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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 181 records · Page 10

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↗

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↗

Explosive Welding of Tubular Configurated Joints for Critical Applications

Explosive welding can provide the answer to problems of permanently joining metals typically used in the aerospace industry. The explosive bonding process is a solid state bonding process enabling material incompatibility problems associated with fusion welding to be overcome. In addition, heat affected zones are eliminated thus, enhancing joint strength, properties and performance. The process requires the parts being joined to be impelled, by means of explosives, to collide with each other. Certain critical collision parameters must be met and controlled and these parameters are defined. Various component geometries which satisfy the collision parameters are described. Examples of transition joints used in the aerospace industry are described and illustrated.

Hardwick, R.↗

Impact of thermal energy storage properties on solar dynamic space power conversion system mass

A 16 parameter solar concentrator/heat receiver mass model is used in conjunction with Stirling and Brayton Power Conversion System (PCS) performance and mass computer codes to determine the effect of thermal energy storage (TES) material property changes on overall PCS mass as a function of steady state electrical power output. Included in the PCS mass model are component masses as a function of thermal power for: concentrator, heat receiver, heat exchangers (source unless integral with heat receiver, heat sink, regenerator), heat engine units with optional parallel redundancy, power conditioning and control (PC and C), PC and C radiator, main radiator, and structure. Critical TES properties are: melting temperature, heat of fusion, density of the liquid phase, and the ratio of solid-to-liquid density. Preliminary results indicate that even though overalll system efficiency increases with TES melting temperature up to 1400 K for concentrator surface accuracies of 1 mrad or better, reductions in the overall system mass beyond that achievable with lithium fluoride (LiF) can be accomplished only if the heat of fusion is at least 800 kJ/kg and the liquid density is comparable to that of LiF (1880 kg/cu m.

Juhasz, Albert J.↗

Impact of thermal energy storage properties on solar dynamic space power conversion system mass

A 16 parameter solar concentrator/heat receiver mass model is used in conjunction with Stirling and Brayton Power Conversion System (PCS) performance and mass computer codes to determine the effect of thermal energy storage (TES) material property changes on overall PCS mass as a function of steady state electrical power output. Included in the PCS mass model are component masses as a function of thermal power for: concentrator, heat receiver, heat exchangers (source unless integral with heat receiver, heat sink, regenerator), heat engine units with optional parallel redundancy, power conditioning and control (PC and C), PC and C radiator, main radiator, and structure. Critical TES properties are: melting temperature, heat of fusion, density of the liquid phase, and the ratio of solid-to-liquid density. Preliminary results indicate that even though overall system efficiency increases with TES melting temperature up to 1400 K for concentrator surface accuracies of 1 mrad or better, reductions in the overall system mass beyond that achievable with lithium fluoride (LiF) can be accomplished only if the heat of fusion is at least 800 kJ/kg and the liquid density is comparable to that of LiF (1800 kg/cu m).

Juhasz, Albert J.↗

Ocean, Land and Meteorology Studies Using Space-Based Lidar Measurements

CALIPSO's main mission objective is studying the climate impact of clouds and aerosols in the atmosphere. CALIPSO also collects information about other components of the Earth's ecosystem, such as oceans and land. This paper introduces the physics concepts and presents preliminary results for the valueadded CALIPSO Earth system science products. These include ocean surface wind speeds, column atmospheric optical depths, ocean subsurface backscatter, land surface elevations, atmospheric temperature profiles, and A-train data fusion products.

