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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS1979

Composites for Advanced Space Transportation Systems (CASTS)

A summary is given of the in-house and contract work accomplished under the CASTS Project. In July 1975 the CASTS Project was initiated to develop graphite fiber/polyimide matrix (GR/PI) composite structures with 589K (600 F) operational capability for application to aerospace vehicles. Major tasks include: (1) screening composites and adhesives, (2) developing fabrication procedures and specifications, (3) developing design allowables test methods and data, and (4) design and test of structural elements and construction of an aft body flap for the Space Shuttle Orbiter Vehicle which will be ground tested. Portions of the information are from ongoing research and must be considered preliminary. The CASTS Project is scheduled to be completed in September 1983.

Davis, J. G., Jr.↗
NASA NTRS1979

Composites for Advanced Space Transportation Systems - (CASTS)

The CASTS Project initiated to develop graphite fiber/polyimide matrix (GR/PI) composite structures with 589K operational capability for aerospace vehicles is described. Near term tasks include screening composites and adhesives for 589K service, developing fabrication procedures and specifications, developing design allowables test methods and data, design and test of structural elements, and construction of a full scale aft body flap for the space shuttle orbiter vehicle for ground testing. Far term tasks include research efforts directed at new materials, manufacturing procedures and design/analysis methodology. Specific results discussed include: (1) identification of four GR/PI composites and three PI adhesives with 589K service potential for periods ranging from 125 to 500 hours; (2) development of an adhesive formulation suitable for bonding reusable surface insulation (RSI) titles to 589K (GR/PI) substructure; (3) the capability to fabricate and nondestructively inspect laminates, hat section shaped stiffeners, honeycomb sandwich panels, and chopped fiber moldings; and (4) test methods for measuring design allowables at 117K.

Davis, J. G., Jr.↗
NASA NTRS1982

Analysis, design, and test of a graphite/polyimide Shuttle orbiter body flap segment

For future missions, increases in Space Shuttle orbiter deliverable and recoverable payload weight capability may be needed. Such increases could be obtained by reducing the inert weight of the Shuttle. The application of advanced composites in orbiter structural components would make it possible to achieve such reductions. In 1975, NASA selected the orbiter body flap as a demonstration component for the Composite for Advanced Space Transportation Systems (CASTS) program. The progress made in 1977 through 1980 was integrated into a design of a graphite/polyimide (Gr/Pi) body flap technology demonstration segment (TDS). Aspects of composite body flap design and analysis are discussed, taking into account the direct-bond fibrous refractory composite insulation (FRCI) tile on Gr/Pi structure, Gr/Pi body flap weight savings, the body flap design concept, and composite body flap analysis. Details regarding the Gr/Pi technology demonstration segment are also examined.

Graves, S. R.↗
NASA NTRS1985

Environmental stability graphite/PMR-15 composites

During the past few years the Boeing Company was screening graphite composites for use in hot areas of engine nacelle structure. Structural and thermal analyses have shown that there is the potential for a 25 to 30 percent weight savings by using a graphite polyimide (Gr/PI) composite material in this type of structure. Work conducted on the NASA CASTS program (Composites for Advanced Space Transportation Systems) amply demonstrated the capability of Graphite/PMR-15 for short term service (125 hours) at temperatures up to 589 K (600 F). In addition, the CASTS program demonstrated that large structures could be fabricated using Gr/PMR-15. In commercial applications, however, the requirement exists for long term service capability (tens of thousands of hours) at temperatures ranging upwards from 449 K (350 F). The results of Graphite/PMR-15 materials characterization efforts conducted at Boeing are presented with emphasis on materials properties after isothermal aging at temperatures of 449 K (350 F) and above.

Sheppard, C. H.↗
NASA NTRS1990

A study of hydrogen environment effects on microstructure property behavior of NASA-23 alloy and related alloy systems

This work is part of the overall advanced main combustion chamber (AMCC) casting characterization program of the Materials and Processes Laboratory of the Marshall Space Flight Center. The influence of hydrogen on the tensile properties and ductility behavior of NASA-23 alloy were analyzed. NASA-23 and other referenced alloys in cast and hipped conditions were solution treated and aged under selected conditions and characterized using optical metallography, scanning electron microscopy, and electron microprobe analysis techniques. The yield strength of NASA-23 is not affected much by hydrogen under tensile tests carried at 5000 psig conditions; however, the ultimate strength and ductility properties are degraded. This implies that the physical mechanisms operating would be related to the plastic deformation process. The fracture surfaces characteristics of NASA-23 specimens tensile tested in hydrogen, helium, and air were also analyzed. These revealed surface cracks around specimen periphery with the fracture surface showing a combination of intergranular and transgranular modes of fracture. It is seen that the specimens charged in hydrogen seem to favor a more brittle fracture mode in comparison to air and helium charged specimens. The AMCC casting characterization program is to be analyzed for their hydrogen behavior. As a result of this program, the basic microstructural factors and fracture characteristics in some cases were analyzed.

