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A genetic algorithm is used for design of infrared filters and in the understanding of the material structure of a resonant tunneling diode. These two components are examples of microdevices and nanodevices that can be numerically simulated using fundamental mathematical and physical models.
A sensitivity evaluation of mounting 100mm optics using elastomer or bipod flexures was completed to determine the relative effects of geometry, structure, material, thermal and vibration environment as they relate to optical distortion. This paper covers both opto-mechanical designs, as well as analytical results from computer modeling and brassboard tests.
A genetic algorithm is used for design of infrared filters and in the understanding of the material structure of a resonant tunneling diode.
NASA is actively researching space crop production to determine its potential to contribute to food system security on long duration missions beyond Low Earth Orbit. Our near-term focus is on nutrient and variety supplementation of prepackaged food with fresh produce that requires little or no processing. The longer-term goal is caloric replacement to become less dependent on Earth, and this will require cultivation of staple crops, processing and cooking equipment, integration with spacecraft air, water, and power systems, and automation. There are numerous technology and knowledge gaps remaining for sustainable space crop production systems, but one high-impact area is in the development of crops specifically customized to meet the needs of controlled environment crop production, astronaut health and well-being, and space-unique environments. Modern crop breeding and genome engineering tools are allowing for rapid development of new genotypes with incredible specificity. Targeted aspects to optimize crops for space have been identified and characterized into five categories: plant growth and development, plant physiology, produce nutrition, produce organoleptic acceptability, and postharvest characteristics. Within each category there are several targets that further the development of crop production systems for spaceflight, such as crop size and harvest index, tolerance to specific environmental stresses, optimizing target nutrients that are low or degrade in the packaged diet, maintenance time requirements, and less indigestible structural material. NASA-funded PIs are already beginning to develop candidate crops, and spaceflight testing and validation of novel space crops is on the horizon. Crops developed for space also have the potential to benefit terrestrial controlled environment agriculture crop production systems. This research was supported by NASA’s Space Biology and Human Research Programs.
NASA is actively researching space crop production to determine its potential to contribute to food system security on long duration missions beyond Low Earth Orbit. Our near-term focus is on nutrient and variety supplementation of prepackaged food with fresh produce that requires little or no processing. The longer-term goal is caloric replacement to become less dependent on Earth, and this will require cultivation of staple crops, processing and cooking equipment, integration with spacecraft air, water, and power systems, and automation. There are numerous technology and knowledge gaps remaining for sustainable space crop production systems, but one high-impact area is in the development of crops specifically customized to meet the needs of controlled environment crop production, astronaut health and well-being, and space-unique environments. Modern crop breeding and genome engineering tools are allowing for rapid development of new genotypes with incredible specificity. Targeted aspects to optimize crops for space have been identified and characterized into five categories: plant growth and development, plant physiology, produce nutrition, produce organoleptic acceptability, and postharvest characteristics. Within each category there are several targets that further the development of crop production systems for spaceflight, such as crop size and harvest index, tolerance to specific environmental stresses, optimizing target nutrients that are low or degrade in the packaged diet, maintenance time requirements, and less indigestible structural material. NASA-funded PIs are already beginning to develop candidate crops, and spaceflight testing and validation of novel space crops is on the horizon. Crops developed for space also have the potential to benefit terrestrial controlled environment agriculture crop production systems. This research was supported by NASA’s Space Biology and Human Research Programs.
Contaminant removal technology, such as the Carbon Dioxide Removal Assembly (CDRA) on the International Space Station (ISS), is critical to Environmental Close-Loop Life Support Systems (ECLSS), which enable humans to live and work in outer space. The CDRA includes an adsorbent bed, which absorbs CO2 and releases it to a Sabatier reactor for water production when thermally cycled. An effective system would heat and cool the adsorbent quickly and uniformly to maximize the amount of CO2 removed from the cabin. Air-Cooled Temperature Swing Adsorption Compressors (AC-TSAC) are promising because they are a simple alternative to more mechanically-complex compressors currently used on the ISS. The current investigation addresses the thermal modeling of potential AC-TSAC designs. Design trades include bed geometry (rectangular vs. cylindrical), bed structural material, and configuration of heat pipes within the bed. Also investigated is AC-TSAC performance sensitivity to the thermal conductivity of the adsorbent material and the heat pipes, the input power for heating, and various heat loss mechanisms. The results from these studies will inform the design of the next generation of the AC-TSAC, and the thermal modeling results will be validated through testing.
