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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

Feature Based Qualification of 17-4PH Stainless Steel to Evaluate Location-Specific Variability in Wire Arc Additive Manufacturing

Qualifying large-scale metal additive manufacturing (M-AM) technologies such as wire arc additive manufacturing (WAAM) can be challenging. This is especially significant in precipitation hardened martensitic stainless steels like SS 17-4PH, where thermal histories induce location-specific microstructural variability and property anisotropy. The Department of Defense (DOD) and the United States Army Combat Capabilities Development Command Ground Vehicle Systems Center (GVSC) Ground Vehicle Materials Engineering (GVME) aim to build robust and qualified large-scale M-AM workflows that could reduce the time and cost through quick and informed evaluation, testing, and development of feedstock, processes, and parts. The report presents the findings from the collaborative efforts between Oak Ridge National Laboratory (ORNL) and the U.S. Army GVSC GVME. The aim of this project was to develop a geometric feature-based qualification framework for WAAM of SS 17-4PH components. This report outlines selection methodology of representative build geometries, optimization of WAAM process parameters, in-situ monitoring, microstructure-property evaluation, thermal simulations, as well as data visualization techniques incorporated in this project. The results from this project demonstrate a clear understanding of thermal history dependent phase evolution and consequent location-specific property variations in WAAM of SS 17-4PH. These results in conjunction with the data-driven methodologies used in this project are expected to reduce qualification timelines, improve predictability, and accelerate the development of reliable feature-based qualification strategies for part production via large-scale M-AM technologies.

36 MATERIALS SCIENCE↗

NASA Progress on the Development and Qualification of a 12-kW Hall-Effect, Solar Electric Propulsion Thruster

I. Motivation and Background Beginning in 2014, the National Aeronautics and Space Administration (NASA) Space Technology Mission Directorate (STMD) began a project to increase the state of the art for the Hall-Effect Solar Electric Propulsion (SEP) technology. The resulting Advanced Electric Propulsion System (AEPS) project has developed a 12 kW Hall Current Thruster in support of the NASA mission to establish a permanent human presence in lunar orbit and to land the next American astronauts on the South Pole of the Moon. The project is led by the NASA Glenn Research Center, supported by the Jet Propulsion Laboratory and development, qualification & flight hardware all provided by L3 Harris Aerojet Rocketdyne (AR).The AEPS project has completed the development testing of a high power, solar electric propulsion Hall Current thruster that will be used on the NASA Power & Propulsion Element (PPE) of the Gateway space station. NASA initially built three Technology Development Units to understand key characteristics of the hall-effect rocket with magnetic shielding. The design led to development testing on two Engineering Test Unit Thrusters and multiple critical components. The project has begun production of the three flight thrusters and entered qualification testing at the component and thruster levels. II. Approach NASA and AR teams completed all development phases of the project, including full development and integration testing of the Engineering Model hardware, Critical Design Review, and ground test equipment validation, as well as fabrication and acceptance testing of the initial qualification thruster. Qualification and verification of the environmental and life requirements of the AEPS design was initiated in the Fall of 2023 and will be accomplished on two thruster units and using a series of component-level tests during 2024 and 2025. Environmental testing will incorporate functional reference firings, shock, vibration, and Thermal Vacuum (TVAC) testing. Life verification will assess the thruster wear and performance over the lifetime of the Gateway spacecraft. Critical component qualification tests include cathode heater, magnet coils, magnet heaters, temperature sensors, and a cathode assembly that will undergo life cycle testing on multiple units. Flight thrusters will complete assembly and acceptance testing and be delivered to the PPE program in early 2025. III. Preliminary and Anticipated Results The program has completed the acceptance testing, including dynamic testing and hot fire characterization, of the first qualification thruster. In the Fall of 2023, the program entered the environmental qualification phase for thruster testing. This paper will present an overview of the AEPS thruster project, thruster capabilities and flight design, preliminary results from the thruster acceptance and qualification testing, component life cycle testing and flight hardware status.

