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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 199 records · Page 11
All sourcesNASA NTRSDOE OSTI
NASA NTRS1993

Prospects for utilization of air liquefaction and enrichment system (ALES) propulsion in fully reusable launch vehicles

A concept is shown for a fully reusable, earth to orbit launch vehicle with horizontal takeoff and landing, employing an air-turborocket for low speed and a rocket for high speed acceleration, both using LH2 fuel. The turborocket employs a modified liquid air cycle to supply the oxidizer. The rocket uses 90 percent pure LOX that is collected from the atmosphere, separated, and stored during operation of the turborocket from about Mach 2 to Mach 5 or 6. The takeoff weight and the thrust required at takeoff are markedly reduced by collecting the rocket oxidizer in-flight. The paper shows an approach and the corresponding technology needs for using ALES propulsion in a SSTO vehicle. Reducing the trajectory altitude at the end of collection reduces the wing area and increases payload. The use of state-of-the-art materials, such as graphite polyimide, is critical to meet the structure weight objective for SSTO. Configurations that utilize 'waverider' aerodynamics show great promise to reduce the vehicle weight.

Bond, W. H.↗
NASA NTRS1985

Structures and materials technology issues for reusable launch vehicles

Projected space missions for both civil and defense needs require significant improvements in structures and materials technology for reusable launch vehicles: reductions in structural weight compared to the Space Shuttle Orbiter of up to 25% or more, a possible factor of 5 or more increase in mission life, increases in maximum use temperature of the external surface, reusable containment of cryogenic hydrogen and oxygen, significant reductions in operational costs, and possibly less lead time between technology readiness and initial operational capability. In addition, there is increasing interest in hypersonic airbreathing propulsion for launch and transmospheric vehicles, and such systems require regeneratively cooled structure. The technology issues are addressed, giving brief assessments of the state-of-the-art and proposed activities to meet the technology requirements in a timely manner.

Dixon, S. C.↗
NASA NTRS1985

Structures and materials technology issues for reusable launch vehicles

Projected space missions for both civil and defense needs require significant improvements in structures and materials technology for reusable launch vehicles: reductions in structural weight compared to the Space Shuttle Orbiter of up to 25 percent or more, a possible factor of 5 or more increase in mission life, increases in maximum use temperature of the external surface, reusable containment of cryogenic hydrogen and oxygen, significant reductions in operational costs, and possibly less lead time between technology readiness and initial operational capability. In addition, there is increasing interest in hypersonic airbreathing propulsion for launch and transmospheric vehicles, and such systems require regeneratively cooled structure. The technology issues are addressed, giving brief assessments of the state-of-the-art and proposed activities to meet the technology requirements in a timely manner.

Dixon, S. C.↗
NASA NTRS1992

Self-dual (48,24;12) codes

Two self-dual (48,24;12) codes are constructed as 6 x 8 matrices whose columns add up to form an extended BCH-Hamming (8,4;4) code and whose rows sum to odd or even parity. The codes constructed have the identical weight structure of the extended quadratic residue code of length 48. Algebraic isomorphisms may exist between pairs of these three codes. However, because of their matrix form, the newly constructed codes are easily correctable for all five-error and many six-error patterns. The first code comes from restricting a binary cyclic (63,18;36) code to a 6 x 7 matrix and then adjoining six dimensions to the extended 6 x 8 matrix. These six dimensions are generated by linear combinations of row permutations of a 6 x 8 matrix of weight 12, whose sums of rows and columns add to one. The second code comes from a slight modification in the parity (eighth) dimension of the Reed-Solomon (8,4;5) code over GF(64). Error correction in both codes uses the row sum parity information to detect errors in the correction algorithm.

Solomon, G.↗
NASA NTRS1990

The physiological cost of wearing the propellant handler's ensemble at the Kennedy Space Center

The potential for exposure to toxins used in the propulsion systems of spacecraft dictates the use of a whole body protective suit, the Propellant Handler's Ensemble (PHE) during preflight preparation and launching. The weight, structure, and operating parameters of the PHE may be expected to have a significant impact upon the metabolic, cardiovascular, and thermal responses of the user, especially during ambient temperature extremes and high workload situations. Four male subjects participated in tests in -7, 23, and 43 C (20, 74, and 110 F) environments in two versions of the PHE, the autonomous backpack (BP) and the hoseline (HL) supplied configuration. Measurements included heart rate (HR) rectal temperature, four skin temperatures, oxygen (O2), and carbon dioxide (CO2) in the helmet area, interior suit temperature, and suit pressure. Exercise metabolism was estimated from HR, PHE weight, and treadmill speed and grade. The HR responses between each PHE configuration were not statistically different. As a percentage of HR maximum, the mean values were 79 percent (COLD), 84 percent (LAB), and 90 percent (HOT). Helmet O2 and CO2 levels were correlated with percent HR max (P less than 0.001). Rectal temperatures were similar for each PHE configuration, except in the HOT exposure where the BP version exceeded the HL configuration (P less than 0.05). In nearly every instance the HR was driven to moderately high levels, the supplied respiratory gases were not optimum, and thermal adversity was a primary stressor. Our findings suggest that medical and physical fitness standards, along with operational restrictions, should be imposed upon PHE users to avoid situations that could adversely affect the worker.