Diwan, Ravinder M.↗
NASA NTRS2000

Development of Metal Matrix Composites for NASA'S Advanced Propulsion Systems

The state-of-the-art development of several aluminum and copper based Metal Matrix Composites (MMC) for NASA's advanced propulsion systems will be presented. The presentation's goal is to provide an overview of NASA-Marshall Space Flight Center's planned and on-going activities in MMC for advanced liquid rocket engines such as the X-33 vehicle's Aerospike and X-34 Fastrac engine. The focus will be on lightweight and environmental compatibility with oxygen and hydrogen of key MMC materials, within each NASA's new propulsion application, that will provide a high payoff for NASA's reusable launch vehicle systems and space access vehicles. Advanced MMC processing techniques such as plasma spray, centrifugal casting, pressure infiltration casting will be discussed. Development of a novel 3D printing method for low cost production of composite preform, and functional gradient MMC to enhanced rocket engine's dimensional stability will be presented.

Lee, Jonathan A.↗
NASA NTRS2001

Development of Aluminum Composites for a Rocket Engine's Lightweight Thrust Cell

The Aerospike liquid fueled rocket engine for the X-33 aerospace vehicle consists of several thrust cells, which can comprise as much as 25% of the engine weight. The interior wall of the thrust cell chamber is exposed to high temperature combustion products and must be cooled by using liquid hydrogen. Ultimately, reducing engine weight would increase vehicle performance and allow heavier payload capabilities. Currently, the thrust cell's structural jacket and manifolds are made of stainless steel 347, which can potentially be replaced by a lighter material such as an Aluminum (Al) Metal Matrix Composites (MMC). Up to 50% weight reduction can be expected for each of the thrust cell chambers using particulate SiC reinforced Al MMC. Currently, several Al MMC thrust cell structural jackets have been produced, using cost-effective processes such as gravity casting and plasma spray deposition, to demonstrate MMC technology readiness for NASA's advanced propulsion systems.

Lee, Jonathan A.↗
NASA NTRS1990

Systems Engineering and Integration (SE and I)

The issue of technology advancement and future space transportation vehicles is addressed. The challenge is to develop systems which can be evolved and improved in small incremental steps where each increment reduces present cost, improves, reliability, or does neither but sets the stage for a second incremental upgrade that does. Future requirements are interface standards for commercial off the shelf products to aid in the development of integrated facilities; enhanced automated code generation system slightly coupled to specification and design documentation; modeling tools that support data flow analysis; and shared project data bases consisting of technical characteristics cast information, measurement parameters, and reusable software programs. Topics addressed include: advanced avionics development strategy; risk analysis and management; tool quality management; low cost avionics; cost estimation and benefits; computer aided software engineering; computer systems and software safety; system testability; and advanced avionics laboratories - and rapid prototyping. This presentation is represented by viewgraphs only.

Chevers, ED↗
NASA NTRS2002

Mechanical Testing of IN718 Lattice Block Structures

Lattice block construction produces a flat, structurally rigid panel composed of thin ligaments of material arranged in a three-dimensional triangulated truss-like structure. Low-cost methods of producing cast metallic lattice block panels are now available that greatly expand opportunities for using this unique material system in today's high-performance structures. Additional advances are being made in NASA's Ultra Efficient Engine Technology (UEET) program to extend the lattice block concept to superalloy materials. Advantages offered by this combination include high strength, light weight, high stiffness, and elevated temperature capabilities. Recently under UEET, the nickel-based superalloy Inconel 718 (IN718) was investment cast into lattice block panels with great success. To evaluate casting quality and lattice block architecture merit, individual ligaments, and structural subelement specimens were extracted from the panels. Tensile tests, structural compression, and bending strength tests were performed on these specimens. Fatigue testing was also completed for several bend test specimens. This paper first presents metallurgical and optical microscopy analysis of the castings. This is followed by mechanical test results for the tensile ligament tests and the subelement compression and bending strength tests, as well as for the fatigue tests that were performed. These tests generally showed comparable properties to base IN718 with the same heat treatment, and they underscored the benefits offered by lattice block materials. These benefits might be extended with improved architecture such as face sheets.

