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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 NTRS1991

An experiment in remote manufacturing using the advanced communications technology satellite

The goal of the completed project was to develop an experiment in remote manufacturing that would use the capabilities of the ACTS satellite. A set of possible experiments that could be performed using the Advanced Communications Technology Satellite (ACTS), and which would perform remote manufacturing using a laser cutter and an integrated circuit testing machine are described in detail. The proposed design is shown to be a feasible solution to the offered problem and it takes into consideration the constraints that were placed on the experiment. In addition, we have developed two more experiments that are included in this report: backup of rural telecommunication networks, and remote use of Synthetic Aperture Radar (SAR) data analysis for on-site collection of glacier scattering data in the Antarctic.

Tsatsoulis, Costas↗

NASA NTRS2004

Simulation Based Acquisition for NASA's Office of Exploration Systems

In January 2004, President George W. Bush unveiled his vision for NASA to advance U.S. scientific, security, and economic interests through a robust space exploration program. This vision includes the goal to extend human presence across the solar system, starting with a human return to the Moon no later than 2020, in preparation for human exploration of Mars and other destinations. In response to this vision, NASA has created the Office of Exploration Systems (OExS) to develop the innovative technologies, knowledge, and infrastructures to explore and support decisions about human exploration destinations, including the development of a new Crew Exploration Vehicle (CEV). Within the OExS organization, NASA is implementing Simulation Based Acquisition (SBA), a robust Modeling & Simulation (M&S) environment integrated across all acquisition phases and programs/teams, to make the realization of the President s vision more certain. Executed properly, SBA will foster better informed, timelier, and more defensible decisions throughout the acquisition life cycle. By doing so, SBA will improve the quality of NASA systems and speed their development, at less cost and risk than would otherwise be the case. SBA is a comprehensive, Enterprise-wide endeavor that necessitates an evolved culture, a revised spiral acquisition process, and an infrastructure of advanced Information Technology (IT) capabilities. SBA encompasses all project phases (from requirements analysis and concept formulation through design, manufacture, training, and operations), professional disciplines, and activities that can benefit from employing SBA capabilities. SBA capabilities include: developing and assessing system concepts and designs; planning manufacturing, assembly, transport, and launch; training crews, maintainers, launch personnel, and controllers; planning and monitoring missions; responding to emergencies by evaluating effects and exploring solutions; and communicating across the OExS enterprise, within the Government, and with the general public. The SBA process features empowered collaborative teams (including industry partners) to integrate requirements, acquisition, training, operations, and sustainment. The SBA process also utilizes an increased reliance on and investment in M&S to reduce design risk. SBA originated as a joint Industry and Department of Defense (DoD) initiative to define and integrate an acquisition process that employs robust, collaborative use of M&S technology across acquisition phases and programs. The SBA process was successfully implemented in the Air Force s Joint Strike Fighter (JSF) Program.

Hale, Joe↗

NASA NTRS1992

The effect of material heterogeneity in curved composite beams for use in aircraft structures

A design tool is presented for predicting the effect of material heterogeneity on the performance of curved composite beams for use in aircraft fuselage structures. Material heterogeneity can be induced during processes such as sheet forming and stretch forming of thermoplastic composites. This heterogeneity can be introduced in the form of fiber realignment and spreading during the manufacturing process causing a gradient in material properties in both the radial and tangential directions. The analysis procedure uses a separate two-dimensional elasticity solution for the stresses in the flanges and web sections of the beam. The separate solutions are coupled by requiring the forces and displacements match at the section boundaries. Analysis is performed for curved beams loaded in pure bending and uniform pressure. The beams can be of any general cross-section such as a hat, T-, I-, or J-beam. Preliminary results show that geometry of the beam dictates the effect of heterogeneity on performance. Heterogeneity plays a much larger role in beams with a small average radius to depth ratio, R/t, where R is the average radius of the beam and t is the difference between the inside and outside radius. Results of the analysis are in the form of stresses and displacements, and they are compared to both mechanics of materials and numerical solutions obtained using finite element analysis.

