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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 217 records · Page 12
All sourcesNASA NTRSDOE OSTI
NASA NTRS2014

Tidal Heating in Multilayered Terrestrial Exoplanets

The internal pattern and overall magnitude of tidal heating for spin-synchronous terrestrial exoplanets from 1 to 2.5 R(sub E) is investigated using a propagator matrix method for a variety of layer structures. Particular attention is paid to ice-silicate hybrid super-Earths, where a significant ice mantle is modeled to rest atop an iron-silicate core, and may or may not contain a liquid water ocean. We find multilayer modeling often increases tidal dissipation relative to a homogeneous model, across multiple orbital periods, due to the ability to include smaller volume low viscosity regions, and the added flexure allowed by liquid layers. Gradations in parameters with depth are explored, such as allowed by the Preliminary Earth Reference Model. For ice-silicate hybrid worlds, dramatically greater dissipation is possible beyond the case of a silicate mantle only, allowing non-negligible tidal activity to extend to greater orbital periods than previously predicted. Surface patterns of tidal heating are found to potentially be useful for distinguishing internal structure. The influence of ice mantle depth and water ocean size and position are shown for a range of forcing frequencies. Rates of orbital circularization are found to be 10-100 times faster than standard predictions for Earth-analog planets when interiors are moderately warmer than the modern Earth, as well as for a diverse range of ice-silicate hybrid super-Earths. Circularization rates are shown to be significantly longer for planets with layers equivalent to an ocean-free modern Earth, as well as for planets with high fractions of either ice or silicate melting.

celestial mechanics↗
NASA NTRS2013

Tools for Asteroid Regolith Operations

This RFI response is targeting Area 5. Crew Systems for Asteroid Exploration: concepts for lightweight and low volume robotic and extra-vehicular activity (EVA) systems, such as space suits, tools, translation aids, stowage containers, and other equipment.The NASA KSC Surface Systems Office, Granular Mechanics and Regolith Operations (GMRO) Lab and the Electrostatics Surface Physics Lab (ESPL) are dedicated to developing technologies for operating in regolith environments on target body surfaces. We have identified two technologies in our current portfolio that are highly relevant and useful for crews that will visit a re-directed asteroid in Cis-Lunar Space. Both technologies are at a high TRL of 56 and could be rapidly implemented in time for an ARM mission in this decade.

Mueller, Robert P.↗
NASA NTRS2015

Remotely Controlled Mixers for Light Microscopy Module (LMM) Colloid Samples

Developed by NASA Glenn Research Center, the LMM aboard the International Space Station (ISS) is enabling multiple biomedical science experiments. Techshot, Inc., has developed a series of colloid specialty cell systems (C-SPECS) for use in the colloid science experiment module on the LMM. These low-volume mixing devices will enable uniform particle density and remotely controlled repetition of LMM colloid experiments. By automating the experiment process, C-SPECS allow colloid samples to be processed more quickly. In addition, C-SPECS will minimize the time the crew will need to spend on colloid experiments as well as eliminate the need for multiple and costly colloid samples, which are expended after a single examination. This high-throughput capability will lead to more efficient and productive use of the LMM. As commercial launch vehicles begin routine visits to the ISS, C-SPECS could become a significant means to process larger quantities of high-value materials for commercial customers.

Kurk, Michael A. (Andy)↗
NASA NTRS2016

Rapid Application of Space Effects for the Small Satellites Systems and Services Symposium

NASA Ames Research Center (ARC) has engaged Military Branches, the Department of Defense, and other Government Agencies in successful partnerships to design, develop, deliver and support various space effects capabilities and space vehicles on timeline of need. Contracts with Industry are in place to execute operational and enabler missions using physical and informational infrastructures including Responsive Manufacturing capabilities and Digital Assurance. The intent is to establish a secure, web-enabled "store front" for ordering and delivering any capabilities required as defined by the users and directed by NASA ARC and Partner Organizations. The capabilities are envisioned to cover a broad range and include 6U CubeSats, 50-100 kg Space Vehicles, Modular Space Vehicle architecture variations, as well as rapid payload integration on various Bus options. The paper will discuss the efforts underway to demonstrate autonomous manufacturing of low-volume, high-value assets, to validate the ability of autonomous digital techniques to provide Mission Assurance, and to demonstrate cost savings through the identification, characterization, and utilization of Responsive Space components. The culmination of this effort will be the integration of several 6U satellites and their launch in 2016.