Clayton Kachele↗

Computational Materials for Qualification and Certification of Process-Intensive Metallic Materials (CM4QC)

NASA and the FAA established the Computational Materials (CM) for Qualification and Certification (Q&C) steering group comprised of representatives from industry, government regulatory and research organizations, and academia with the following goals: - Inform the research and development investments made by U.S. industry and the U.S. government toward maturation of CM-based approaches for Qualification and Certification (Q&C) of process intensive metallic materials (PIM) including additive manufacturing. - Identify key considerations and enablers required to increase airworthiness / certifying authorities’ acceptance of CM methods use for Q&C of structural or flight-critical parts produced with PIM technologies. - Identify key CM technology gaps and maturation paths (in the context of Q&C applications). - Increase dialogue among stakeholder organizations. This presentation will summarize the technology and regulatory considerations that motivate this national effort, discuss progress and provide a summary and status of a multi-year roadmap that is being developed to guide technology development in this important area.

Computational Materials↗

Apollo experience report: Power generation system

A comprehensive review of the design philosophy and experience of the Apollo electrical power generation system is presented. The review of the system covers a period of 8 years, from conception through the Apollo 12 lunar-landing mission. The program progressed from the definition phase to hardware design, system development and qualification, and, ultimately, to the flight phase. Several problems were encountered; however, a technology evolved that enabled resolution of the problems and resulted in a fully manrated power generation system. These problems are defined and examined, and the corrective action taken is discussed. Several recommendations are made to preclude similar occurrences and to provide a more reliable fuel-cell power system.

Bell, D., III↗

Mini-BRU/BIPS 1300 watt (sub)e dynamic power conversion system development: Executive summary

The status of the Brayton Isotope Power System (BIPS) is summarized. A 1200 watt sub e ground development unit was built and tested in a 0.000010 torr vacuum environment. Peformance mapping and 1000 hours of proof of concept system testing were completed. Specific components, primarily turbocompressor/alternator and recuperator performed according to predictions, thus achieving the design goal of 25 percent net power conversion efficiency. The system was fabricated from superalloy (Hastelloy-X and Waspaloy) thus placing it entirely within current state-of-the-art technology. The system could be flyable in the early 1980's pending flight qualification.

Source record↗

High efficiency solar panel /HESP/

A family of high efficiency, weldable silicon solar cells, incorporating nearly every feature of advanced cell technology developed in the past four years, was produced and subjected to space qualification testing. This matrix contained both field and non-field cells ranging in thickness from 0.10 mm to 0.30 mm, and in base resistivity from nominal two to one hundred ohm-cm. Initial power outputs as high as 20 mW/sq cm (14.8% AM0 efficiency) were produced by certain cell types within the matrix.

Stella, P. M.↗

ROSA and Solar Cell Module Combined Environments Test Plan

Roll-out solar array (ROSA) technology is an emerging component of the future of spacecraft photovoltaic power subsystems. Qualification and risk reduction testing are necessary to demonstrate design worthiness for spaceflight implementation of the array and solar cell modules. Maxar Space LLC and NASA have undertaken a rigorous combined environment (CE) test campaign for a ROSA design expected to be a part of the Power and Propulsion Element (PPE) for the NASA Gateway which will be an outpost orbiting the Moon. The CE tests consist of several simulated space environment exposures associated with the planned mission: UV radiation, electron/proton radiation, xenon ion plume exposures, and vacuum thermal cycling and electrostatic discharge (ESD). These tests are conducted on small coupons consisting of the planned ROSA flight elements, and all tests are performed at the NASA Marshall Space Flight Center. This paper discusses the test plan, requirements for each environment, and the functional testing performed. Of note is a new approach for the induced primary arc used in the ESD testing, which better simulates the plasma expansion during the ESD event. Progress on executing the test plan is presented.