Otoole, Brendan J.↗

NASA NTRS2017

Comparison of Oxygen Liquefaction Methods for Use on the Martian Surface

In order to use oxygen that is produced on the surface of Mars from In-Situ production processes in a chemical propulsion system, the oxygen must first be converted from vapor phase to liquid phase and then stored within the propellant tanks of the propulsions system. There are multiple ways that this can be accomplished, from simply attaching a liquefaction system onto the propellant tanks to carrying separate tanks for liquefaction and storage of the propellant and loading just prior to launch (the way that traditional rocket launches occur on earth). A study was done into these various methods by which the oxygen (and methane) could be liquefied and stored on the Martian surface. Five different architectures or cycles were considered: Tube-on-Tank (also known as Broad Area Cooling or Distributed Refrigeration), Tube-in-Tank (also known as Integrated Refrigeration and Storage), a modified Linde open liquefaction/refrigeration cycle, the direct mounting of a pulse tube cryocooler onto the tank, and an in-line liquefier at ambient pressure. Models of each architecture were developed to give insight into the performance and losses of each of the options. The results were then compared across eight categories: Mass, Power (both input and heat rejection), Operability, Cost, Manufacturability, Reliability, Volumility, and Scalability. The result was that, given the current state of technology maturity, Tube-on-Tank architectures were the most attractive solution, closely followed by Tube-in-Tank. As a result of this technical analysis and other factors, NASA has determined to focus its Martian surface liquefaction activities and technology development on Tube-on-Tank liquefaction cycles.

Cryogenic propellants↗

NASA NTRSDate not supplied

rHealth One Demonstration Aboard ISS: A Microfluidic Bioanalyzer Based on Sheath/Hydrodynamic Focusing Flow Cytometry

The Exploration Medical Capability (ExMC) element aims to provide astronauts with the means for their own health monitoring, diagnosis, and treatment during exploration missions. As space flight ventures further from earth, the need for autonomous medical care increases under greater constraints on size, mass, and resources. One pillar for diagnosis that crew would be separated from is laboratory analysis. Even now on ISS, blood samples must be collected and returned to earth for testing. In response, ExMC is assessing how assays for hematology, bone health, radiation exposure etc. could be addressed through commercial-off-the-shelf (COTS) and Small Business Innovation Research (SBIR) funded bioanalyzers that are miniaturizing lab technology. Since missions will reach distances where there are no timely replacements, validation on the International Space Station (ISS) is a necessary part of that assessment. In partnership with NASA Johnson Space Center (JSC) Immunology Lab and the Research Operations and Integration (ROI) element, ExMC conducted a technology demonstration on ISS of the rHEALTH ONE, a flow cytometry based bioanalyzer, to assess future devices based on this design. In flow cytometry, there are predominantly three ways to focus the cells (or particles) into a single file stream: hydrodynamic focusing, microcapillary, and acoustic focusing. The rHEALTH ONE utilizes the commercial standard, sheath-based hydrodynamic focusing. rHEALTH itself represents both a company and a suite of medical tools NASA has funded through SBIR grants towards the development of a promising diagnosis instrument for exploration missions. rHEALTH ONE is the interim version of the technology, functional as a benchtop analyzer and test bed for the next generation of rHEALTH in development. Several modifications were made to the rHEALTH ONE analyzer for operation in microgravity. For function, fluid management was key. A sheath-based analyzer uses sheath fluid to flow the sample, cleaning fluid to prevent biological contamination, and a reservoir to collect the liquid waste. The rHEALTH ONE analyzer uses bottles dependent on gravity to separate the air and liquid pathways and keep the liquids contained. It uses only 1 psig of air pressure to directly push the liquid through the device, requiring little-to-no resistance at inlet and outlet. A microtubing assembly with self-sealing luer connectors was designed – featuring 0.014 mm thick durable medical balloons to hold water inside the supply bottles – to create safe containment and easy access for the crew while maintaining the analyzer’s function. For safety, copper tape was added to the interior of the plastic housing to reduce electromagnetic interference, fluid and electrical connections were secured against vibration and leaks, and gaps were further sealed to ensure containment of the optical block and lasers. Water as the sheath and cleaning fluid and TOX 0 samples were used to reduce the biohazard risk to the crew. In May 2022, European Space Agency astronaut Samantha Cristoforetti demonstrated the rHEALTH ONE aboard ISS for its sample loading, flow cytometry, and data collection capability in microgravity. The JSC Immunology Lab provided flow cytometry expertise, designed the sample test protocol, and manufactured and benchmarked the flight samples on a ‘gold-standard’ flow cytometer. The analyzer was primed with water, purged of air, and four calibration solutions of polystyrene microparticles were tested to characterize its performance. Tightly controlled procedures and excellent execution prevented air bubble interference during air/water separation, fluid transfer, sample mixing and loading. Data showed a slight increase in signal noise on 3 of 5 channels and an anomaly of fluorophores migrating in one sample (confirmed by JSC post-flight). Flight results correctly detected the change in sample, matched the analyzer’s ground performance, and were consistent with the gold-standard’s ground results. Although areas were noted for improvement, these outcomes signified complete mission success.