As NASA prepares for the next human footsteps on the lunar surface, the Agency is already looking ahead to systems that will enable a sustained human presence on the lunar surface and mission to Mars, including a lunar Surface Habitat and Mars Transit Habitat (TH). This paper describes the latest NASA government reference design for the TH and how it will support NASA's Moon to Mars human exploration architecture. First, it will serve as a test and demonstration platform in lunar orbit, demonstrating capabilities required for long-duration microgravity human spaceflight as part of the lunar-Mars analog missions. Then, the TH will also serve as a major Mars habitation exploration element to support the crew during their transit from the lunar orbit to Mars and returning them safely to lunar orbit. This paper will cover several considerations contributing to the latest habitat design refinement, including data on the TH's concept of operations, system functional definition, subsystem assumptions, notional interior layouts, a detailed mass and volume breakdown, and trade studies and analyses required to close identified technology/ development/architecture gaps. In addition to a technical description of the TH, this paper describes how the current TH government reference design will achieve many of the current lunar and Mars mission goals. Additionally, there are many assumed technological advances needed to support the prescribed mission phases leading up to the crewed mission to Mars in the late 2030s. The paper will describe many of the TH systems requiring further technology development and identify architectural solutions to achieve these mass, reliability, autonomy, and crew health targets. As a whole, the data in the paper shows that a TH meeting the 43 metric tons launch mass/trans-Mars injection burn limits specified by the Evolvable Mars Campaign is achievable near the desired timeframe with moderate strategic investments including maintainable life support systems, re-purposable structures and packaging, and lightweight exercise modalities. It also identifies operational and technological options to reduce this mass to less than 41 metric tons, including staging of launch structure/packaging and alternate structural materials. The resulting design detail and data contained in this paper are intended to help teams across NASA and potential commercial, academic, or international partners understand the current performance targets of the Transit Habitat and vehicle interface considerations imposed by the latest Moon to Mars mission scope.
Contaminant removal technology, such as the Carbon Dioxide Removal Assembly (CDRA) on the International Space Station (ISS), is critical to Environmental Control and Life Support Systems (ECLSS), which enable humans to live and work in outer space. The CDRA includes an adsorbent bed, which absorbs CO 2 from the cabin air and releases it to a Sabatier reactor for water production when thermally cycled. An effective system would heat and cool the adsorbent quickly and uniformly to maximize the amount of CO 2 removed from the cabin and delivered to the Sabatier reactor. Air-Cooled Temperature Swing Adsorption Compressors (AC-TSAC) are promising for use downstream of the CDRA because they are a simple alternative to more mechanically-complex compressors, which are currently in use on the ISS. The current investigation addresses the thermal modeling of potential AC-TSAC designs. An initial thermal model was created and validated by comparing the model outputs to experimental data for the heating phase. Several design trades were conducted, including bed geometry (rectangular vs. cylindrical), bed structural material (i.e., the material that makes up the walls and shelves), and configuration of heat spreading elements within the bed. Also investigated is AC-TSAC performance sensitivity to the thermal conductivity of the adsorbent material and the heat pipes as well as the input power for heating. The results from these studies will inform the design of the next generation of the AC-TSAC, and the thermal modeling results will be further validated through testing.
Coatings for hot section aero turbine engine structural materials are subject to thermochemical degradation after interacting with calcium-magnesium-aluminosilicates (CMAS). Molten CMAS viscosity is the primary glass property of importance, correlating with coating infiltration and reaction depth. CMAS viscosity was measured using a spindle-dipped viscometer at temperatures between 1300-1550°C in 25°C increments. Experimental data were compared to Thermo-Calc and FactSage computational models, which showed good agreement with experimental trends. CMXAS compositions, where X denotes a fifth oxide, of Ca30.75-Mg9-X5-Al13-Si42.25 (single cation oxide mol%) for X = Fe2+, Fe3+, Gd3+, Hf4+, Na1+, Ti4+, Y3+, Yb3+, Zr4+ additions were used. Oxide precipitation was observed in X = Hf4+ , Zr4+ CMXAS specimens, indicating coating dissolution is an increased threat for T ≥ 1390°C. Molten CMAS and CMXAS viscosity measurements were shown to correlate with net cation field strength, offering an alternative in property prediction where thermodynamic data are unavailable.
Among the potential future technologies for low-carbon transport aircraft, all-electric concepts stand out environmentally, yet their feasibility and cost-effectiveness at scale remain uncertain. This paper examines the conceptual design of an all-electric 150-passenger aircraft with a range of 840 NM based on assumed future battery cell-level specific energy of1620Wh/kg. The tube and wing design is propelled by open rotors driven by four electric motors per nacelle and utilizes advanced structural materials for weight reduction. Powertrain technology gaps are identified. The conceptual design shows that all-electric aviation could supplant about 30% of current fossil fuel use by transport aircraft and potentially more with air-traffic-control modifications.