Space Environments Effects Testing↗

High Temperature Testing of Refractory Alloys

- NASA Refractory Alloy Projects: - STMD-GRC – Refractory Alloy Additive Manufacturing Build Optimization (RAAMBO) - Hypersonic Technology (HTP) Project. - Advance material characterization and prototypic testing allowing for critical data needed to demonstrate TRL advancement and for component flight qualification - Enable national supply chain for refractory alloy feedstock essential for production of historical to custom alloys for R&D to component fabrication. - Develop materials and processing for high performance in extreme environments enabling technologies for Moon to Mars missions.

Justin L. Milner↗

Space shuttle electrical power generation and reactant supply system

The design philosophy and development experience of fuel cell power generation and cryogenic reactant supply systems are reviewed, beginning with the state of technology at the conclusion of the Apollo Program. Technology advancements span a period of 10 years from initial definition phase to the most recent space transportation system (STS) flights. The development program encompassed prototype, verification, and qualification hardware, as well as post-STS-1 design improvements. Focus is on the problems encountered, the scientific and engineering approaches employed to meet the technological challenges, and the results obtained. Major technology barriers are discussed, and the evolving technology development paths are traced from their conceptual beginnings to the fully man-rated systems which are now an integral part of the shuttle vehicle.

Simon, W. E.↗

NASA Aerospace Flight Battery Program: Generic Safety, Handling and Qualification Guidelines for Lithium-Ion (Li-Ion) Batteries; Availability of Source Materials for Lithium-Ion (Li-Ion) Batteries; Maintaining Technical Communications Related to Aerospace Batteries (NASA Aerospace Battery Workshop)

This NASA Aerospace Flight Battery Systems Working Group was chartered within the NASA Engineering and Safety Center (NESC). The Battery Working Group was tasked to complete tasks and to propose proactive work to address battery related, agency-wide issues on an annual basis. In its first year of operation, this proactive program addressed various aspects of the validation and verification of aerospace battery systems for NASA missions. Studies were performed, issues were discussed and in many cases, test programs were executed to generate recommendations and guidelines to reduce risk associated with various aspects of implementing battery technology in the aerospace industry. This document contains Part 1 - Volume I: Generic Safety, Handling and Qualification Guidelines for Lithium-Ion (Li-Ion) Batteries, Availability of Source Materials for Lithium-Ion (Li-Ion) Batteries, and Maintaining Technical Communications Related to Aerospace Batteries (NASA Aerospace Battery Workshop).

Manzo, Michelle A.↗

Thermal Protection Materials Technology for NASA's Exploration Systems Mission Directorate

To fulfill the President s Vision for Space Exploration - successful human and robotic missions between the Earth and other solar system bodies in order to explore their atmospheres and surfaces - NASA must reduce trip time, cost, and vehicle weight so that payload and scientific experiment capabilities are maximized. As a collaboration among NASA Centers, this project will generate products that will enable greater fidelity in mission/vehicle design trade studies, support risk reduction for material selections, assist in optimization of vehicle weights, and provide the material and process templates for development of human-rated qualification and certification Thermal Protection System (TPS) plans. Missions performing aerocapture, aerobraking, or direct aeroentry rely on technologies that reduce vehicle weight by minimizing the need for propellant. These missions use the destination planet s atmosphere to slow the spacecraft. Such mission profiles induce heating environments on the spacecraft that demand thermal protection heatshields. This program offers NASA essential advanced thermal management technologies needed to develop new lightweight nonmetallic TPS materials for critical thermal protection heatshields for future spacecraft. Discussion of this new program (a December 2004 new start) will include both initial progress made and a presentation of the work to be preformed over the four-year life of the program. Additionally, the relevant missions and environments expected for Exploration Systems vehicles will be presented, along with discussion of the candidate materials to be considered and of the types of testing to be performed (material property tests, space environmental effects tests, and Earth and Mars gases arc jet tests).