R. S. Miller↗

NASA NTRS2022

Test methods for image-based information in next-generation manufacturing

Typical control designs in the process systems engineering literature have assumed that the primary sensing methodologies are traditional instruments such as thermocouples. Digitalization is changing the landscape for manufacturing, and data-based sensing modalities (e.g., image-based sensing) are becoming of greater interest for plant control. These considerations require novel test/evaluation solutions. For example, process systems engineering researchers may wish to test image-based sensors in simulation. In this work, we provide preliminary thoughts on how image-based technologies might be evaluated via simulation for process systems.

Henrique Oyama↗

NASA NTRS2011

Product Lifecycle Management and the Quest for Sustainable Space Exploration Solutions

Product Lifecycle Management (PLM) is an outcome of lean thinking to eliminate waste and increase productivity. PLM is inextricably tied to the systems engineering business philosophy, coupled with a methodology by which personnel, processes and practices, and information technology combine to form an architecture platform for product design, development, manufacturing, operations, and decommissioning. In this model, which is being implemented by the Marshall Space Flight Center (MSFC) Engineering Directorate, total lifecycle costs are important variables for critical decision-making. With the ultimate goal to deliver quality products that meet or exceed requirements on time and within budget, PLM is a powerful concept to shape everything from engineering trade studies and testing goals, to integrated vehicle operations and retirement scenarios. This briefing will demonstrate how the MSFC Engineering Directorate is implementing PLM as part of an overall strategy to deliver safe, reliable, and affordable space exploration solutions and how that strategy aligns with the Agency and Center systems engineering policies and processes. Sustainable space exploration solutions demand that all lifecycle phases be optimized, and engineering the next generation space transportation system requires a paradigm shift such that digital tools and knowledge management, which are central elements of PLM, are used consistently to maximum effect. Adopting PLM, which has been used by the aerospace and automotive industry for many years, for spacecraft applications provides a foundation for strong, disciplined systems engineering and accountable return on investment. PLM enables better solutions using fewer resources by making lifecycle considerations in an integrative decision-making process.