Small Satellite Systems↗
NASA NTRS2019

Cracking Problems in Low-Voltage Chip Ceramic Capacitors

Cracking remains the major reason of failures in multilayer ceramic capacitors (MLCCs) used in in space electronics. Due to a tight quality control of space-grade components, the probability that as manufactured capacitors have cracks is relatively low, and cracking is often occurs during assembly, handling and the following testing of the systems. Majority of capacitors with cracks are revealed during the integration and testing period, but although extremely rarely, defective parts remain undetected and result in failures during the mission. This situation is aggravated by manual soldering and rework that are often used during low volume production of circuit boards for space. Although failures of MLCCs are often attributed to the post-manufacturing stresses, in many cases they are due to a combination of certain deviations in the manufacturing processes that result in hidden defects in the parts and excessive stresses during assembly and use. This report gives an overview of design, manufacturing and testing processes of MLCCs focusing on elements related to cracking problems. The existing and new screening and qualification procedures and techniques are briefly described and assessed by their effectiveness in revealing cracks. The capability of different test methods to simulate stresses resulting in cracking, mechanisms of failures in capacitors with cracks, and possible methods of selecting the most robust to manual soldering stresses capacitors are discussed.

testing↗
NASA NTRSDate not supplied

Next Generation Durability and Damage Tolerance to Support Certification of Flight Hardware

Durability and Damage Tolerance (D&DT), as currently applied to flight hardware throughout the Agency, is based on continuum and similitude assumptions and does not consider local material properties, environments and responses. These limitations impact our ability to support certification of new component designs, material systems and manufacturing approaches. The primary concern in this Engineering R&A plan is related to the imminent proliferation of parts produced by additive manufacturing (AM). These parts are being advocated by NASA’s suppliers for use on a myriad of flight hardware because of their design flexibility and cost advantages. AM provides opportunities to reduce part counts through complex geometry and reduce manufacturing costs of low volume parts. However, AM materials have some notable metallurgical and microstructural differences compared to traditionally fabricated materials. One of the challenges for the acceptance of AM is the greater tendency for a deleterious defect state, most commonly in the form of porosity, to exist in AM parts. Though this defect state is typically reduced through a hot isostatic pressing (HIP) processing step, the structural performance risks associated with the remaining defects and HIP-healed features is not known. Potential fracture control issues that must be resolved stem from the real possibility that an unhealed defect or a closed defect with less than pristine strength remains at a fracture critical location after HIP. As a result, NASA and the entire aerospace community have been confronted with the need to develop a robust and relevant certification methodology to enable safe implementation of these components. The present work is an important step toward positioning NASA to credibly respond to vendors’ push to implement this new AM materials technology by improving our understanding of AM processing and performance and transitioning that research-based understanding to next-generation engineering capabilities.

Edward H Glaessgen↗
NASA NTRSDate not supplied

Contracting Quality Early in the Lifecycle Using AS9145 Data Deliverables

Development schedules and a highly dynamic supply chain are a challenge to developers of complex systems produced at low volume. Flaws in designs, parts and materials availability problems, poor manufacturability, and a lack of knowledge about critical items and key process attributes can be realized well before traditional second-party quality assurance activities begin. Supplier audits and product inspections may have little mitigating effect once these foundational problems have been realized. Their impacts can be significant lifecycle disruption, cost overruns, inability to deliver to plan, and even project cancellation. AS9145, Requirements for Advanced Product Quality Planning and Production Part Approval Process, can be used to drive quality engineering practices into early development lifecycles to significantly reduce this late-cycle risk and to reduce the cost of quality overall. Since its initial publication in 2016, it has had very limited adoption by the DoD, no adoption by NASA, and sparse adoption in the aerospace and defense supply chain. A task group within the Aerospace Industries Association's (AIA) Joint Strategic Quality Council (JSQC) identified that both acquirers and suppliers see as AS9145 as a cost-adder and are hesitant to use it as an alternative to late-stage-heavy quality assurance approaches. A lack of prior use creates large capability gaps in request-for-proposal (RFP) teams, proposal teams, suppliers’ quality management systems (QMS), and in experienced personnel executing the early lifecycle approach. To create a more realizable on-ramp for using AS9145 in the space and defense sectors, the AIA JSQC task team created five deliverable requirements descriptions (DRDs) that can be used in a contract to begin to engage both parties in early lifecycle quality engineering and quality assurance activities, that reduce exposure to late-stage cost and schedule collapse due to unidentified risks in design, supply chain, and manufacturability. These DRDs drive the parties to engage in planning and analysis discussions early on to understand what production risks can be known and how they will focus resources based on safety criticality and the key elements of design and construction. The suppliers and acquirers who will produce the data and information required by the DRD will be able to incrementally evolve their QMS and the acquirer will incrementally be able to track and understand the benefits of cost shifting from late to early development phases. A white paper describing this approach and the five recommended DRDs will be published by the AIA in late 2024 or early 2025.

