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NASA NTRS2012

Materials Advance Chemical Propulsion Technology

In the future, the Planetary Science Division of NASA's Science Mission Directorate hopes to use better-performing and lower-cost propulsion systems to send rovers, probes, and observers to places like Mars, Jupiter, and Saturn. For such purposes, a new propulsion technology called the Advanced Materials Bipropellant Rocket (AMBR) was developed under NASA's In-Space Propulsion Technology (ISPT) project, located at Glenn Research Center. As an advanced chemical propulsion system, AMBR uses nitrogen tetroxide oxidizer and hydrazine fuel to propel a spacecraft. Based on current research and development efforts, the technology shows great promise for increasing engine operation and engine lifespan, as well as lowering manufacturing costs. In developing AMBR, ISPT has several goals: to decrease the time it takes for a spacecraft to travel to its destination, reduce the cost of making the propulsion system, and lessen the weight of the propulsion system. If goals like these are met, it could result in greater capabilities for in-space science investigations. For example, if the amount (and weight) of propellant required on a spacecraft is reduced, more scientific instruments (and weight) could be added to the spacecraft. To achieve AMBR s maximum potential performance, the engine needed to be capable of operating at extremely high temperatures and pressure. To this end, ISPT required engine chambers made of iridium-coated rhenium (strong, high-temperature metallic elements) that allowed operation at temperatures close to 4,000 F. In addition, ISPT needed an advanced manufacturing technique for better coating methods to increase the strength of the engine chamber without increasing the costs of fabricating the chamber.

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NASA NTRS2012

Performance of Simple Gas Foil Thrust Bearings in Air

Foil bearings are self-acting hydrodynamics devices used to support high speed rotating machinery. The advantages that they offer to process fluid lubricated machines include: high rotational speed capability, no auxiliary lubrication system, non-contacting high speed operation, and improved damping as compared to rigid hydrodynamic bearings. NASA has had a sporadic research program in this technology for almost 6 decades. Advances in the technology and understanding of foil journal bearings have enabled several new commercial products in recent years. These products include oil-free turbochargers for both heavy trucks and automobiles, high speed electric motors, microturbines for distributed power generation, and turbojet engines. However, the foil thrust bearing has not received a complimentary level of research and therefore has become the weak link of oil-free turbomachinery. In an effort to both provide machine designers with basic performance parameters and to elucidate the underlying physics of foil thrust bearings, NASA Glenn Research Center has completed an effort to experimentally measure the performance of simple gas foil thrust bearing in air. The database includes simple bump foil supported thrust bearings with full geometry and manufacturing techniques available to the user. Test conditions consist of air at ambient pressure and temperatures up to 500 C and rotational speeds to 55,000 rpm. A complete set of axial load, frictional torque, and rotational speed is presented for two different compliant sub-structures and inter-pad gaps. Data obtained from commercially available foil thrust bearings both with and without active cooling is presented for comparison. A significant observation made possible by this data set is the speed-load capacity characteristic of foil thrust bearings. Whereas for the foil journal bearing the load capacity increases linearly with rotational speed, the foil thrust bearing operates in the hydrodynamic high speed limit. In this case, the load capacity is constant and in fact often decreases with speed if other factors such as thermal conditions and runner distortions are permitted to dominate the bearing performance.

Bruckner, Robert J.↗

NASA NTRS2012

Sizing and Lifecycle Cost Analysis of an Ares V Composite Interstage

The Interstage Element of the Ares V launch vehicle was sized using a commercially available structural sizing software tool. Two different concepts were considered, a metallic design and a composite design. Both concepts were sized using similar levels of analysis fidelity and included the influence of design details on each concept. Additionally, the impact of the different manufacturing techniques and failure mechanisms for composite and metallic construction were considered. Significant details were included in analysis models of each concept, including penetrations for human access, joint connections, as well as secondary loading effects. The designs and results of the analysis were used to determine lifecycle cost estimates for the two Interstage designs. Lifecycle cost estimates were based on industry provided cost data for similar launch vehicle components. The results indicated that significant mass as well as cost savings are attainable for the chosen composite concept as compared with a metallic option.