Valentine, Peter G.↗

Environmental Degradation in Advanced Reactor Environments

The Advanced Materials and Manufacturing Technologies (AMMT) program operating under the Department of Energy Office of Nuclear Energy is accelerating the qualification and deployment of additively manufactured materials in advanced reactor environments. Laser powder bed fusion (LPBF) has emerged as a promising additive manufacturing technique to fabricate complex components with the potential of tailored material properties. In the nuclear industry, metal additive manufacturing can offer numerous advantages, such as reduced lead times, streamlined quality assurance, and cost-effective low-volume production of new and replacement components with conventional or novel materials and geometries. The rapid and effective qualification of the effect of processing variability on the performance and degradation of additively manufactured materials is essential for the deployment of these components into advanced reactor environments. This talk presents an overview of the Environmental Effects area activities within AMMT. AMMT is performing irradiation and corrosion testing of several materials built by LPBF, including 316L and 316H stainless steels. Our irradiation efforts encompass neutron irradiation testing and ion irradiation testing to provide a robust technical basis for understanding the effect of process variability on materials degradation. We develop focused irradiation test plans that align well with risk-informed and technologically inclusive approaches to licensing. We will also discuss our plans and specific concerns for corrosion testing additively manufactured material, with a primary focus on molten salt and liquid sodium environments.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Affordable Development and Qualification Strategy for Nuclear Thermal Propulsion

A number of recent assessments have confirmed the results of several earlier studies that Nuclear Thermal Propulsion (NTP) is a leading technology for human exploration of Mars. It is generally acknowledged that NTP provides the best prospects for the transportation of humans to Mars in the 2030's. Its high Isp coupled with the high thrusts achievable, allow reasonable trip times, thereby alleviating concerns about space radiation and "claustrophobia" effects. NASA has embarked on the latest phase of the development of NTP systems, and is adopting an affordable approach in response to the pressure of the times. The affordable strategy is built on maximizing the use of the large NTP technology base developed in the 1950's and 60's. The fact that the NTP engines were actually demonstrated to work as planned, is a great risk reduction feature in its development. The strategy utilizes non-nuclear testing to the fullest extent possible, and uses focused nuclear tests for the essential qualification and certification tests. The perceived cost risk of conducting the ground tests is being addressed by considering novel testing approaches. This includes the use of boreholes to contain radioactive effluents, and use of fuel with very high retention capability for fission products. The use of prototype flight tests is being considered as final steps in the development prior to undertaking human flight missions. In addition to the technical issues, plans are being prepared to address the institutional and political issues that need to be considered in this major venture. While the development and deployment of NTP system is not expected to be cheap, the value of the system will be very high, and amortized over the many missions that it enables and enhances, the imputed costs will be very reasonable. Using the approach outlined, NASA and its partners, currently the DOE, and subsequently industry, have a good chance of creating a sustained development program leading to human missions to Mars within the next few decades.

Gerrish, Harold P., Jr.↗

NEXT Ion Propulsion System Development Status and Performance

NASA s Evolutionary Xenon Thruster (NEXT) project is developing next generation ion propulsion technologies to provide future NASA science missions with enhanced mission performance benefit at a low total development cost. The objective of the NEXT project is to advance next generation ion propulsion technology by producing engineering model and prototype model system components, validating these through qualification-level and integrated system testing, and ensuring preparedness for transitioning to flight system development. This paper describes the NEXT ion propulsion system development status, characteristics and performance. A review of mission analyses results conducted to date using the NEXT system is also provided.

Patterson, Michael J.↗

NASA's Certification and Qualification Challenges for Additively Manufactured Hardware: What Is Next?

In 2021, NASA released NASA-STD-6030 “Additive Manufacturing Requirements for Spaceflight Systems” to create qualification and certification strategies for mature metallic and non-metallic AM materials and technologies. While these standards have had an immediate impact on the additive manufacturing (AM) industry, there remain many challenges that have yet to be overcome. NASA and its partners in academia and industry are working together to proactively address these issues. One of the most critical needs is a Probabilistic Damage Tolerance Assessment (PDTA) approach, which includes the development of computational modeling, understanding the “effect of defects”, and the implementation of in-situ process monitoring and inspection techniques.