Jeannette Plante↗
DOE OSTI2020

Ghostbusters for Batteries

End-of-life lithium-ion batteries are Class 9 hazardous materials due to flammability of electrolyte and lithium. It is why the transportation cost ranges from $2.49/kg - $7.20/kg for civilian and defense disposition, that is over 50% of the cost of recycling. Damaged batteries have many times greater transportation cost. Dead batteries require costly bunker-storage that occupies real estate and personnel that could be used for productive purposes. Insurance is expensive and accidents are almost assured even with relatively low volumes of waste. Tipping fees on top of this adds an unpredictable, inflated cost for the EV industry, which is very cost sensitive for survival. Transforming lithium-ion into a class of non-hazardous material reduces transportation cost to $0.10/kg, providing a value opportunity of ~$2/kg to ~$6/kg for civilian and defense disposition respectively. OnTo can eliminate the risk of thermal runaway with a brief, non-toxic treatment to eliminate flammability and toxic risks in most any battery, except Pb, which is inherently toxic. With the service, OnTo also can provide rigorous certainty that cells are rendered inert. OnTo’s patented and patent pending deactivation technology improves the cost and safety for disposition of end-of-life lithium-ion battery packs and cells. Deactivation uses non-toxic chemical processing to remove inherent risks in lithium-ion and other primary and secondary chemistries. The technology has been demonstrated and developed through DOE contract with OnTo Technology LLC (EE0008475).

25 ENERGY STORAGE↗
DOE OSTI2021

Lessons Learned Using Iridium to Communicate with a CubeSat in Low Earth Orbit

This paper presents the design and approval process for operating an Iridium transceiver on orbit and provide on-orbit performance data obtained from a CubeSat platform in Low Earth Orbit (LEO) (500 km orbit). On-orbit data demonstrates that use of a commercial, low-cost Iridium transceiver can serve as a valuable communication approach for low volume telemetry with less than a 30-minute lag for approximately 90% of the time. In this work, we also demonstrate that a radial differential velocity of 7 km/sec corresponding to about a 37.5kHz doppler shift and a distance of less than 2,000 km can be used for mission planning.

42 ENGINEERING↗
DOE OSTI2021

Control-Theory-Informed Feature Selection for Detecting Malicious Tampering in Additive Layer Manufacturing Processes

Additive layer manufacturing (ALM) is rapidly becoming an appealing solution to the low-volume manufacturing of metal, polymer, or composite parts. However, ALM’s reliance on digital part specifications, microcontrollers, and modern networking makes these devices vulnerable to malicious tampering by cyber attackers, which can negatively affect part performance and even result in catastrophic failure. We present a hybrid analytic approach to feature discovery using control theoretic techniques and linear modelling on input-output data collected from a representative controller system. Employing this approach, we design, train, and test an anomaly detection system. The preliminary results show that the proposed approach effectively discovers useful input-output relationships for anomaly detection in a simulated ALM process. Application to larger and more complex systems are discussed.