Mann, Troy↗

NASA NTRS2012

Evaluation of Parallel-Element, Variable-Impedance, Broadband Acoustic Liner Concepts

Recent trends in aircraft engine design have highlighted the need for acoustic liners that provide broadband sound absorption with reduced liner thickness. Three such liner concepts are evaluated using the NASA normal incidence tube. Two concepts employ additive manufacturing techniques to fabricate liners with variable chamber depths. The first relies on scrubbing losses within narrow chambers to provide acoustic resistance necessary for sound absorption. The second employs wide chambers that provide minimal resistance, and relies on a perforated sheet to provide acoustic resistance. The variable-depth chambers used in both concepts result in reactance spectra near zero. The third liner concept employs mesh-caps (resistive sheets) embedded at variable depths within adjacent honeycomb chambers to achieve a desired impedance spectrum. Each of these liner concepts is suitable for use as a broadband sound absorber design, and a transmission line model is presented that provides good comparison with their respective acoustic impedance spectra. This model can therefore be used to design acoustic liners to accurately achieve selected impedance spectra. Finally, the effects of increasing the perforated facesheet thickness are demonstrated, and the validity of prediction models based on lumped element and wave propagation approaches is investigated. The lumped element model compares favorably with measured results for liners with thin facesheets, but the wave propagation model provides good comparisons for a wide range of facesheet thicknesses.

Jones, Michael G.↗

NASA NTRS2009

Recent Electric Propulsion Development Activities for NASA Science Missions

(The primary source of electric propulsion development throughout NASA is managed by the In-Space Propulsion Technology Project at the NASA Glenn Research Center for the Science Mission Directorate. The objective of the Electric Propulsion project area is to develop near-term electric propulsion technology to enhance or enable science missions while minimizing risk and cost to the end user. Major hardware tasks include developing NASA s Evolutionary Xenon Thruster (NEXT), developing a long-life High Voltage Hall Accelerator (HIVHAC), developing an advanced feed system, and developing cross-platform components. The objective of the NEXT task is to advance next generation ion propulsion technology readiness. The baseline NEXT system consists of a high-performance, 7-kW ion thruster; a high-efficiency, 7-kW power processor unit (PPU); a highly flexible advanced xenon propellant management system (PMS); a lightweight engine gimbal; and key elements of a digital control interface unit (DCIU) including software algorithms. This design approach was selected to provide future NASA science missions with the greatest value in mission performance benefit at a low total development cost. The objective of the HIVHAC task is to advance the Hall thruster technology readiness for science mission applications. The task seeks to increase specific impulse, throttle-ability and lifetime to make Hall propulsion systems applicable to deep space science missions. The primary application focus for the resulting Hall propulsion system would be cost-capped missions, such as competitively selected, Discovery-class missions. The objective of the advanced xenon feed system task is to demonstrate novel manufacturing techniques that will significantly reduce mass, volume, and footprint size of xenon feed systems over conventional feed systems. This task has focused on the development of a flow control module, which consists of a three-channel flow system based on a piezo-electrically actuated valve concept, as well as a pressure control module, which will regulate pressure from the propellant tank. Cross-platform component standardization and simplification are being investigated through the Standard Architecture task to reduce first user costs for implementing electric propulsion systems. Progress on current hardware development, recent test activities and future plans are discussed.

Pencil, Eric J.↗

NASA NTRS2013

Ultra-Thin Coatings Beautify Art

The craftsmen in the Roman Empire who constructed the Lycurgus Cup 17 centuries ago probably didn't think their artifact would survive for nearly 2,000 years as a prized possession. And they certainly couldn't have known that the technology they used to make it would eventually become an important part of space exploration. Carved from one solid mass, the cup is one of the few complete glass objects from that period, and the only one made from dichroic glass. Meaning "two-colored" in Greek, dichroic glass was originally created by adding trace amounts of gold and silver to a large volume of glass melt. The resulting medium partially reflects the light passing through it, causing an observer to see different colors depending on the direction of the light source. The Lycurgus Cup, for example, is famous for appearing green in daylight and red when lit at night, symbolic of the ripening grapes used to fill it with wine. NASA revitalized the production of dichroic glass in the 1950s and 1960s as a means of protecting its astronauts. Ordinary clear substances cannot protect human vision from the harsh rays of unfiltered sunlight, and everything from the human body to spacecraft sensors and computers are at risk if left unprotected from the radiation that permeates space. The microscopic amounts of metal present in dichroic glass make it an effective barrier against such harmful radiation. While the ancient manufacturing technique called for adding metals to glass melt, NASA developed a process in which metals are vaporized by electron beams in a vacuum chamber and then applied directly to surfaces in an ultra-thin film. The vapor condenses in the form of crystal structures, and the process is repeated for up to several dozen coatings. The resulting material, still only about 30 millionths of an inch thick, is sufficient to reflect radiation even while the glass, or polycarbonate, as in the case of space suit helmets, remains transparent to the human eye.