Caruso, Pamela W.↗

NASA NTRS2005

Solid State Digital Propulsion "Cluster Thrusters" For Small Satellites Using High Performance Electrically Controlled Extinguishable Solid Propellants (ECESP)

Electrically controlled extinguishable solid propellants (ESCSP) are capable of multiple ignitions, extinguishments and throttle control by the application of electrical power. Both core and end burning no moving parts ECESP grains/motors to three inches in diameter have now been tested. Ongoing research has led to a newer family of even higher performance ECESP providing up to 10% higher performance, manufacturing ease, and significantly higher electrical conduction. The high conductivity was not found to be desirable for larger motors; however it is ideal for downward scaling to micro and pico- propulsion applications with a web thickness of less than 0.125 inch/ diameter. As a solid solution propellant, this ECESP is molecularly uniform, having no granular structure. Because of this homogeneity and workable viscosity it can be directly cast into thin layers or vacuum cast into complex geometries. Both coaxial and grain stacks have been demonstrated. Combining individual propellant coaxial grains and/or grain stacks together form three-dimensional arrays yield modular cluster thrusters. Adoption of fabless manufacturing methods and standards from the electronics industry will provide custom, highly reproducible micro-propulsion arrays and clusters at low costs. These stack and cluster thruster designs provide a small footprint saving spacecraft surface area for solar panels and/or experiments. The simplicity of these thrusters will enable their broad use on micro-pico satellites for primary propulsion, ACS and formation flying applications. Larger spacecraft may find uses for ECESP thrusters on extended booms, on-orbit refueling, pneumatic actuators, and gas generators.

Sawka, Wayne N.↗

NASA NTRS2007

Thermoelectric Devices Advance Thermal Management

Thermoelectric (TE) devices heat, cool, and generate electricity when a temperature differential is provided between the two module faces. In cooperation with NASA, Chico, California-based United States Thermoelectric Consortium Inc. (USTC) built a gas emissions analyzer (GEA) for combustion research. The GEA precipitated hydrocarbon particles, preventing contamination that would hinder precise rocket fuel analysis. The USTC research and design team uses patent-pending dimple, pin-fin, microchannel and microjet structures to develop and design heat dissipation devices on the mini-scale level, which not only guarantee high performance of products, but also scale device size from 1 centimeter to 10 centimeters. USTC continues to integrate the benefits of TE devices in its current line of thermal management solutions and has found the accessibility of NASA technical research to be a valuable, sustainable resource that has continued to positively influence its product design and manufacturing

Source record↗

NASA NTRS2012

Roadmap for In-Space Propulsion Technology

NASA has created a roadmap for the development of advanced in-space propulsion technologies for the NASA Office of the Chief Technologist (OCT). This roadmap was drafted by a team of subject matter experts from within the Agency and then independently evaluated, integrated and prioritized by a National Research Council (NRC) panel. The roadmap describes a portfolio of in-space propulsion technologies that could meet future space science and exploration needs, and shows their traceability to potential future missions. Mission applications range from small satellites and robotic deep space exploration to space stations and human missions to Mars. Development of technologies within the area of in-space propulsion will result in technical solutions with improvements in thrust, specific impulse (Isp), power, specific mass (or specific power), volume, system mass, system complexity, operational complexity, commonality with other spacecraft systems, manufacturability, durability, and of course, cost. These types of improvements will yield decreased transit times, increased payload mass, safer spacecraft, and decreased costs. In some instances, development of technologies within this area will result in mission-enabling breakthroughs that will revolutionize space exploration. There is no single propulsion technology that will benefit all missions or mission types. The requirements for in-space propulsion vary widely according to their intended application. This paper provides an updated summary of the In-Space Propulsion Systems technology area roadmap incorporating the recommendations of the NRC.

Meyer, Michael↗

NASA NTRSDate not supplied

Optimization of Rocket Engine Components using Multi-Metallic Additive Manufacturing

