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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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NASA NTRS2011

Active-Controlled Fluid Film Based on Wave-Bearing Technology

It has been known since 1967 that the steady-state and dynamic performance, including the stability of a wave bearing, are highly dependent on the wave amplitude. A wave-bearing profile can be readily obtained by elastically distorting the stationary bearing sleeve surface. The force that distorts the elastic sleeve surface could be an applied force or pressure. The magnitude and response of the distorting force would be defined by the relation between the bearing surface stiffness and the bearing pressure, or load, in a feedback loop controller. Using such devices as piezoelectric or other electromechanical elements, one could step control or fully control the bearing. The selection between these systems depends on the manner in which the distortion forces are applied, the running speed, and the reaction time of the feedback loop. With these techniques, both liquid- (oil-) or gas- (air-) lubricated wave bearings could be controlled. This report gives some examples of the dependency of the bearing's performance on the wave amplitude. The analysis also was proven experimentally.

Dimofte, Florin↗

NASA NTRS2018

Space: An Exciting Place to Work! Working in Space (without Ever Leaving Earth?)

In addition to the highly visible astronauts, NASA personnel include thousands of engineers, scientists, technicians and support staff. These vital employees develop technologies and solution to the many problems the Agency faces while undertaking space exploration. In this presentation to STEM students, the engineering that has been done to develop and maintain critical mechanism on the International Space Station will be reviewed and discussed. The overall goal of the presentation is to clearly show that many individuals can make meaningful contributions to space exploration without ever leaving the earth.

bearings↗

NASA NTRS1984

Ground test challenges in the development of the Space Shuttle orbiter auxiliary power unit

A conventional aircraft hydraulic system design approach was selected to provide fluid power for the Space Shuttle Orbiter. Developing the power unit, known as the Auxiliary Power Unit (APU), to drive the hydraulic pumps presented a major technological challenge. A small, high speed turbine drive unit powered by catalytically decomposed hydrazine and operating in the pulse mode was selected to meet the requirement. Because of limitations of vendor test facilities, significant portions of the development, flight qualification, and postflight anomaly testing of the Orbiter APU were accomplished at the Johnson Space Center (JSC) test facilities. This paper discusses the unique requirements of attitude, gravity forces, pressure profiles, and thermal environments which had to be satisfied by the APU, and presents the unique test facility and simulation techniques employed to meet the ground test requirements. In particular, the development of the zero-g lubrication system, the development of necessary APU thermal control techniques, the accomplishment of integrated systems tests, and the postflight investigation of the APU lube oil cooler behavior are discussed.

Chaffee, N. H.↗

NASA NTRS2012

Design and Manufacturing Considerations for Shockproof and Corrosion-Immune Superelastic Nickel-Titanium Bearings for a Space Station Application

An intermetallic nickel-titanium alloy, 60NiTi (60wt%Ni, 40wt%Ti), is a promising tribological material for space mechanisms. 60NiTi offers a broad combination of physical properties that make it unique among bearing materials. 60NiTi is hard, electrically conductive, highly corrosion resistant, readily machined prior to final heat treatment, easily lubricated and is non-magnetic. It also falls within the class of superelastic alloys and can elastically endure large strains (beyond 5 percent) making it highly resistant to excessive and unexpected (shock) loads. Key material properties and characteristics such as elastic modulus, tensile fracture sensitivity and residual stress behavior, however, differ from conventional alloys such as steel and this significantly affects bearing design and manufacturing. In this paper, the preliminary design and manufacture of ball bearings made from 60NiTi are considered for a highly corrosive, lightly loaded, low speed bearing application found inside the International Space Station s water recycling system. The information presented is expected to help guide more widespread commercialization of this new technology into space mechanism and other applications.