Krause, David L.↗
NASA NTRS1990

Space Technology for the Iron Foundry

Electric Power Research Institute (EPRI) initiated development of a plasma melter intended to solve a major problem in the U.S. foundry industry. EPRI is a non-profit organization that manages research and development for some 600 electric utility member companies. For the plasma melter program, EPRI enlisted as co-sponsors Westinghouse Electric's Environmental Systems and Services Division, General Motors Corporation, and Modern Equipment Company, supplier of equipment and services to the foundry industry. General Motor's plasma melter, first in the U.S., is an advanced technology system designed to improve the efficiency of coke-burning cupolas that melt iron to produce automotive castings. The key elements are six Westinghouse plasma torches. Electrically-powered plasma torch creates an ionized gas that superheats air entering the cupola to 10,000 degrees Fahrenheit. That great heat, three times higher than that attainable by oil or natural gas systems, is the key to making iron cheaper, cleaner, and faster. System offers an environmental bonus in reduced cupola emissions. Plasma torches increase GM's electric bill at Defiance, but that cost is more than compensated by the savings in charge material. The EPRI-sponsored Center for Materials Production (CMP) is evaluating the potential of plasma cupola technology.

Source record↗
NASA NTRS2006

Cryogenic Fracture Toughness Evaluation of an Investment Cast Al-Be Alloy for Structural Applications

Aluminum-Beryllium metal matrix composite materials are useful due to their desirable performance characteristics for aerospace applications. Desirable characteristics of this material includes light-weight, dimensional stability, stiffness, good vibration damping characteristics, low coefficient of thermal expansion, and workability, This material is 3.5 times stiffer and 22% lighter than conventional aluminum alloys. electro-optical systems, advanced sensor and guidance components for flight and satellite systems, components for light-weight high-performance aircraft engines, and structural components for helicopters. Aluminum-beryllium materials are now available in the form of near net shape investment castings. In this materials properties characterization study, the cryogenic tensile and fracture properties of an investment casting alloy, Beralcast 363, were determined. Tensile testing was performed at 21 C (70 F), -73.3 C (-100 F), -195.5 C (-320 F) and -252.8 C (-423 F), and fracture (K(sub lc) and da/dN) testing was performed at -73.3 C (-100 F), -195.5 C (-320 F) and -252.8 C (-423 F). Their use is attractive for weight critical structural applications such as advanced

Gamwell, W. R.↗
NASA NTRS1984

Mod II engine and technology development

The second-generation automotive Stirling engine, known as the Mod II, will be used to accomplish the Automotive Stirling Engine (ASE) Program objectives. Preliminary design has advanced to the point of procuring long-lead components to evaluate manufacturability. The heater head castings of the Hot Engine System (working gas cycle) are being procured, while the V-block casting of the Cold Engine/Drive system is being sectioned for evaluation. The technology required for these designs, and their impact on Mod II performance, have progressed to the design substantiation stage, and successful accomplishment of the program objectives is expected.

Ernst, W. D.↗
NASA NTRS1999

Monitoring and Modeling Astronaut Occupational Radiation Exposures in Space: Recent Advances

In 1982 astronauts were declared to be radiation workers by OSHA, and as such were subject to the rules and regulations applied to that group. NASA was already aware that space radiation was a hazard to crewmembers and had been studying and monitoring astronaut doses since 1962 at the Johnson Space Center. It was quickly realized NASA would not be able to accomplish all of its goals if the astronauts were subject to the ground based radiation worker limits, and thus received a waiver from OSHA to establish independent limits. As part of the stipulation attached to setting new limits, OSHA included a requirement to perform preflight dose projections for each crew and inform them of the associated risks. Additional requirements included measuring doses from various sources during the flight, making every effort to prevent a crewmember from exceeding the new limits, and keeping all exposures As Low As Reasonably Achievable (a.k.a. ALARA - a common health physics principle). The assembly of the International Space Station (ISS) and its initial manned operations will coincide with the 4-5 year period of high space weather activity at the next maximum in the solar cycle. For the first time in NASA's manned program, US astronauts will be in orbit continuously throughout a solar maximum period. During this period, crews are at risk of significantly increased radiation exposures due to solar particle events and trapped electron belt enhancements following geomagnetic storms. The problem of protecting crews is compounded by the difficulty of providing continuous real-time monitoring over a period of a decade in an era of tightly constrained budgets. In order to prepare for ISS radiological support needs, the NASA Space Radiation Analysis Group and the NOAA Space Environment Center have undertaken a multiyear effort to improve and automate ground-based space weather monitoring systems and real-time radiation analysis tools. These improvements include a coupled, automated space weather monitoring and alarm system--SPE exposure analysis system, an advanced space weather data distribution and display system, and a high-fidelity space weather simulation system. In addition, significant new real-time space weather data sets, which will enhance the forecasting and now-casting of near-Earth space environment conditions, are being made available through unique NASA-NOAA-USAF collaborations. These new data sets include coronal mass ejection monitoring by the Solar and Heliospheric Observatory (SOHO) and in-situ plasma and particle monitoring at the L1 libration point by the Solar Wind Monitor (SWIM) and Advanced Composition Explorer (ACE) spacecraft. Advanced real-time radiation monitoring data from charged particle telescopes and tissue equivalent proportional counters will also be available to assist crew and flight controllers in monitoring the external and intravehicular radiation environment.