Additive manufacturing (AM) is advancing many applications of component design for liquid rocket engines. AM has been demonstrated in various rocket component applications using a variety of monolithic metal alloys, many of which are traditional alloys for extreme environments. NASA and industry partners have focused in recent years to advance processing to create bimetallic and multicomponent AM processes and materials. The role of multi-metallic AM offers advantages since it can further optimize weight, optimize reliability and performance by increasing the strength to weight ratio of a component, and can optimize materials for various engineering requirements. NASA’s Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project has designed and manufactured a series of additively manufactured (AM) coupled combustion chambers, nozzles, and other engine components to advance new AM processes and materials with the goal of reducing cost and schedule for engine manufacturing. These designs incorporated multimetallic AM, which further enabled carbon-fiber composite overwrap to reduce overall thrust chamber assembly (TCA) mass. Various AM processes were demonstrated on these components using a copper-based alloy/superalloy bimetallic solution. The AM processes being explored individually and in combination for bimetallic applications include Laser Powder Bed Fusion (L-PBF), Laser Powder Directed Energy Deposition (LP-DED), and cold spray. The combination of bimetallic material combinations explored in this research include GRCop-based alloys and superalloys, Inconel 625 or NASA HR-1. One unique development that will be presented is the combustion chamber and nozzle as a single component by using freeform integrated DED to build the nozzle directly onto the aft end of the chamber. The various aspects of the additive manufacturing processes and challenges, materials characterization and mechanical testing, and hot-fire testing of bimetallic components in a relevant rocket engine environment will be discussed.

Additive Manufacturing↗

NASA NTRS2006

Development of a Thin Gauge Metallic Seal for Gas Turbine Engine Applications to 1700 F

The goal of doubling thrust-to-weight ratio for gas turbine engines has placed significant demands on engine component materials. Operating temperatures for static seals in the transition duct and turbine sections for instance, may well reach 2000 F within the next ten years. At these temperatures conventional age-hardenable superalloys lose their high strength via overaging and eventual dissolution of the gamma precipitate, and are well above their oxidation stability limit. Conventional solid-solution-strengthened alloys offer metallurgical stability, but suffer from rapid oxidation and little useful load bearing strength. Ceramic materials can theoretically be used at these temperatures, but manufacturing processes are in the developmental stages.

England, Raymond O.↗

NASA NTRS2017

Hemispherical Optical Dome for Underwater Communication

For many years, acoustic systems have been used as the primary method for underwater communication; however, the data transfer rate of such systems is low because sound propagates slowly through the water. A higher throughput can be achieved using visible light to transmit data underwater. The first issue with using this approach is that there is generally a large loss of the light signal due to scattering and absorption in water even though there is an optimal wavelength for transmission in the blue or green wavelengths of the visible spectrum. The second issue is that a simple system consisting only of a highly directional source transmitter and small optical detector receiver has a very narrow field of view. The goal of this project is to improve an optical, underwater communication system by increasing the effective field of view of the receiving optics. To this end, we make two changes to the simple system: (1) An optical dome was added near the receiver. An array of lenses is placed radially on the surface of the dome, reminiscent of the compound eye of an insect. The lenses make the source and detector planes conjugate, and each lens adds a new region of the source plane to the instrument's total field of view. (2) The receiver was expanded to include multiple photodiodes. With these two changes, the receiver has much more tolerance to misalignments (in position and angle) of the transmitter.Two versions of the optical dome (with 6 and 8 diameters) were designed using the CREO CAD software and modeled using the CODE V optical design software. A series of these transparent hemispherical domes, with both design diameters, were manufactured using a 5-axis mill. The prototype was then retrofitted with lenses and compared with the computer-generated model to demonstrate the effectiveness of this solution. This work shows the dome design improves the optical field of view of the underwater communication system considerably. Furthermore, with the experimental test results, a geometric optimization model was derived providing insights to the design performance limits.