Dawson, Joel↗
DOE OSTI2023

Carbon Fiber and Polymer Composites

Tooling is an integral part of composites manufacturing. Composite tools, also called ‘soft’ tools, are more easily constructed than ‘hard’ metal tools and, because they are made from materials similar to the manufactured composite part, they can be made in-house and have a good co-efficient of thermal expansion match. However, as the ‘soft’ designation suggests, they are more vulnerable to wear and typically find application in relatively low-volume production. Additive manufacturing of thermoplastics has proven to be a lucrative option that can help improve the tooling functionalities, as it offers more design flexibility. Owing to the inherent nature of additive manufacturing, the possibility of printing sensors within the tool material and at proximity to otherwise inaccessible areas of the tool become a reality. Continuous carbon fiber (CCF)-reinforced three-dimensional (3D) printing of engineering thermoplastics has proven to be a viable option to strengthen a part well beyond the ideal moduli of unmodified thermoplastic. Furthermore, adding nanotubes or graphene to the thermoplastic matrix will also improve both the thermal conductivity and interlaminar shear strength within the tool. Carbon nanotubes (CNTs) and carbon fibers (CFs) are microwave susceptors; exploiting the physics of Joule heating to increase the energy efficiency of tool hardening and cure rates is a core goal of this project. Because of the rapid volumetric heating enabled by the absorption of microwave or radio frequency energy and electromagnetic (EM) annealing presents an attractive opportunity to significantly reduce manufacturing cycle times while improving part performance.

Craps, Matthew G.↗
DOE OSTI2023

Irradiation and corrosion testing of laser powder bed fusion-manufactured materials in the AMMT program

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. As part of this effort, AMMT is performing irradiation and corrosion testing of several materials built by LPBF, including 316L and 316H stainless steels. Our efforts encompass neutron irradiation testing, ion irradiation testing, and advanced modeling to provide a robust technical basis for understanding the effect of process variability on materials degradation and developing a sound methodology for accelerated ion irradiation testing. 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.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

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↗
DOE OSTI2025

Toolpath Optimization of Polymer Composite Additive Manufacturing AM Printed Mold to Improve Performance for Compression Molding Applications

This study explores the optimization of toolpaths for short fiber polymer composite additive manufacturing (AM) printed molds in compression molding applications, an emerging trend driven by advancements in 3D printing technology. AM printed molds offer reduced tooling costs and greater design flexibility, particularly for prototyping and low-volume production. The proposed optimization approach evaluates mold performance using two key metrics: deformation and shape accuracy. Multiple toolpaths are generated, and finite element (FE) simulations capture fiber orientation and material properties, which are then integrated into a mechanical performance model. Shape accuracy is assessed by comparing the deformed mold shape with the original using surface normals as a descriptor. The analysis identifies the toolpath that delivers the best overall performance, establishing it as the most suitable option for achieving optimal mold characteristics in compression molding applications.

Limaye, Madhura [ORNL]↗
NASA NTRS1990

A trajectory generation and system characterization model for cislunar low-thrust spacecraft. Volume 2: Technical manual

The documentation of the Trajectory Generation and System Characterization Model for the Cislunar Low-Thrust Spacecraft is presented in Technical and User's Manuals. The system characteristics and trajectories of low thrust nuclear electric propulsion spacecraft can be generated through the use of multiple system technology models coupled with a high fidelity trajectory generation routine. The Earth to Moon trajectories utilize near Earth orbital plane alignment, midcourse control dependent upon the spacecraft's Jacobian constant, and capture to target orbit utilizing velocity matching algorithms. The trajectory generation is performed in a perturbed two-body equinoctial formulation and the restricted three-body formulation. A single control is determined by the user for the interactive midcourse portion of the trajectory. The full spacecraft system characteristics and trajectory are provided as output.

Korsmeyer, David J.↗
NASA NTRS1972

Design guide for low cost standardized payloads, volume 1

Concept point designs of low cost and refurbishable spacecraft, subsystems, and modules revealed payload program savings up to 50 percent. The general relationship of payload approaches to program costs; cost reductions from low cost standardized payloads; cost effective application of payload reliability, MMD, repair, and refurbishment; and implementation of standardization for future spacecraft are discussed. Shuttle interfaces and support equipment for future payloads are also considered

Source record↗
NASA NTRS1972

Design guide for low cost standardized payloads, volume 2

Sixteen engineering approaches to low cost standardized payloads in spacecraft are presented. Standard earth observatory satellite, standard U.S. domestic communication satellite, planetary spacecraft subsystems, standard spacecraft, and cluster spacecraft are reviewed.

Source record↗