Schonfeld, Brian R.↗
NASA NTRS1993

Nonlinear aerodynamics and the design of wing tips

This contract began in April 1990 with studies on the effect of wingtip shape on induced drag. That work considered problems of determining induced drag from computational aerodynamic methods and examined effects of wake roll up on the induced drag of elliptical and crescent wings. The research contract was continued in April 1991 and again in April 1992 with scope augmented to include considerations other than induced drag. The idea was to develop methods for comparing wing tip shapes on the basis of their effects on total drag, structural weight, and high lift performance. To accomplish this, work was done to improve methods for multidisciplinary analysis and optimization of wings. This report describes results of research conducted from April 1992 through March 1993. The general objective was to improve an existing wing optimization method and apply the method to specific problems of interest. The method, while a valuable tool for wing tip design studies, can be applied to more general problems, and has been applied to some of these other problems during its development. Specific goals that were accomplished are listed below and are explained in more detail in attached reports: analysis methods were improved in the area of structural modeling; small improvements to the high lift model were made, and ideas were collected on how clean wing c(sub l(sub max)) should vary with sweep - these ideas should provide a guide for future examination of high lift with experiment or CFD; and a calculation for drag due to the loss of leading edge suction was added to the wing analysis.

Kroo, Ilan↗
NASA NTRS1991

Application of a design-build-team approach to low cost and weight composite fuselage structure

Relationships between manufacturing costs and design details must be understood to promote the application of advanced composite technologies to transport fuselage structures. A team approach, integrating the disciplines responsible for aircraft structural design and manufacturing, was developed to perform cost and weight trade studies for a twenty-foot diameter aft fuselage section. Baseline composite design and manufacturing concepts were selected for large quadrant panels in crown, side, and keel areas of the fuselage section. The associated technical issues were also identified. Detailed evaluation of crown panels indicated the potential for large weight savings and costs competitive with aluminum technology in the 1995 timeframe. Different processes and material forms were selected for the various elements that comprise the fuselage structure. Additional cost and weight savings potential was estimated for future advancements.

Ilcewicz, L. B.↗
NASA NTRS2008

Aircraft System Analysis of Technology Benefits to Civil Transport Rotorcraft

An aircraft systems analysis was conducted to evaluate the net benefits of advanced technologies on two conceptual civil transport rotorcraft, to quantify the potential of future civil rotorcraft to become operationally viable and economically competitive, with the ultimate goal of alleviating congestion in our airways, runways and terminals. These questions are three of many that must be resolved for the successful introduction of civil transport rotorcraft: 1) Can civil transport rotorcraft actually relieve current airport congestion and improve overall air traffic and passenger throughput at busy hub airports? What is that operational scenario? 2) Can advanced technology make future civil rotorcraft economically competitive in scheduled passenger transport? What are those enabling technologies? 3) What level of investment is necessary to mature the key enabling technologies? This study addresses the first two questions, and several others, by applying a systems analysis approach to a broad spectrum of potential advanced technologies at a conceptual level of design. The method was to identify those advanced technologies that showed the most promise and to quantify their benefits to the design, development, production, and operation of future civil rotorcraft. Adjustments are made to sizing data by subject matter experts to reflect the introduction of new technologies that offer improved performance, reduced weight, reduced maintenance, or reduced cost. This study used projected benefits from new, advanced technologies, generally based on research results, analysis, or small-scale test data. The technologies are identified, categorized and quantified in the report. The net benefit of selected advanced technologies is quantified for two civil transport rotorcraft concepts, a Single Main Rotor Compound (SMRC) helicopter designed for 250 ktas cruise airspeed and a Civil Tilt Rotor (CTR) designed for 350 ktas cruise airspeed. A baseline design of each concept was sized for a representative civil passenger transport mission, using current technology. Individual advanced technologies are quantified and applied to resize the aircraft, thereby quantifying the net benefit of that technology to the rotorcraft. Estimates of development cost, production cost and operating and support costs are made with a commercial cost estimating program, calibrated to Boeing products with adjustments for future civil production processes. A cost metric of cash direct operating cost per available seat-mile (DOC ASM) is used to compare the cost benefit of the technologies. The same metric is used to compare results with turboprop operating costs. Reduced engine SFC was the most advantageous advanced technology for both rotorcraft concepts. Structural weight reduction was the second most beneficial technology, followed by advanced drive systems and then by technology for rotorcraft performance. Most of the technologies evaluated in this report should apply similarly to conventional helicopters. The implicit assumption is that resources will become available to mature the technologies for fullscale production aircraft. That assumption is certainly the weak link in any forecast of future possibilities. The analysis serves the purpose of identifying which technologies offer the most potential benefit, and thus the ones that should receive the highest priority for continued development. This study directly addressed the following NASA Subsonic Rotary Wing (SRW) subtopics: SR W.4.8.I.J Establish capability for rotorcraft system analysis and SRW. 4.8.I.4 Conduct limited technology benefit assessment on baseline rotorcraft configurations.