Design↗

NASA NTRS2017

Hemispherical Optical Dome for Underwater Communication

For many years, acoustic systems have been used as the primary method for underwater communication; however, the data transfer rate of such systems is low because sound propagates slowly through the water. A higher throughput can be achieved using visible light to transmit data underwater. The first issue with using this approach is that there is generally a large loss of the light signal due to scattering and absorption in water even though there is an optimal wavelength for transmission in the blue or green wavelengths of the visible spectrum. The second issue is that a simple system consisting only of a highly directional source/transmitter and small optical detector/receiver has a very narrow field of view. The goal of this project is to improve an optical, underwater communication system by increasing the effective field of view of the receiving optics. To this end, we make two changes to the simple system: (1) An optical dome was added near the receiver. An array of lenses is placed radially on the surface of the dome, reminiscent of the compound eye of an insect. The lenses make the source and detector planes conjugate, and each lens adds a new region of the source plane to the instrument's total field of view. (2) The receiver was expanded to include multiple photodiodes. With these two changes, the receiver has much more tolerance to misalignments (in position and angle) of the transmitter.Two versions of the optical dome (with 6 and 8 diameters) were designed using the CREO CAD software and modeled using the CODE V optical design software. A series of these transparent hemispherical domes, with both design diameters, were manufactured using a 5-axis mill. The prototype was then retrofitted with lenses and compared with the computer-generated model to demonstrate the effectiveness of this solution. This work shows the dome design improves the optical field of view of the underwater communication system considerably. Furthermore, with the experimental test results, a geometric optimization model was derived providing insights to the design performance limits.

Underwater↗

NASA NTRS2006

Calibration Issues and Operating System Requirements for Electron-Probe Microanalysis

Instrument purchase requirements and dialogue with manufacturers have established hardware parameters for alignment, stability, and reproducibility, which have helped improve the precision and accuracy of electron microprobe analysis (EPMA). The development of correction algorithms and the accurate solution to quantitative analysis problems requires the minimization of systematic errors and relies on internally consistent data sets. Improved hardware and computer systems have resulted in better automation of vacuum systems, stage and wavelength-dispersive spectrometer (WDS) mechanisms, and x-ray detector systems which have improved instrument stability and precision. Improved software now allows extended automated runs involving diverse setups and better integrates digital imaging and quantitative analysis. However, instrumental performance is not regularly maintained, as WDS are aligned and calibrated during installation but few laboratories appear to check and maintain this calibration. In particular, detector deadtime (DT) data is typically assumed rather than measured, due primarily to the difficulty and inconvenience of the measurement process. This is a source of fundamental systematic error in many microprobe laboratories and is unknown to the analyst, as the magnitude of DT correction is not listed in output by microprobe operating systems. The analyst must remain vigilant to deviations in instrumental alignment and calibration, and microprobe system software must conveniently verify the necessary parameters. Microanalysis of mission critical materials requires an ongoing demonstration of instrumental calibration. Possible approaches to improvements in instrument calibration, quality control, and accuracy will be discussed. Development of a set of core requirements based on discussions with users, researchers, and manufacturers can yield documents that improve and unify the methods by which instruments can be calibrated. These results can be used to continue improvements of EPMA.

Carpenter, P.↗

NASA NTRS1978

Water system microbial check valve development

A residual iodine microbial check valve (RIMCV) assembly was developed and tested. The assembly is designed to be used in the space shuttle potable water system. The RIMCV is based on an anion exchange resin that is supersaturated with an iodine solution. This system causes a residual to be present in the effluent water which provides continuing bactericidal action. A flight prototype design was finalized and five units were manufactured and delivered.

Colombo, G. V.↗

NASA NTRS1979

Liquid hydrogen/oxygen external tank development for the Space Shuttle

The evolution of the Space Shuttle System using an expendable External Tank was discussed. The reasoning for the cryogenic propellant selection for the Space Shuttle Main Engine was addressed. The unique problems, solutions, and design features imposed on the External Tank by the cryogenic propellants was discussed with special emphasis on the use of cryogenic insulation for aerodynamic heating protection. Manufacturing techniques for high production rate cryogenic tankage concluded the report.

Odom, J. B.↗

NASA NTRS1983

The role of simulation prior to manufacturing in space

Prior to manufacturing in space, it is useful to conduct analog experiments where possible so that problems that are apt to be encountered may be identified and planning toward their solution considered. An example is presented involving containerless casting in a near zero gravitational field using paraffin wax as the material cast surrounded by a heated fluid immiscible with the wax that renders it neutrally buoyant.

Shaw, M. C.↗