Will Tilson↗

22 N HPGP Thruster Life Testing

In the ever-changing paradigm of efficient and capable spacecraft design, scientific missions continue pushing the envelope enabling spacecraft subsystems to deliver effective solutions to meet challenging new mission/spacecraft needs. From an in-space storable liquid chemical propulsion perspective, monopropellant hydrazine has been, and continues to be, a dependable propellant with considerable flight heritage, a variety of engine thrust classes available from multiple vendors, with repeatable and reliable performance. Additionally, the space propulsion industry has learned to successfully handle hydrazine, its regulations, the safety protocols, the personnel protective equipment, and the unique training standards–all requisite for loading spacecraft propulsion systems with toxic hypergolic hydrazine. The question now arises as to “what is next for in-space chemical propulsion?” Further, with the evolution and concrete advancements in innovative in-space green propellant technologies, capable of providing realizable benefits to scientific missions, concern over the reliability and availability of this higher performing and safer to handle class of propellants is waning. As science missions move forward with the potential flight in fusion of High Performance Green Propulsion (HPGP), NASA and its industry partners are working to address any gaps in system reliability, performance, or unique operational considerations. Propellant technology that offers both higher performance and significant reduction in personnel hazards compared to hydrazine presents an attractive propulsion subsystem design opportunity. Increased propulsion subsystem performance can result in lower spacecraft launch mass, larger scientific payloads, or extended on-orbit lifetimes. Mission trades using green propulsion technologies have been documented on multiple NASA Goddard Space Flight Center (GSFC) mission classes, examining various parameters and requirements to support mission architectures in Low Earth Orbit (LEO), High Earth Orbit (HEO), geostationary, lunar, planetary, and Quasi-halo orbit around Sun-Earth Lagrange point (L2). The results of these trade studies show promising, attainable benefits. The perceived programmatic risk of flying a newer propulsion technology has, unfortunately, not outweighed the benefits to date. To take advantage of the improved performance and mitigate programmatic risk, HPGP engines must demonstrate life testing at higher propellant throughputs than have currently been demonstrated. In an effort to proactively address the challenges with technology infusion into a risk-averse community, NASA and the Swedish National Space Agency (SNSA) outlined a collaborative Implementing Arrangement (IA) for the respective agencies to pursue increased HPGP technology maturation. This initial IA effort began in 2013, fresh off the heels of the successful PRISMA HPGP technology demonstration mission. The IA targeted objective is to reduce risk to potential future HPGP missions and fully characterize the LMP-103S propellant and associated engine performance. Over the past eight years, HPGP has flown in propulsion systems on twenty-five(25) spacecraft from seven(7) different Launch Ranges around the globe and on seven (7) different Launch Vehicles. Six(6) of these launches involved multiple loading operations for multiple spacecraft. For U.S. Range operations, nine (9) HPGP systems have been processed at Vandenberg Space Force Base(VSFB):six(6) in 2017, and three (3) in 2018. Six (6) more have been processed at Cape Canaveral Air Force Station (CCAFS)in May 2020, with three (3) systems launched in June 2020 and the remaining three (3) system were left loaded and ready until their launch in August of 2020. Three (3) more systems have been processed at Wallops Flight Facility(WFF)and launched in June 2021. In addition, these propulsion subsystems employed heritage propulsion subsystem component such as valves, filters, and pressure transducers, and have further demonstrated nominal functionality in both diaphragm and Propellant Management Device (PDM) propellant tanks. Based on these successes, HPGP technology continues to be considered for NASA Science Mission Directorate missions at GSFC. The work presented herein represents many years of development and collaborative efforts to successfully align higher performance, low toxicity hydrazine alternatives into scientific missions. NASA GSFC Propulsion Engineering, in collaboration with Bradford ECAPS, has developed mission specific thruster design and testing requirements to establish GSFC’s desired test conditions and firing sequences.In2017, the first flight-like 22N HPGP thruster Engineering Qualification Model (EQM-1)was designed and built by Bradford ECAPS to prove out the thruster design, materials, build process, and test campaign with respect to NASA GSFC critical component and mission requirements. This test program was developed to comprehensively test the thruster, the technology, and ultimately increase the 22N HPGP Technology Readiness Level(TRL). EQM-1was tested to environmental qualification levels prior to hot fire performance testing to represent the relevant end-to-end environment (launch to on-orbit operation)with required margin. This thruster demonstrated steady-state and pulse mode operational capability with propellant thruster throughput up to~53kg.At this throughput level, the EQM-1 engine began to present off-nominal performance and the test campaign was halted to allow for non-destructive testing and identify the root cause for the an omalous performance. Capitalizing on the successful elements of the EQM-1 campaign, an upgraded 22N HPGP EQM-2 has been manufactured by Bradford ECAPS to meet the complete GSFC requirements. The EQM-2 thruster’s test campaign has further demonstrated the robustness of the HPGP propulsion technology and increased the Technology Readiness Level (TRL) by undergoing a full acceptance test program, then proceeding into qualification, including environmental testing (vibration and shock to qualification levels),as well as hot-fire life testing, operating at steady-state and pulse modes with increased propellant thruster throughput to~150kg. The HPGP thruster performance testing enables effective HPGP thruster readiness evaluation to meet NASA candidate mission requirements in the future.