DellaCorte, Christopher↗

NASA NTRS1985

Advanced Gas Turbine (AGT) technology report

Engine testing, ceramic component fabrication and evaluation, component performance rig testing, and producibility experiments at Pontiac comprised AGT 100 activities of this period, January to December 1984. Two experimental engines were available and allowed the evaluation of eight experimental assemblies. Operating time accumulated was 115 hr of burning and 156 hr total. Total cumulative engine operating time is now 225 hr. Build number 11 and 12 of engine S/N 1 totaled 28 burning hours and constituted a single assembly of the engine core--the compressor, both turbines, and the gearbox. Build number 11 of engine S/N 1 included a 1:07 hr continuous test at 100% gasifier speed (86,000 rpm). Build number 8 of engine S/N 2 was the first engine test with a ceramic turbine rotor. A mechanical loss test of an engine assembly revealed the actual losses to be near the original design allowance. Component development activity included rig testing of the compressor, combustor, and regenerator. Compressor testing was initiated on a rig modified to control the transfer of heat between flow path, lubricating oil, and structure. Results show successful thermal decoupling of the rig and lubricating/cooling oil. Rig evaluation of a reduced-friction compressor was initiated. Combustor testing covered qualification of ceramic parts for engine use, mapping of operating range limits, and evaluation of a relocated igniter plug. Several seal refinements were tested on the hot regenerator rig. An alternate regenerator disk, extruded MAS, was examined and found to be currently inadequate for the AGT 100 application. Also, a new technique for measuring leakage was explored on the regenerator rig. Ceramic component activity has focused on the development of state-of-the-art material strength characteristics in full-scale hardware. Injection-molded sintered alpha-SiC rotors were produced at Carborundum in an extensive process and tool optimization study.

Source record↗

NASA NTRS2018

Two-Speed Rotorcraft Research Transmission Power-Loss Associated with the Lubrication and Hydraulic Rotating Feed-Through Design Feature

An investigation was completed into the power loss associated with a rotating feed-through (RFT) design feature used to transfer lubrication and a hydraulic control signal from the static reference frame to a rotating reference frame in the NASA GRC two-speed transmission tests conducted in the Variable-Speed Drive Test Rig. The RFT feature, not commercially available, was created specifically for this research project and is integral to all two-speed transmission configurations tested, as well as a variant concept design for a geared variable-speed transmission presented at AHS Forum 71 in 2015. The experimental set-up and results from measurements in the isolated rotating-feed-through (RFT) experiments are presented. Results were used in an overall power loss assessment for a scaled conceptual 1,000 horsepower inline concentric two-speed transmission to support a NASA Revolutionary Vertical Lift Technologies (RVLT) Technical Challenge, demonstrating 50% speed change with less than 2% power loss while maintaining current power-to-weight ratios.

Rotorcraft↗

NASA NTRS2018

Two-Speed Rotorcraft Research Transmission Power-Loss Associated with the Lubrication and Hydraulic Rotating Feed-Through Design Feature

Rotorcraft↗

NASA NTRS2018

Two-Speed Rotorcraft Research Transmission Power-Loss Associated with the Lubrication and Hydraulic Rotating Feed-Through Design Feature

Rotorcraft↗

NASA NTRS2014

Intentional Collaboration & Innovation Spaces at NASA

Collaboration and Innovation (C&I) are extremely popular terms in corporate jargon, and institutions with reputations for creativity often have clever and fun spaces set aside for hatching ideas and developing products or services. In and of themselves, a room full of "collaboration furniture" and electronics can't make C&I happen, any more than oil makes a gas or diesel engine run. As with the engine, though, quality lubrication is a huge factor in the smooth operation, power, and longevity of C&I activity. This paper describes spaces deliberately set up at numerous NASA field centers to support collaborative and creative thinking and processes. (Sometimes support is not so much a matter of doing things to spark discussion as it is removing constraints imposed by traditional settings and making information sharing as easy as possible.) Some spaces are rooms or suites dedicated to C&I, with significant electronic support and/or intentional lack thereof (to emphasize the human element). Others are small, comfortable "roosting places" that invite conversations of opportunity. Descriptions include the sponsoring organization, underlying goals and philosophies, lessons learned, and opportunities to excel. There is discussion about how such areas might interconnect within centers, across NASA, and with external entities using current technology and what tools and approaches may be in our future.

Scott, David W.↗

NASA NTRS1984

Status of Understanding for Bearing Materials

The structural materials and potential failure modes for high technology aircraft gas turbine bearings are reviewed. Among the failure modes discussed for iron-base through-hardened bearing materials are fatigue, surface distress, and corrosion. It is shown that the sub-surface initiated rolling-contact fatigue failure mode is reasonably well understood and in most cases can be controlled by proper material selection and design. Current bearing materials provide long life and high reliability in existing applications. A new generation of materials are being developed which will provide improved fracture toughness, better corrosion resistance, and a further extension of bearing fatigue life. Bearing problems due to surface distress, caused by a variety of surface and near surface anomalies, are less well understood. This area will require the implementation of an interdisciplinary effort to improve the level of understanding of metallic surface-lubricant reactions and interactions.