Hu,Yongxiang↗

GEER Status Update

History: The Glenn Extreme Environments Rig (GEER) first became operational in the early part of 2015. Since that time GEER has completed a number of scientific tests and has undergone improvements in the chemical delivery system and analytics following a year of operations experience. Recent Updates: In June 2016, the GEER process system was rebuilt to provide a more robust system, higher accuracy and new capabilities. New insulation was installed on the exterior of the pressure vessel and gas lines. The newly revamped GEER plumbing system can provide extremely precise custom gas mixtures using any gas desired by the investigator in any combination. GEER can heat the resulting mixture up to 500 deg C and 1500 psia. The 304 stainless steel vessel walls were polished to reduce corrosion rate and reduce unwanted chemical reactions. The process lines were replaced with high purity Sulfinert coated tubing. The GEER team added the ability to individually boost specialty gases to GEER thus allowing operators to make very precise changes to the gas chemistry inside of GEER during a test while at high temperature and pressure. High accuracy mass flow meters were added to further improve gas mixing accuracy and precision. An in-line, integrated Inficon MicroGC Fusion was added for real time gas analysis along with a high purity gas sampling system, providing fully automated, real time analysis of the gas chemistry inside of GEER in minutes. This complements a co-located mass spectrometer and both are used for regular monitoring of the vessel chemistry. All internal vessel components were replaced with polished 304SS equivalents. Hot vent down capability was increased. Finally, an automated liquid injection system was added and is rated for max vessel operating conditions of (1500 psia, 500 C). Recent Results and Publications: In May 2016, GEER completed a test that exposed high temperature electronics to Venus surface conditions for 21.5 days. This demonstrated the potential for operating robotic spacecraft in the Venus environment without the need for thermal or environmental protection. Results from this test were published in December 2016 and received national media attention. In April 2017 GEER implemented an 80 day test at Venus surface conditions to simulate chemical weathering of expected Venus minerals. This test supported a ROSES award to a team led by Prof. Ralph Harvey of Case Western Reserve University. The test concluded in July 2017 and nearly doubled previous operation record of 42 days at Venus surface conditions. Preliminary results of these and previous experiments were presented at the recent Venus Modeling Workshop. In June 2017, NASA TM2017-219437 "Chemical and Microstructural Changes in Metallic and Ceramic Materials Exposed to Venusian Surface Conditions" was published. This report provides an extensive and valuable resource detailing the behavior of a variety of engineering materials at Venus surface conditions. Community Involvement: An external science advisory panel has been formed.

Kremic, Tibor↗

Development of a Data Fusion Methodology for Lineload Aerodynamic Databases for a Launch Vehicle during Liftoff and Transition

The need for databases for the distributed loading on launch vehicles during the early portion of flight necessitates the use of expensive computational flows in regimes where wake effects dominate. While also being expensive, this is a regime that computational tools tend to historically have problems simulating accurately. To help tackle this problem, a method of data fusion to combine computational results to wind tunnel derived force and moment data is developed. Using this method, significant reduction in computational costs and increases in confidence of the final product is possible and has been used to generate several databases for the Space Launch System (SLS) at NASA. While the full details of database generation are not part of this work, the crucial method at its core is developed here. Two SLS geometries are used throughout the work to demonstrate the techniques. These are two of the larger geometries and represent both planned crewed missions to the Moon as well as potential cargo missions to deep space. The method uses principal component analysis (PCA) to generate a reduced ordered model (ROM) to help fill in the full parameter space. Other similar techniques are explored, but were not found to have a significant result on the predictions of the ROM. Because the full number of components are kept to generate the model, this lack of difference is expected. This method is then extended to ensure that predicted surfaces match trusted force and moment data derived from wind tunnel testing. This extension is done by setting up a constrained optimization problem in order to minimize the deviation from the surface resolved computational data while still integrating to the desired values. When generating the constrained optimization problem, a weighting factor to balance these competing needs is introduced. The work compares previously introduced weighting terms from similar work to the proposed terms and shows that the previously used terms do not have as desirable behavior in this flow regime. This method is then expanded by developing a technique to incorporate uncertainty quantification into the developed data fusion methodology. This expansion takes a two pronged approach. One examines transferring the uncertainties in the force and moment database and characterizes how those adjustments change the predicted lineloads. The second looks at model form error and looks how rebuilding the model using slightly different data changes the predictions. These two terms are then combined in order to create an uncertainty model that takes both effects into account. The limitations of the proposed methods is then discussed as well as possible techniques to address these shortcomings.