High↗

Thermal Management Design for the X-33 Lifting Body

The X-33 Advantage Technology Demonstrator offers a rare and exciting opportunity in Thermal Protection System development. The experimental program incorporates the latest design innovation in re-useable, low life cycle cost, and highly dependable Thermal Protection materials and constructions into both ground based and flight test vehicle validations. The unique attributes of the X-33 demonstrator for design application validation for the full scale Reusable Launch Vehicle, (RLV), are represented by both the configuration of the stand-off aeroshell, and the extreme exposures of sub-orbital hypersonic re-entry simulation. There are several challenges of producing a sub-orbital prototype demonstrator of Single Stage to Orbit/Reusable Launch Vehicle (SSTO/RLV) operations. An aggressive schedule with budgetary constraints precludes the opportunity for an extensive verification and qualification program of vehicle flight hardware. However, taking advantage of off the shelf components with proven technologies reduces some of the requirements for additional testing. The effects of scale on thermal heating rates must also be taken into account during trajectory design and analysis. Described in this document are the unique Thermal Protection System (TPS) design opportunities that are available with the lifting body configuration of the X-33. The two principal objectives for the TPS are to shield the primary airframe structure from excessive thermal loads and to provide an aerodynamic mold line surface. With the relatively benign aeroheating capability of the lifting body, an integrated stand-off aeroshell design with minimal weight and reduced procurement and operational costs is allowed. This paper summarizes the design objectives of the X-33 TPS, the flight test requirements driven configuration, and design benefits. Comparisons are made of the X-33 flight profiles and Space Shuttle Orbiter, and lifting body Reusable Launch Vehicle aerothermal environments. The X-33 TPS is based on a design to cost configuration concept. Only RLV critical technologies are verified to conform to cost and schedule restrictions. The one-off prototype vehicle configuration has evolved to minimize the tooling costs by reducing the number of unique components. Low cost approaches such as a composite/blanket leeward aeroshell and the use of Shuttle technology are implemented where applicable. The success of the X-33 will overcome the ballistic re-entry TPS mindset. The X-33 TPS is tailored to an aircraft type mission while maintaining sufficient operational margins. The flight test program for the X-33 will demonstrate that TPS for the RLV is not simply a surface insulation but rather an integrated aeroshell system.

Bouslog, S.↗

Space station propulsion system trade study

This study evaluates alternative space station propulsion system options for a range of space station configurational and operational architectures. Space station propulsion requirements ranging from those representative of the first generation space station to those of an advanced space station with a space based OTV are considered. A methodology for comparing the candidate propulsion technologies is developed which considers design/development/qualification and operational costs, system mass, performance, reliability, and other relevant parameters. Advanced propulsion systems are shown to reduce space station costs by providing higher performance but to require a larger front end investment for development and qualification. This study indicates that if the full potential of such systems is to be realized, then low cost implementations of this technology must be developed.

Garrison, P. W.↗