E N Bamberger↗

NASA NTRS2017

Design Solutions for the Treatment of DMSD in the ISS Water Recovery System

Dimethylsilanediol (DMSD) has been identified as a problematic organic on ISS. This contaminant was initially identified in the Water Processor Assembly (WPA) product water in 2010 by the Total Organic Carbon Analyzer (TOCA). DMSD is not a crew health hazard at the levels observed in the product water, but it may degrade the performance of the Oxygen Generation System (OGS) which uses the WPA product water for electrolysis and does impact the effective operation of the WPA catalytic reactor. To mitigate these impacts, early replacement of the Multifiltration Beds in the WPA is required. An investigation has determined that the decomposition of atmospheric polydimethylsiloxanes (PDMSs) is the primary source of DMSD in the condensate. PDMSs are prevalent on ISS from a variety of sources, including crew hygiene products, adhesives, caulks, lubricants, and various nonmetallics. These PDMSs also contribute to degradation of the CHX hydrophilic coating, rendering it hydrophobic and therefore affecting its ability to transmit water to the condensate bus. In addition, literature research has determined that PDMSs are likely oxidized to DMSD in the atmosphere when exposed to hydroxyl radicals in the ISS atmosphere. To address these mechanisms, filters have been developed for removal of PDMSs from the ISS atmosphere. However, ongoing analysis indicates a significant reduction in atmospheric PDMSs is required to achieve a measurable reduction of DMSD in the condensate. As a result, additional measures are being pursued to mitigate this issue. First, credible sources are being investigated to quantity to the extent possible the significant sources of PDMSs and identify sources that can be reasonably removed from ISS. Second, a Reverse Osmosis technology is being investigated as an alternate means for removing DMSD from the condensate. This paper summarizes the current status of the overall effort to mitigate DMSD in the US condensate.

Perry, Jay↗

NASA NTRS1974

Design of H2-O2 space shuttle APU. Volume 1: APU design

The H2-O2 space shuttle auxiliary power unit (APU) program is a NASA-Lewis effort aimed at hardware demonstration of the technology required for potential use on the space shuttle. It has been shown that a hydrogen-oxygen power unit (APU) system is an attractive alternate to the space shuttle baseline hydrazine APU system for minimum weight. It has the capability for meeting many of the heat sink requirements for the space shuttle vehicle, thereby reducing the amount of expendable evaporants required for cooling in the baseline APU. Volume 1 of this report covers preliminary design and analysis of the current reference system and detail design of the test version of this reference system. Combustor test results are also included. Volume 2 contains the results of the analysis of an initial version of the reference system and the computer printouts of system performance. The APU consists of subsystems for propellant feed and conditioning, turbopower, and control. Propellant feed and conditioning contains all heat exchangers, valves, and the combustor. The turbopower subsystem contains a two-stage partial-admission pressure-modulated, 400-hp, 63,000-rpm turbine, a 0-to 4-g lubrication system, and a gearbox with output pads for two hydraulic pumps and an alternator (alternator not included on test unit). The electronic control functions include regulation of speed and system temperatures; and start-and-stop sequences, overspeed (rpm) and temperature limits, failsafe provisions, and automatic shutdown provisions.