Launch Vehicles↗

Maturation of Additive Manufactured Aerospace Alloys and Development of Mechanical and Thermophysical Properties for Space Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts have focused on the understanding of AM processes through design optimization, component fabrication, material characterization, testing, standards development, and infusion into propulsion development for flight applications. NASA and partners have matured commonly used aerospace alloys from various alloy families (Nickel, Steel, Iron, Aluminum, and Titanium) and AM processes. An extensive effort has been ongoing between NASA, industry partners, and academia to complete detailed AM process and heat treatment characterization, in addition to generating temperature-dependent mechanical and thermophysical properties. This presentation highlights the characterization and property results using laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes among various alloys. In addition to commonly used alloys, there is a need for ongoing AM optimized alloys using integrated computational materials engineering (ICME) and process development for high performance applications. The applications targeted are launch vehicles, liquid rocket engines, advanced propulsion systems, advanced power systems, and in-space propulsion with high heat fluxes, high pressure, and that utilize propellants such as hydrogen, which can degrade alloys. This presentation will also discuss some of the ongoing novel alloy development and maturation using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, and C-103. The results from these processes have demonstrated that AM can enable rapid development and new AM optimized alloys can yield higher performance. These alloys have undergone modeling, fundamental metallurgical evaluations, heat treatment studies, and microstructure characterization and mechanical testing campaigns. This, combined with direct application-specific component fabrication and hot-fire testing, can enable the increase of the Technology Readiness Level (TRL) through high duty-cycle testing. This presentation provides a background and overview of these various common and AM-enabled alloys and processing developments including the initial effort related to metallurgical, mechanical, and thermophysical property studies. It also covers the latest advancement in the parallel component development, hot-fire testing, and future developments for these alloys.

Additive Manufacturing↗

Geographic information system for fusion and analysis of high-resolution remote sensing and ground data

We seek to combine high-resolution remotely sensed data with models and ground truth measurements, in the context of a Geographical Information System (GIS), integrated with specialized image processing software. We will use this integrated system to analyze the data from two Case Studies, one at a boreal forest site, the other a tropical forest site. We will assess the information content of the different components of the data, determine the optimum data combinations to study biogeophysical changes in the forest, assess the best way to visualize the results, and validate the models for the forest response to different radar wavelengths/polarizations. During the 1990's, unprecedented amounts of high-resolution images from space of the Earth's surface will become available to the applications scientist from the LANDSAT/TM series, European and Japanese ERS-1 satellites, RADARSAT and SIR-C missions. When the Earth Observation Systems (EOS) program is operational, the amount of data available for a particular site can only increase. The interdisciplinary scientist, seeking to use data from various sensors to study his site of interest, may be faced with massive difficulties in manipulating such large data sets, assessing their information content, determining the optimum combinations of data to study a particular parameter, visualizing his results and validating his model of the surface. The techniques to deal with these problems are also needed to support the analysis of data from NASA's current program of Multi-sensor Airborne Campaigns, which will also generate large volumes of data. In the Case Studies outlined in this proposal, we will have somewhat unique data sets. For the Bonanza Creek Experimental Forest (Case 1) calibrated DC-8 SAR (Synthetic Aperture Radar) data and extensive ground truth measurement are already at our disposal. The data set shows documented evidence to temporal change. The Belize Forest Experiment (Case 2) will produce calibrated DC-8 SAR and AVIRIS data, together with extensive measurements on the tropical rain forest itself. The extreme range of these sites, one an Arctic forest, the other a tropical rain forest, has been deliberately chosen to find common problems which can lead to generalized observations and unique problems with data which raise issues for the EOS System.

Freeman, Anthony↗

Advancement of Extreme Environment Additively Manufactured Alloys for Next Generation Space Propulsion Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into propulsion development and flight applications. NASA matured commonly used aerospace alloys from various alloy families (Nickel, Copper, Stainless and Steel, Aluminum, and Titanium-based) through detailed AM process and heat treatment characterization, in addition to mechanical and thermophysical testing. While these alloys are actively used in many propulsion applications, there is a need for ongoing AM optimized alloys using integrated computational materials engineering (ICME) and process development for high performance applications. The applications targeted are liquid rocket engines; advanced propulsion systems; and in-space propulsion with high heat fluxes, high pressure, and/or that use propellants that can degrade alloys (e.g., hydrogen). This paper highlights the characterization and physical properties of the more common AM alloys using laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Additionally, this paper discusses some of the ongoing novel alloy development and maturation using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, GRX-810, and C-103. The results from these processes demonstrated that AM could enable rapid development and ongoing efforts for optimized alloys using ICME, yielding higher performances. These alloys have undergone modeling, fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing campaigns. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL) through high duty-cycle testing. A background and overview of these novel AM-enabled alloys and AM processing developments including metallurgical and mechanical property studies is presented here. The latest advancement in the parallel component development and hot-fire testing and future developments for these alloys is also discussed.