With an increased demand on reducing the time, cost, and effort to develop new materials, Integrated Computational Materials Engineering (ICME) has received widespread attention in various engineering disciplines as a catalyst for significantly reducing experimental testing during the material design process. An ICME approach to design can enable ‘fit-for-purpose’ materials to be realized in engineering applications by incorporating well-understood process-property-performance relationships between the various length and time scales in a material’s structure, enabling material optimization. However, such an approach requires validated multiscale models at the various length scales for a material, which in turn requires a large amount of data, a robust means of storing the data, and the ability to link data to developed material models. The NASA Vision 2040 [1] has identified nine key elements to enabling ICME approaches in system level design, with one being “Data, Information, and Visualization”, thus outlining the importance of a robust information management system for ICME. As the relationship between microstructure, properties, and material performance become better understood and incorporated into multiscale models that can be leveraged in application design, the emergence of new materials with application-driven properties can be realized. One such new material class that has seen growing attention are shape memory materials (SMM), in which a material can transition between a deformed and undeformed state via a reversible phase transformation when subject to a thermal, mechanical, or magnetic load [2]. SMMs have been used widely in aerospace and biomedical industries, including applications such as actuators, low-shock mechanisms, medical staples, braces, and stents [3, 4]. These materials exhibit unique behavior due to their ability to transition between phases, and thus the mechanisms that enable this transition must be captured in a data information management system and incorporated into SMM material models. At NASA Glenn Research Center, the Shape Memory Materials Database (SMMD) Tool has been developed to capture the necessary information that governs SMM material behavior and provide users the ability to select and visualize various SMMs for a specific application [5]. The database contains point-wise data for published SMM materials, along with the pedigree metadata for traceability necessary for a robust information management system. The database is also capable of storing in-house test data performed at NASA GRC by interacting with the developed Shape Memory Alloy (SMA) Analytics tool to extract the necessary point-wise values and populate the database. Although the SMMD Tool offers its users a single, authoritative source for SMM material data that is critical for model development and material design, the full material pedigree of the in-house test data for SMMs is not currently captured and is out of the scope for the SMMD tool. In this work, the schema for capturing SMM test data within the larger NASA GRC ICME Schema [6, 7, 8, 9] will be developed and implemented for thermomechanical tests conducted at NASA GRC. The developed schema will not only store the relevant data needed for the SMMD tool, but also the material pedigree (i.e., production of the bulk material, bulk material analysis, sample cut-out diagrams, sample fabrication procedure, etc.), test pedigree (i.e., test equipment used, measurement systems used, raw test data), and analysis pedigree (i.e., how the data in the SMMD tool is calculated). Furthermore, a Python-based framework will be developed to seamlessly interact between the SMA Analytics and SMMD tools, which will write the full dataset and associated metadata to the GRC Information Management System before passing the required point-wise data to the SMMD tool. Data informatics is a key element of the NASA Vision 2040, which requires not only that data is stored and maintained throughout the material lifecycle, but that the data is also accessible and reusable such that material development efforts can be minimized. Therefore, for an ICME design approach to be realized, a centralized information management system that drives the ICME process must be able to communicate with other databases. The work that will be presented in this presentation will therefore not only demonstrate the ability of NASA GRC’s information management system to capture SMM data, but also its ability to interact with pre-existing tools specialized for such materials.
The use of a superconducting rotor in the High Efficiency Megawatt Motor (HEMM) comes with a number of challenges. The HEMM’s rotor must be designed so that the superconducting coil can tolerate the forces it will encounter during operation. These forces introduce considerable risk to the design of the HEMM. Because this risk cannot be adequately addressed through refined analysis, a set of experiments was deemed necessary to demonstrate that the HEMM’s superconducting coils can survive the stresses imparted by the centrifugal forces acting on the coil during full-speed operation of the machine. These experiments required spin testing a full-scale HEMM coil on a representative rotor structure at room temperature and sequentially higher rotation speeds and measuring the superconductivity response of the coil in liquid nitrogen (LN2) before and after each spin test. Tests were carried out to the full centripetal loading of a recent HEMM design. According to finite element analysis, this load produced stress components in the coil that exceed their design limit by a factor of 1 to 7.4. Although not yet confirmed, the current HEMM design is expected to produce even smaller stresses in the coil due to a 20 percent reduction in the coil’s mass and an increased volume of structural material. The only degradation of the coil that occurred during this testing resulted from a test rig failure and from the voltage taps, which are not part of the final coil design.
This paper presents an overview of the International Space Station life extension project, focusing on the analytical approach used to assess its primary structure. Also addressed are life extension approaches for other affected sub-systems, including secondary structure, materials, Environmental Control and Life Support Systems (ECLSS), Electrical Power Systems (EPS), and Logistics and Maintenance (L&M). The United States On-orbit Segment (USOS) of the International Space Station (ISS) was initially designed for a 15-year on-orbit life, but with the realization of its continued importance, efforts were made to extend its operations through 2030. The paper discusses the various analyses conducted, including future operations planning, load simulation, material degradation studies, thermal analyses, and fracture analyses. The results demonstrate the feasibility and achievability of extending the ISS's life, ensuring its on-going role as a hub for scientific research, international cooperation, and educational endeavors. With the life extension process in place, continuous operations beyond 2030 are possible to maintain an uninterrupted human presence in Low Earth Orbit, facilitating the testing of new technologies, and allow for a seamless transition to new commercially owned and operated destinations.