Weyland, Mark↗
NASA NTRS1988

Infrared systems and components II; Proceedings of the Meeting, Los Angeles, CA, Jan. 14, 15, 1988

The present conference on the development status of IR electrooptics technologies discusses topics concerning such systems' materials and architectures, their modeling and data processing requirements, and advancements in IR automatic target recognition. Attention is given to active multispectral three-dimensional vision sensor image evaluation, a VHSIC processor-based real-time image tracker, the use of Al-alloy castings as diamond machining substrates for optical surfaces, a two-dimensional recognition range model, calculations of the optical blurring in IR systems, synthetic IR scene generation, and automatic target recognition evaluation.

Liaw, H. M.↗
NASA NTRS2008

Intelligent Engine Systems: Thermal Management and Advanced Cooling

The objective of the Advanced Turbine Cooling and Thermal Management program is to develop intelligent control and distribution methods for turbine cooling, while achieving a reduction in total cooling flow and assuring acceptable turbine component safety and reliability. The program also will develop embedded sensor technologies and cooling system models for real-time engine diagnostics and health management. Both active and passive control strategies will be investigated that include the capability of intelligent modulation of flow quantities, pressures, and temperatures both within the supply system and at the turbine component level. Thermal management system concepts were studied, with a goal of reducing HPT blade cooling air supply temperature. An assessment will be made of the use of this air by the active clearance control system as well. Turbine component cooling designs incorporating advanced, high-effectiveness cooling features, will be evaluated. Turbine cooling flow control concepts will be studied at the cooling system level and the component level. Specific cooling features or sub-elements of an advanced HPT blade cooling design will be downselected for core fabrication and casting demonstrations.

Bergholz, Robert↗
NASA NTRS1984

The movement of particles in liquid metals under gravity forces and the interaction of particles with advancing solid-liquid interface

The problems of shrinkage and gas porosity are discussed. Gravity forces enhance the removal of gas bubbles from a metal melt and contribute to the feeding of shrinkage porosity in castings. Experiments are reviewed which determine how large a density difference is required for metal particles to float or sink in a metal melt and to what extent do factors not considered in Stokes Law influence particle movement in a real system. As to the interaction of particles with an advancing solid-liquid interface, the results indicate that the metal particles are not rejected in a metal melt, and that concentrations of particles in a metal following solidification are due to other factors.

Weinberg, F.↗
NASA NTRS1994

Advanced diesel engine component development program, tasks 4-14

This report summarizes the Advanced Diesel Engine Component Development (ADECD) Program to develop and demonstrate critical technology needed to advance the heavy-duty low heat rejection engine concept. Major development activities reported are the design, analysis, and fabrication of monolithic ceramic components; vapor phase and solid film lubrication; electrohydraulic valve actuation; and high pressure common rail injection. An advanced single cylinder test bed was fabricated as a laboratory tool in studying these advanced technologies. This test bed simulates the reciprocator for a system having no cooling system, turbo compounding, Rankine bottoming cycle, common rail injection, and variable valve actuation to achieve fuel consumption of 160 g/kW-hr (.26 lb/hp-hr). The advanced concepts were successfully integrated into the test engine. All ceramic components met their functional and reliability requirements. The firedeck, cast-in-place ports, valves, valve guides, piston cap, and piston ring were made from silicon nitride. Breakthroughs required to implement a 'ceramic' engine included the fabrication of air-gap cylinder heads, elimination of compression gaskets, machining of ceramic valve seats within the ceramic firedeck, fabrication of cast-in-place ceramic port liners, implementation of vapor phase lubrication, and elimination of the engine coolant system. Silicon nitride valves were successfully developed to meet several production abuse test requirements and incorporated into the test bed with a ceramic valve guide and solid film lubrication. The ADECD cylinder head features ceramic port shields to increase insulation and exhaust energy recovery. The combustion chamber includes a ceramic firedeck and piston cap. The tribological challenge posed by top ring reversal temperatures of 550 C was met through the development of vapor phase lubrication using tricresyl phosphate at the ring-liner interface. A solenoid-controlled, variable valve actuation system that eliminated the conventional camshaft was demonstrated on the test bed. High pressure fuel injection via a common rail system was also developed to reduce particulate emissions.

Kaushal, Tony S.↗