Additive Manufacturing↗

Synergism of He-3 acquisition with lunar base evolution

Researchers have discovered that the lunar surface contains a valuable fusion fuel element that is relatively scarce on Earth. This element, He-3, originates from the solar wind that has bombarded the surface of the Moon over geologic time. Mining operations to recover this resource would allow the by-product acquisition of hydrogen, water, carbon dioxide, carbon monoxide, methane, and nitrogen from the lunar surface with relatively minimal additional resource investment when compared to the costs to supply these resources from Earth. Two configurations for the He-3 mining system are discussed, and the impacts of these mining operations on a projected lunar base scenario are assessed. We conclude that the acquisition of He-3 is feasible with minimal advances in current state-of-the-art technologies and could support a terrestrial nuclear fusion power economy with the lowest hazard risk of any nuclear reaction known. Also, the availability of the by-products of He-3 acquisition from the Moon could significantly reduce the operational requirements of a lunar base and increase the commercialization potential of the base through consumable resupply of the lunar base itself, other components of the space infrastructure, and other space missions.

Crabb, T. M.↗

Geographic information system for fusion and analysis of high-resolution remote sensing and ground truth data

We seek to combine high-resolution remotely sensed data with models and ground truth measurements, in the context of a Geographical Information System, integrated with specialized image processing software. We will use this integrated system to analyze the data from two Case Studies, one at a bore Al forest site, the other a tropical forest site. We will assess the information content of the different components of the data, determine the optimum data combinations to study biogeophysical changes in the forest, assess the best way to visualize the results, and validate the models for the forest response to different radar wavelengths/polarizations. During the 1990's, unprecedented amounts of high-resolution images from space of the Earth's surface will become available to the applications scientist from the LANDSAT/TM series, European and Japanese ERS-1 satellites, RADARSAT and SIR-C missions. When the Earth Observation Systems (EOS) program is operational, the amount of data available for a particular site can only increase. The interdisciplinary scientist, seeking to use data from various sensors to study his site of interest, may be faced with massive difficulties in manipulating such large data sets, assessing their information content, determining the optimum combinations of data to study a particular parameter, visualizing his results and validating his model of the surface. The techniques to deal with these problems are also needed to support the analysis of data from NASA's current program of Multi-sensor Airborne Campaigns, which will also generate large volumes of data. In the Case Studies outlined in this proposal, we will have somewhat unique data sets. For the Bonanza Creek Experimental Forest (Case I) calibrated DC-8 SAR data and extensive ground truth measurement are already at our disposal. The data set shows documented evidence to temporal change. The Belize Forest Experiment (Case II) will produce calibrated DC-8 SAR and AVIRIS data, together with extensive measurements on the tropical rain forest itself. The extreme range of these sites, one an Arctic forest, the other a tropical rain forest, has been deliberately chosen to find common problems which can lead to generalized observations and unique problems with data which raise issues for the EOS System.

Freeman, Anthony↗

Simplified Explosive Joining of Tubes to Fittings

Technique simplifies tube-to-fitting joining, as compared to fusion welding, and provides improvement on standard procedures used to join tubes explosively to tube fittings. Special tool inserted into tube to be joined. Tool allows strip of ribbon explosive to be placed right at joint. Ribbon explosive and mild detonating fuse allows use of smaller charge. Assembled tool storable, and process amenable to automation. Assembly of components, insertion of tool into weld site, and joining operation mechanized without human contact. Used to assemble components in nuclear reactors or in other environments hostile to humans.