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NASA NTRS2013

ISRU Propellant Selection for Space Exploration Vehicles

Chemical propulsion remains the only viable solution as technically matured technology for the near term human space transportation to Lunar and Mars. Current mode of space travel requires us to "take everything we will need", including propellant for the return trip. Forcing the mission designers to carry propellant for the return trip limits payload mass available for mission operations and results in a large and costly (and often unaffordable) design. Producing propellant via In-Situ Resource Utilization (ISRU) will enable missions with chemical propulsion by the "refueling" of return-trip propellant. It will reduce vehicle propellant mass carrying requirement by over 50%. This mass reduction can translates into increased payload to enhance greater mission capability, reduces vehicle size, weight and cost. It will also reduce size of launch vehicle fairing size as well as number of launches for a given space mission and enables exploration missions with existing chemical propulsion. Mars remains the ultimate destination for Human Space Exploration within the Solar System. The Mars atmospheric consist of 95% carbon dioxide (CO2) and the presence of Ice (water) was detected on Mars surfaces. This presents a basic chemical building block for the ISRU propellant manufacturing. However, the rationale for the right propellant to produce via ISRU appears to be limited to the perception of "what we can produce" as oppose to "what is the right propellant". Methane (CH4) is often quoted as a logical choice for Mars ISRU propellant, however; it is believed that there are better alternatives available that can result in a better space transportation architecture. A system analysis is needed to determine on what is the right propellant choice for the exploration vehicle. This paper examines the propellant selection for production via ISRU method on Mars surfaces. It will examine propellant trades for the exploration vehicle with resulting impact on vehicle performance, size, and on launch vehicles. It will investigate propellant manufacturing techniques that will be applicable on Mars surfaces and address related issues on storage, transfer, and safety. Finally, it will also address the operability issues associated with the impact of propellant selection on ground processing and launch vehicle integration.

Chen, Timothy T.↗

NASA NTRS2014

Small, Low Cost, Launch Capability Development

A recent explosion in nano-sat, small-sat, and university class payloads has been driven by low cost electronics and sensors, wide component availability, as well as low cost, miniature computational capability and open source code. Increasing numbers of these very small spacecraft are being launched as secondary payloads, dramatically decreasing costs, and allowing greater access to operations and experimentation using actual space flight systems. While manifesting as a secondary payload provides inexpensive rides to orbit, these arrangements also have certain limitations. Small, secondary payloads are typically included with very limited payload accommodations, supported on a non interference basis (to the prime payload), and are delivered to orbital conditions driven by the primary launch customer. Integration of propulsion systems or other hazardous capabilities will further complicate secondary launch arrangements, and accommodation requirements. The National Aeronautics and Space Administration's Marshall Space Flight Center has begun work on the development of small, low cost launch system concepts that could provide dedicated, affordable launch alternatives to small, high risk university type payloads and spacecraft. These efforts include development of small propulsion systems and highly optimized structural efficiency, utilizing modern advanced manufacturing techniques. This paper outlines the plans and accomplishments of these efforts and investigates opportunities for truly revolutionary reductions in launch and operations costs. Both evolution of existing sounding rocket systems to orbital delivery, and the development of clean sheet, optimized small launch systems are addressed.

Brown, Thomas↗

NASA NTRS2014

Enabling Dedicated, Affordable Space Access Through Aggressive Technology Maturation

A recent explosion in nano-sat, small-sat, and university class payloads has been driven by low cost electronics and sensors, wide component availability, as well as low cost, miniature computational capability and open source code. Increasing numbers of these very small spacecraft are being launched as secondary payloads, dramatically decreasing costs, and allowing greater access to operations and experimentation using actual space flight systems. While manifesting as a secondary payload provides inexpensive rides to orbit, these arrangements also have certain limitations. Small, secondary payloads are typically included with very limited payload accommodations, supported on a non interference basis (to the prime payload), and are delivered to orbital conditions driven by the primary launch customer. Integration of propulsion systems or other hazardous capabilities will further complicate secondary launch arrangements, and accommodation requirements. The National Aeronautics and Space Administration's Marshall Space Flight Center has begun work on the development of small, low cost launch system concepts that could provide dedicated, affordable launch alternatives to small, risk tolerant university type payloads and spacecraft. These efforts include development of small propulsion systems and highly optimized structural efficiency, utilizing modern advanced manufacturing techniques. This paper outlines the plans and accomplishments of these efforts and investigates opportunities for truly revolutionary reductions in launch and operations costs. Both evolution of existing sounding rocket systems to orbital delivery, and the development of clean sheet, optimized small launch systems are addressed. A launch vehicle at the scale and price point which allows developers to take reasonable risks with new propulsion and avionics hardware solutions does not exist today. Establishing this service provides a ride through the proverbial "valley of death" that lies between demonstration in laboratory and flight environments. This effort will provide the framework to mature both on-orbit and earth-to-orbit avionics and propulsion technologies while also providing dedicated, affordable access to LEO for cubesat class payloads.