Wilkerson, Joseph B.↗
DOE OSTI2022

Extracting single fiber transverse and shear moduli from off-axis misalignment fiber tensile testing

Small diameter (<100 μm) fibers (e.g. carbon fibers, Kevlar, and fiberglass) and wires (e.g. ultrafine copper and aluminum wires) are frequently used in many different engineering applications, such as for light weighting structures, electromagnetic shielding for aircraft/infrastructure/EVs, vibration damping, biological sensors, aerospace electrical devices, and electric windings just to name a few. Due to the manufacturing process, the fibers and wires are pulled and stretched to produce a preferential alignment. Therefore, thin fibers and wires typically display different properties along the length of the fiber as opposed to their cross section and many fibers/wires are considered transversely isotropic. The axial properties of fibers/wires can be ascertained via tensile testing of single-filaments or fiber tows, but the radial properties require much more effort to measure. Knowing these properties is important for the accurate prediction of micromechanical models and manipulation of fibers during micromanufacturing. In this paper, a new technique was developed to determine the transverse/shear moduli and strength of a material by conducting tensile tests of the material at increasing misalignment angles from the tensile axis. Due to the transversely isotropic nature of the material, the transverse/shear moduli and strength influence the experimental results recorded by the test machine to different degrees based on the amount of misalignment in the test setup. An equation was derived to determine the influence of each of the material properties based on the misalignment angle by manipulating the stiffness matrix for transversely isotropic materials using the transformation matrices. Then, curve fitted coefficients were used to identify the material properties. Here, the strengths were similarly determined by curve fitting an off-axis Tsai-Hill failure criteria to determine the influence of transverse, shear, and tensile strengths based on the complex loading condition provided by the off-axis tensile test. Zoltek Panex 35 carbon fibers were used to demonstrate this new technique and the determined properties were then compared to those obtained from nanoindentation and from literature. Fracture surfaces provide insight into the different failure mechanisms at various misalignment angles.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Joining Light Metals with Polymer Composites Through Metal Overcasting

This work investigates a unique technique to join aluminum (Al) and magnesium (Mg) alloys to carbon fiber reinforced polymer (CFRP) composites without the use of adhesives or mechanical fasteners. The joints were made using an overcasting technique where the molten alloys were cast around the polymer composites using high pressure die casting method. Rapid cooling during casting allowed the composite to be embedded inside the cast metal without causing any gross damage to the former even though the molten metal temperature exceeded the melting point of the composite matrix by several 100’s of deg. C. The metal/composite interface was examined using optical microscopy and x-ray imaging and the joint strength was examined through tensile testing. Although evidence of polymer melting was evident in the x-ray images, the embedded section of the composite coupons retained their overall shape and integrity. Preliminary tension tests on Al/CFRP composites showed strength degradation of the CFRP and it failed near the metal/CFRP interface (outside the joint). Strength degradation in the CFRP suggests that the overcasting process needs further optimization to minimize thermal excursion in the CFRP. Nevertheless, the overcasting process shows great promise as a unique joining technique with application in fabricating light-weight structures for automotive and transportation industries.

overcasting, Casting, Mg Castings, Al Casting, Joi↗
DOE OSTI2023

Magnesium production by molten salt electrolysis with liquid tin cathode and multiple effect distillation

Low-cost clean primary production of magnesium metal is important for its use in many applications, from light-weight structural components to energy technologies. This work describes new experiments and cost and emissions analysis for a magnesium metal production process. The process combines molten salt electrolysis of MgO using MgF₂-CaF₂ electrolyte and a reactive liquid tin cathode, with gravity-driven multiple effect thermal system (G-METS) distillation to separate out the magnesium product, and re-use of the tin. Electrolysis experiments with carbon anodes showed current yield above 90%, while a yttria-stabilized zirconia solid oxide membrane (SOM) anode experiment showed 84% current yield. G-METS distillation is an important component of the envisioned process. It can potentially lower costs and energy use considerably compared with conventional magnesium distillation. Techno-economic analysis including detailed mass and energy balances shows that this electrolyte composition could lower costs by utilizing CaO, which is the primary impurity in MgO, as the Hall-Héroult process uses the sodium impurity in alumina. Analysis options include: raw material types (magnesite rock vs. brine or seawater), drying and calcining using electricity vs. natural gas, and carbon vs. SOM anode type. Using SOM inert anodes results in a cost premium around 10%–15%, mostly due to higher electrical energy usage resulting from membrane resistance, and reduces GHG emissions by approximately 1 kg CO₂/kg Mg product. Capital and operating cost estimates, and cradle to gate greenhouse gas (GHG) emissions analysis under several raw material and process technology scenarios, show comparable costs and emissions to those of aluminum production.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1966

Heat treatment stabilizes welded aluminum jigs and tool structures

Heat treatment processes, applied after welding but before machining, imparts above normal stability to welded aluminum jigs and tool structures. Weight saving will not be realized in these tools if rigidity equal to that of a comparable steel tool is required.

Mehnert, R. S.↗