Harris, E.↗

NASA NTRS2002

NASA Space Mechanisms Handbook and Reference Guide Expanded Into CD-ROM Set

Several NASA missions suffered failures and anomalies due to problems in applying space mechanisms technology to specific projects. Research shows that engineers often lack either adequate knowledge of mechanism design or sufficient understanding of how mechanisms affect sensitive systems. The Space Mechanisms Project conducted a Lessons Learned study and published a Space Mechanisms Handbook to help space industry engineers avoid recurring design, qualification, and application problems. The Space Mechanisms Handbook written at the NASA Glenn Research Center details the state-of-the-art in space mechanisms design as of 1998. NASA's objective in developing this Space Mechanisms Handbook was to provide readily accessible information on such areas as space mechanisms design, mechanical component availability and use, testing and qualification of mechanical systems, and a listing of worldwide space mechanisms experts and testing facilities in the United States. This handbook has been expanded into a two-volume CD-ROM set in an Adobe Acrobat format. In addition to the handbook, the CD's include (1) the two volume Space Mechanisms Lessons Learned Study, (2) proceedings from all the NASA hosted Aerospace Mechanisms Symposia held through the year 2000, (3) the Space Materials Handbook, (4) the Lubrication Handbook for the Space Industry, (5) the Structural & Mechanical Systems Long-Life Assurance Design Guidelines, (6) the Space Environments and Effects Source-Book, (7) the Spacecraft Deployable Appendages manual, (8) the Fastener Design Manual, (9) A Manual for Pyrotechnic Design, Development and Qualification, (10) the Report on Alternative Devices to Pyrotechnics on Spacecraft, and (11) Gearing (a manual). In addition, numerous other papers on tribology and lubrication are included.This technical summary of the project provides information on how to obtain the handbook and related information.

Fusaro, Robert L.↗

NASA NTRS2004

NASA Glenn's Single-Stage Axial Compressor Facility Upgraded

NASA Glenn Research Center's Single-Stage Axial Compressor Facility was upgraded in fiscal year 2003 to expand and improve its research capabilities for testing high-speed fans and compressors. The old 3000-hp drive motor and gearbox were removed and replaced with a refurbished 7000-hp drive motor and gearbox, with a maximum output speed of 21,240 rpm. The higher horsepower rating permits testing of fans and compressors with higher pressure ratio or higher flow. A new inline torquemeter was installed to provide an alternate measurement of fan and compressor efficiency, along with the standard pressure and temperature measurements. A refurbished compressor bearing housing was also installed with bidirectional rotation capability, so that a variety of existing hardware could be tested. Four new lubrication modules with backup capability were installed for the motor, gearbox, torquemeter, and compressor bearing housing, so that in case the primary pump fails, the backup will prevent damage to the rotating hardware. The combustion air supply line for the facility inlet air system was activated to provide dry air for repeatable inlet conditions. New flow conditioning hardware was installed in the facility inlet plenum tank, which greatly reduced the inlet turbulence. The new inlet can also be easily modified to accommodate 20- or 22-in.-diameter fans and compressors, so a variety of existing hardware from other facilities (such as Glenn's 9- by 15-Foot Low-Speed Wind Tunnel) can be tested in the Single-Stage Axial Compressor Facility. An exhaust line was also installed to provide bleed capability to remove the inlet boundary layer. To improve the operation and control of the facility, a new programmable logic controller (PLC) was installed to upgrade from hardwired relay logic to software logic. The PLC also enabled the usage of human-machine interface software to allow for easier operation of the facility and easier reconfiguration of the facility controls when necessary. Finally, a new health-monitoring system was installed to measure shaft speed, shaft movement, and machine vibration on all of the rotating equipment. The system also provides automatic alarms and shutdown of the equipment when required. An integrated systems test for checkout of the facility was completed on June 17, 2003. Research testing resumed on June 30 with data obtained in support of the Ultra-Efficient Engine Technology Project's Compressor Casing Treatment Project.

Brokopp, Richard A.↗

NASA NTRS2016

Z-2 Threaded Insert Design and Testing Abstract

The Z-2 Prototype Planetary Extravehicular Space Suit Assembly is a continuation of NASA's Z series of spacesuits. The Z-2 is another step in the NASA's technology development roadmap leading to human exploration of the Martian surface. To meet a more challenging set of requirements than previous suit systems standard design features, such as threaded inserts, have been re-analyzed and improved. NASA's Z-2 prototype space suit contains several components fabricated from an advanced hybrid composite laminate consisting of IM10 carbon fiber and fiber glass. One requirement NASA levied on the suit composites was the ability to have removable, replaceable helicoil inserts to which other suit components would be fastened. An approach utilizing bonded in inserts with helicoils inside of them was implemented. The design of the interface flanges of the composites allowed some of the inserts to be a "T" style insert that was installed through the entire thickness of the laminate. The flange portion of the insert provides a mechanical lock as a redundancy to the adhesive aiding in the pullout load that the insert can withstand. In some locations it was not possible to utilize at "T" style insert and a blind insert was used instead. These inserts rely completely on the bond strength of the adhesive to resist pullout. It was determined during the design of the suit that the inserts did not need to withstand loads induced from pressure cycling but instead tension induced from torqueing the screws to bolt on hardware which creates a much higher stress on them. Bolt tension is determined by dividing the torque on the screw by a k value multiplied by the thread diameter of the bolt. The k value is a factor that accounts for friction in the system. A common value used for k for a non-lubricated screw is 0.2. The k value can go down by as much as 0.1 if the screw is lubricated which means for the same torque, a much larger tension could be placed on the bolt and insert. This paper summarizes testing that was performed to determine a k value for helicoil inserts in the Z2 suit and how the insert design was modified to resist a higher pull out tension.