Jones, Jonathan↗

NASA NTRS2014

Electrohydrodynamic Printing and Manufacturing

An stable electrohydrodynamic filament is obtained by causing a straight electrohydrodynamic filament formed from a liquid to emerge from a Taylor cone, the filament having a diameter of from 10 nm to 100.mu.m. Such filaments are useful in electrohydrodynamic printing and manufacturing techniques and their application in liquid drop/particle and fiber production, colloidal deployment and assembly, and composite materials processing.

Aksay, Ilhan A.↗

NASA NTRS2013

Lap Shear Testing of Candidate Radiator Panel Adhesives

During testing of a subscale radiator section used to develop manufacturing techniques for a full-scale radiator panel, the adhesive bonds between the titanium heat pipes and the aluminum face sheets failed during installation and operation. Analysis revealed that the thermal expansion mismatch between the two metals resulted in relatively large shear stresses being developed even when operating the radiator at moderate temperatures. Lap shear testing of the adhesive used in the original joints demonstrated that the two-part epoxy adhesive fell far short of the strength required. A literature review resulted in several candidate adhesives being selected for lap shear joint testing at room temperature and 398 K, the nominal radiator operating temperature. The results showed that two-part epoxies cured at room and elevated temperatures generally did not perform well. Epoxy film adhesives cured at elevated temperatures, on the other hand, did very well with most being sufficiently strong to cause yielding in the titanium sheet used for the joints. The use of an epoxy primer generally improved the strength of the joint. Based upon these results, a new adhesive was selected for the second subscale radiator section.

Ellis, David↗

NASA NTRS2015

Next Generation Life Support: High Performance EVA Glove

The objectives of the High Performance EVA Glove task are to develop advanced EVA gloves for future human space exploration missions and generate corresponding standards by which progress may be quantitatively assessed. New technologies and manufacturing techniques will be incorporated into the new gloves to address finger and hand mobility, injury reduction and durability in nonpristine environments. Three prototypes will be developed, each focusing on different technological advances. A robotic assist glove will integrate a powered grasping system into the current EVA glove design to reduce astronaut hand fatigue and hand injuries. A mechanical counter pressure (MCP) glove will be developed to further explore the potential of MCP technology and assess its capability for countering the effects of vacuum or low pressure environments on the body by using compression fabrics or materials to apply the necessary pressure. A gas pressurized glove, incorporating new technologies, will be the most flight-like of the three prototypes. Advancements include the development and integration of aerogel insulation, damage sensing components, dust-repellant coatings, and dust tolerant bearings.

Walsh, Sarah K.↗

NASA NTRS2015

Summary of LOX/CH4 Thruster Technology Development at NASA/MSFC

In recent years, a variety of injectors for liquid oxygen (LOX) and methane (CH4) propellant systems have been designed, fabricated, and demonstrated with hot-fire testing at Marshall Space Flight Center (MSFC). Successful designs for liquid methane (LCH4) and gaseous methane (GCH4) have been developed. A variety of chambers, including a transpiration cooled design, along with uncooled ablatives and refractory metals, have also been hot-fire tested by MSFC for use with LOX/LCH4 injectors. Hot-fire testing has also demonstrated multiple ignition source options. Heat flux data for selected injectors has been gathered by testing with a calorimeter chamber. High performance and stable combustion have been demonstrated, along with designs for thrust levels ranging from 500 to 7,000 lbf. The newest LOX/CH4 injector and chamber developed by MSFC have been fabricated with additive manufacturing techniques and include unique design features to investigate regenerative cooling with methane. This low cost and versatile hardware offers a design for 4,000 lbf thrust and will be hot-fire tested at MSFC in 2015. Its design and operation can easily be scaled for use in systems with thrust levels up to 25,000 lbf.