In this study, we apply the electromagnetic (EM) melt processing of thermoplastics on an innovative EM field-driven powder bed fusion additive manufacturing (AM) concept for high-performance functional parts: Selective Microwave Melting/Sintering (SMM/SMS). This technique leverages the EM susceptibility of carbon nanotube-coated polymer micro-pellets to achieve rapid, localized heating and powder fusion. Thus, selective microwave melting (SMM) was used to fabricate multilayer specimens made of recycled polyphenylene sulfide (rPPS) and carbon nanotubes (CNTs). The resulting SMM specimens exhibited very good interlayer integrity, localized fusion at pellet boundaries, and tolerable residual porosity, indicating effective fusion and acceptable consolidation. CNT-rich interphases were retained after irradiation, generating anisotropic electrically active network pathways and enabling conductivity enhancement at low filler content. At only 1.0 wt% CNT, the specimens exhibited electrical conductivity approximately three orders of magnitude higher than neat rPPS. Dynamic mechanical analysis showed improved viscoelastic response relative to neat rPPS, while tensile testing confirmed that the SMM-processed specimens retained practical mechanical integrity despite localized voids. These results demonstrate that SMM can effectively consolidate EM susceptible thermoplastic powder beds while preserving their segregated conductive networks. This may become a scalable route for producing multifunctional thermoplastic parts with low filler loadings, tunable anisotropy, and structured materials and parts. Overall, the findings suggest that EM field-based AM can help overcome key limitations of conventional thermoplastic processing by enabling scalable, energy-efficient fabrication of nanostructured composites and expanding AM to a broader range of resins, including high-performance thermoplastics with customized functional properties.
We report on progress on the STABLE study, which was awarded on the NASA 2023 ROSES D.19 opportunity. In the study, we are developing technologies for the Habitable Worlds Observatory (HWO) in four areas: Micrometeoroid Impact Mitigation, Telescope Temperature Control, Ultra-Stable Telescope Structure Materials and Modeling, and Improvement of Thermal Expansion Test Capability. This study is a collaboration between Northrop Grumman, Kratos, NeXolve, JPL, STScI, NASA’s White Sands Test Facility, and NASA Goddard’s Ultra-Stable Test Facility. We will also discuss our plans for our follow-on study as part of NASA’s 2024 ROSES D.19. In this study, we will address additional technologies as well as perform analysis of HWO architecture options.
Biomass derived pyrolysis oil is a promising renewable energy source. Due to the variety of biomass feedstocks, the bio-oils could contain a wide range of organic constituents which would provide unique corrosive environments for structural materials. A preliminary work exposed different classes of steels and stainless steels to selected organic constituents of biomass pyrolysis oils and found that corrosion susceptibility, assessed using electrochemical impedance spectroscopy (EIS), was prominent in the steels with Cr lower than 11 wt.%. Although this result suggests stainless steels will resist corrosion by certain organic constituents, it may not be sufficient to predict the corrosion performance in real bio-oils. Therefore, this study attempted electrochemical measurements on Cr-alloyed steels and stainless steels directly exposed to a biomass derived pyrolysis oil. To overcome the low conductivity of bio-oils, a customized Luggin capillary was designed to minimize the ohmic path in bio-oils. The results of this work will be reported.
Section III, Division 5 of the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (BPVC) specifies rules for elevated temperature nuclear reactors. Time dependent allowable stresses are an important aspect of the high temperature design models and are related to the time to 1% strain, time to rupture, and time to onset of tertiary creep. The time to onset of tertiary creep criterion has an overly strong negative influence on the allowable stresses for some structural materials, likely due to very limited datasets and misidentification of microstructural changes rather than onset of significant creep damage, as tertiary creep is meant to represent. It is recommended that the onset of tertiary creep be determined through an alloy specific ratio between onset of tertiary creep and creep rupture time, which would give access to the significantly larger creep rupture time datasets.
High entropy alloys (HEAs) have been considered as structural materials for nuclear applications due to their promising mechanical properties and radiation resistance. For this purpose, irradiation-induced defect evolution and microstructure change have been characterized to evaluate the irradiation performance of different HEAs. This article reviews recent advances in understanding the irradiation response of HEAs, including the effect of disordered states on the defect energy landscape and defect evolution, irradiation-induced microstructure changes, void swelling, phase stability, mechanical properties under irradiation, as well as the He irradiation effects.