Rhodes, RIchard↗

NASA NTRS1999

Engineering of Novel Biocolloid Suspensions

Colloidal suspensions are materials with a variety of uses from cleaners and lubricants to food, cosmetics, and coatings. In addition, they can be used as a tool for testing the fundamental tenets of statistical physics. Colloidal suspensions can be synthesized from a wide variety of materials, and in the form of monodisperse particles, which can self-assemble into highly ordered colloidal crystal structures. As such they can also be used as templates for the construction of highly ordered materials. Materials design of colloids has, to date, relied on entropic self-assembly, where crystals form as result of lower free energy due to a transition to order. Here, our goal is to develop a completely new method for materials fabrication using colloidal precursors, in which the self-assembly of the ordered colloidal structures is driven by a highly controllable, attractive interaction. This will greatly increase the range of potential structures that can be fabricated with colloidal particles. In this work, we demonstrate that colloidal suspensions can be crosslinked through highly specific biological crosslinking reactions. In particular, the molecules we use are protein-carbohydrate interactions derived from the immune system. This different driving force for self-assembly will yield different and novel suspensions structures. Because the biological interactions are heterotypic (A binding to B), this chemical system can be used to make binary alloys in which the two colloid subpopulations vary in some property - size, density, volume fraction, magnetic susceptibility, etc. An additional feature of these molecules which is unique - even within the realm of biological recognition - is that the molecules bind reversibly on reasonable time-scales, which will enable the suspension to sample different configurations, and allow us to manipulate and measure the size of the suspension dynamically. Because of the wide variety of structures that can be made from these novel colloids, and because the suspension structure can be altered dynamically, we believe this biocolloid system will yield a novel set of materials with many technological applications, including sensors (both biological and non-biological), optical filters and separation media.

Hammer, D. A.↗

NASA NTRS2001

Thermal Processing Effects on the Adhesive Strength of PS304 High Temperature Solid Lubricant Coatings

In this paper the effects of post deposition heat treatments on the cohesive and adhesive strength properties of PS304, a plasma sprayed nickel-chrome based, high temperature solid lubricant coating deposited on stainless steel, are studied. Plasma spray deposited coating samples were exposed in air at temperatures from 432 to 650 C for up to 500 hr to promote residual stress relief, enhance particle to particle bonding and increase coating to substrate bond strength. Coating pull-off strength was measured using a commercial adhesion tester that utilizes 13 mm diameter aluminum pull studs attached to the coating surface with epoxy. Pull off force was automatically recorded and converted to coating pull off strength. As deposited coating samples were also tested as a baseline. The as-deposited (untreated) samples either delaminated at the coating-substrate interface or failed internally (cohesive failure) at about 17 MPa. Samples heat treated at temperatures above 540 C for 100 hr or at 600 C or above for more than 24 hr exhibited strengths above 31 MPa, nearly a two fold increase. Coating failure occurred inside the body of the coating (cohesive failure) for nearly all of the heat-treated samples and only occasionally at the coating substrate interface (adhesive failure). Metallographic analyses of heat-treated coatings indicate that the Nickel-Chromium binder in the PS304 appears to have segregated into two phases, a high nickel matrix phase and a high chromium precipitated phase. Analysis of the precipitates indicates the presence of silicon, a constituent of a flow enhancing additive in the commercial NiCr powder. The exact nature and structure of the precipitate phase is not known. This microstructural change is believed to be partially responsible for the coating strength increase. Diffusion bonding between particles may also be playing a role. Increasing the heat treatment temperature, exposure time or both accelerate the heat treatment process. Preliminary measurements indicate that the heat treatment also results in a one time, permanent coating thickness increase of about 3%. Based upon these results, the incorporation of a heat treatment prior to final finishing has been incorporated in the application process of this coating technology.

DellaCorte, Christopher↗