Bement, L. J.↗

Ground to Air Testing of a Fused Optical-Radar Aircraft Detection and Tracking System

Onboard detection and tracking capability are integral to the sensing component in collision avoidance systems needed to safely operate autonomous urban air taxis and small Unmanned Aircraft Systems. Ground-based validation of detection and tracking systems is an important milestone towards the end goal of real-time collision avoidance using onboard sensors and algorithms. In this work, we evaluate three Extended Kalman Filter(EKF)based fusion trackers with radar and vision detection inputs, and compare them with baseline trackers for each sensor type. Performance is assessed using field collected data of ground to air test flights with the sensors co-located on a stable platform with an instrumented multirotor acting as the intruder performing a waypoint pattern at a distance of1.1km to 0.3km to simulate a head-on collision geometry. Fusing an image-based morphological detector with a radar detector using an EKF covered 74% of the ground truth position updates logged by the flight controller on the multirotor within 50 meters after accounting for alignment offsets while covering 15% more ground truth updates relative to radar only. Removing timestamps when the intruder aircraft is occluded by trees and only considering timestamps where the radar has an update, the EKF image-based morphological detector combined with the radar detector covered 90% of the of the ground truth position updates within 50metersand 97% within 100 meters.

Chester V Dolph↗

Time-dependent outgassing and impurities in the NASA Lewis Bumpy Torus

To investigate the importance to fusion devices of desorption of gas from walls or cryosurfaces under long time operation, preliminary mass spectrometric investigations were carried out on the NASA Lewis Bumpy Torus with a 0.1-2A discharge in D2 at a pressure of 4.0 to 6.6 x 0.00001 torr. During the initial tens of minutes of discharge operation large quantities of a component with mass number 28, believed to be nitrogen, were released. The decrease with time of the nitrogen density after its initial maximum, indicated a diffusion controlled outgassing from cryodeposits or wall material. When cold surfaces were allowed to warm up, large quantities of gas were released. The integrated amount of N2 was typically the same as that released during a discharge, while the amount of H2O was orders of magnitude larger.

Persson, H.↗

ECI Final Report: Closing of Critical Technology Gaps for Rotating Detonation Rocket Engines

NASA has successfully fired several configurations of a dual regenerative 10K lbf class Rotating Detonation Rocket Engines using cryogenic liquid methane, liquid hydrogen, and RP-1 as fuel and liquid or gaseous oxygen as the oxidizer. In addition, 3 hot fire test phases were conducted to evaluate parametrically varying combustor geometries using a subscale 500-1K lbf class thruster RDRE. Several studies were successfully completed to evaluate the impacts of contraction ratio, annulus L’, heat transfer through calorimetry, and varying injector designs. Laser powder bed fusion GRCop-42, GRX-810, and C-103 alloys were used for the outer bodies, inner bodies, nozzles, and injector variations. The development of RDRE technology is only now possible with additive manufacturing techniques and these specialized alloys. Critical design parameters, design rules of thumb, and operability limitations have been identified. Major lessons learned in the development of critical components have also been documented. All critical technology gaps have been demonstrated at one scale or another and closed. A major finding of this work is that the combustion efficiency of the RDRE is far superior to that of the traditional liquid rocket engine requiring an order of magnitude lower chamber volume and residence time to react. Because of this, the design trade space opens up significantly. More compact chamber geometries are now possible with potential mass savings and significant length savings possible to flight geometries. In addition, the ceiling for the technology, in terms of Isp, has not yet been reached. It is likely that an additional ~10% better Isp over equivalent state-of-the-art combustion devices may be achieved over the next decade should the technology continue to be developed. This technology has been shown to be viable for near term infusion (2-5 years) into space missions and enable cost effective space access for US industry. This final report documents all major findings from this early career initiative (ECI) project and lays out what is needed post ECI.

Thomas Teasley↗

Real-Time Cognitive Computing Architecture for Data Fusion in a Dynamic Environment

A novel cognitive computing architecture is conceptualized for processing multiple channels of multi-modal sensory data streams simultaneously, and fusing the information in real time to generate intelligent reaction sequences. This unique architecture is capable of assimilating parallel data streams that could be analog, digital, synchronous/asynchronous, and could be programmed to act as a knowledge synthesizer and/or an "intelligent perception" processor. In this architecture, the bio-inspired models of visual pathway and olfactory receptor processing are combined as processing components, to achieve the composite function of "searching for a source of food while avoiding the predator." The architecture is particularly suited for scene analysis from visual data and odorant.

Duong, Tuan A.↗