driven convection and assess the feasibility of laser fusion target glass microsphere preparation with a microgravity apparatus of the present type. A ternary calcia-gallia-silica glass thus obtained indicated a 2-3-fold increase in glass-formation tendency for this material composition in microgravity, by comparison with 1g.

Ray, C. S.↗

NASA NTRSDate not supplied

Metal Additive Manufacturing Process Selection and Development for Propulsion Components

Metal additive manufacturing (AM) is a generic term that captures a variety of fabrication processes. Each of these manufacturing process has unique advantages and challenges for use in aerospace propulsion applications. The most commonly used AM processes include Powder Bed Fusion (PBF), Directed Energy Deposition (DED), and solid-state processes as in Cold Spray, Ultrasonic Additive Manufacturing, and Additive Friction Stir Deposition. While detailed research has been conducted among many of the AM processes to mature processing parameters and material properties, navigating which processes are best to select is difficult as it is based on specific component requirements. The focus of this presentation is to provide an overview of considerations for each of metal AM process selection for aerospace components based on various key attributes. These key attributes include geometric considerations, metallurgical characteristics, cost basis, post-processing and maturity of the processes. The data for these trade selections are based on studies that NASA as performed internally and with academic and industry partners. These studies include multiple AM build experiments to evaluate (1) geometric variations and constraints within the processes, (2) alloy characterization and mechanical testing, (3) pathfinder component development and hot-fire evaluations, and (4) certification approaches. This presentation summarizes these results and is meant to introduce specific examples which show what to consider when designing a metal AM component for aerospace propulsion applications.

Additive Manufacturing↗

NASA NTRS2004

Transmission Bearing Damage Detection Using Decision Fusion Analysis

A diagnostic tool was developed for detecting fatigue damage to rolling element bearings in an OH-58 main rotor transmission. Two different monitoring technologies, oil debris analysis and vibration, were integrated using data fusion into a health monitoring system for detecting bearing surface fatigue pitting damage. This integrated system showed improved detection and decision-making capabilities as compared to using individual monitoring technologies. This diagnostic tool was evaluated by collecting vibration and oil debris data from tests performed in the NASA Glenn 500 hp Helicopter Transmission Test Stand. Data was collected during experiments performed in this test rig when two unanticipated bearing failures occurred. Results show that combining the vibration and oil debris measurement technologies improves the detection of pitting damage on spiral bevel gears duplex ball bearings and spiral bevel pinion triplex ball bearings in a main rotor transmission.

Dempsey, Paula J.↗

NASA NTRS1989

Knowledge-based imaging-sensor fusion system

An imaging system which applies knowledge-based technology to supervise and control both sensor hardware and computation in the imaging system is described. It includes the development of an imaging system breadboard which brings together into one system work that we and others have pursued for LaRC for several years. The goal is to combine Digital Signal Processing (DSP) with Knowledge-Based Processing and also include Neural Net processing. The system is considered a smart camera. Imagine that there is a microgravity experiment on-board Space Station Freedom with a high frame rate, high resolution camera. All the data cannot possibly be acquired from a laboratory on Earth. In fact, only a small fraction of the data will be received. Again, imagine being responsible for some experiments on Mars with the Mars Rover: the data rate is a few kilobits per second for data from several sensors and instruments. Would it not be preferable to have a smart system which would have some human knowledge and yet follow some instructions and attempt to make the best use of the limited bandwidth for transmission. The system concept, current status of the breadboard system and some recent experiments at the Mars-like Amboy Lava Fields in California are discussed.

Westrom, George↗

NASA NTRS2020

Ignition and Burn in a Hybrid Nuclear Fuel for a Pulsed Rocket Engine

This work explores the parameter space of a cylindrical hybrid nuclear fuel in support of a z-pinch driven pulsed fission-fusion (PuFF) engine. 0D power balance and 1D burn wave calculations have been performed to explore the parameter space of hybrid cylindrical nuclear fuels. The boundary of minimal initial conditions needed to reach breakeven are found within the context of the model. The effects of initial conditions upon the yield at the end of burn wave expansion are also determined. The model is used to examine the minimum initial energies predicted to result in yields of a few MJ. The goal of this work is to guide fuel design, inform future models and experiments as well as look for the most efficient parameter space for ignition in a z-pinch driven hybrid nuclear reaction. The impact of initial parameters upon ignition, burn, and gain are discussed. It is found that a hybrid cylindrical target may breakeven with initial energy near the axis of approximately 4 to 6 MJ in lithium deuteride/uranium 235 fuel. It is also found that magnetic field can lower the threshold further of which the magnitude changes across the parameter space. The dual fusion/fission reactions are found to boost each other leading to lower initial driving energies needed to reach breakeven in the hybrid cylindrical nuclear fuel.

fission↗

NASA NTRS1993

Vaporization by shock loading of albite, jadeite, and pyrex glass: Experimental study

Produced by shock experiments impact melts of albite, jadeite, and Pyrex glass demonstrate a loss of both Na and Al relative to Si, which can be due to selective vaporization. It is suggested that the high volatility of Al is related to volatility of a Na-Al compound of proposed NaAlO2 composition. The similar loss of Al and Na seems to be possible during tektite-forming processes. A degree of selective vaporization and modification of a melt chemical composition during impact processes is still poorly understood. The selective vaporization of some elements has been shown by shock experiments. The vaporization and condensation processes can take place in the lunar regolith. On this basis, there are hypotheses explaining differentiation of planetary bodies through the impact vaporization. On the other hand, studies of tektites, impact glasses, and lunar soils show that bulk compositions of impact melts are not modified significantly. In order to estimate degree of the vaporization during shock fusion, chemical compositions of experimentally produced impact melts were studied. We chose Al-containing compositions, because a high volatilization of Al during unequlibrated evaporization had been demonstrated.

Badjukov, D. D.↗