Greene, Sandra Elam↗

NASA NTRS2015

Main Oxidizer Valve Design

A developmental Main Oxidizer Valve (MOV) was designed by NASA-MSFC using additive manufacturing processes. The MOV is a pneumatically actuated poppet valve to control the flow of liquid oxygen to an engine's injector. A compression spring is used to return the valve to the closed state when pneumatic pressure is removed from the valve. The valve internal parts are cylindrical in shape, which lends itself to traditional lathe and milling operations. However, the valve body represents a complicated shape and contains the majority of the mass of the valve. Additive manufacturing techniques were used to produce a part that optimized mass and allowed for design features not practical with traditional machining processes.

Addona, Brad↗

NASA NTRS2015

An Introduction to Atomic Layer Deposition with Thermal Applications

Atomic Layer Deposition (ALD) is a cost effective nano-manufacturing technique that allows for the conformal coating of substrates with atomic control in a benign temperature and pressure environment. Through the introduction of paired precursor gases thin films can be deposited on a myriad of substrates ranging from glass, polymers, aerogels, and metals to high aspect ratio geometries. This talk will focus on the utilization of ALD for engineering applications.

0000↗

NASA NTRS2015

Embedded Thermal Control for Subsystems for Next Generation Spacecraft Applications

Thermal Fluids and Analysis Workshop, Silver Spring MD NCTS 21070-15. NASA, the Defense Department and commercial interests are actively engaged in developing miniaturized spacecraft systems and scientific instruments to leverage smaller cheaper spacecraft form factors such as CubeSats. This paper outlines research and development efforts among Goddard Space Flight Center personnel and its several partners to develop innovative embedded thermal control subsystems. Embedded thermal control subsystems is a cross cutting enabling technology integrating advanced manufacturing techniques to develop multifunctional intelligent structures to reduce Size, Weight and Power (SWaP) consumption of both the thermal control subsystem and overall spacecraft. Embedded thermal control subsystems permit heat acquisition and rejection at higher temperatures than state of the art systems by employing both advanced heat transfer equipment (integrated heat exchangers) and high heat transfer phenomena. The Goddard Space Flight Center Thermal Engineering Branch has active investigations seeking to characterize advanced thermal control systems for near term spacecraft missions. The embedded thermal control subsystem development effort consists of fundamental research as well as development of breadboard and prototype hardware and spaceflight validation efforts. This paper will outline relevant fundamental investigations of micro-scale heat transfer and electrically driven liquid film boiling. The hardware development efforts focus upon silicon based high heat flux applications (electronic chips, power electronics etc.) and multifunctional structures. Flight validation efforts include variable gravity campaigns and a proposed CubeSat based flight demonstration of a breadboard embedded thermal control system. The CubeSat investigation is technology demonstration will characterize in long-term low earth orbit a breadboard embedded thermal subsystem and its individual components to develop optimized operational schema.

Spacecraft Systems↗

NASA NTRS2016

Active CryoCubeSat

The Active CryoCubeSat project will demonstrate an advanced thermal control system for a 6-Unit (6U) CubeSat platform. A miniature, active thermal control system, in which a fluid is circulated in a closed loop from thermal loads to radiators, will be developed. A miniature cryogenic cooler will be integrated with this system to form a two-stage thermal control system. Key components will be miniaturized by using advanced additive manufacturing techniques resulting in a thermal testbed for proving out these technologies. Previous CubeSat missions have not tackled the problem of active thermal control systems nor have any past or current CubeSat missions included cryogenic instrumentation. This Active CryoCubeSat development effort will provide completely new capacities for CubeSats and constitutes a major advancement over the state-of-the-art in CubeSat thermal control.

CubeSat↗

NASA NTRS2015

Advanced Near Net Shape Technology

The objective of the Advanced Near Net Shape Technology (ANNST) project is to radically improve near net shape manufacturing methods from the current Technology/ Manufacturing Readiness Levels (TRL/MRL 3-4) to the point where they are viable candidates (TRL/ MRL-6) for shortening the time and cost for insertion of new aluminum alloys and revolutionary manufacturing methods into the development/improvement of space structures. Conventional cyrotank manufacturing processes require fabrication of multiple pieces welded together to form a complete tank. A variety of near net shape manufacturing processes has demonstrated excellent potential for enabling single-piece construction of components such as domes, barrels, and ring frames. Utilization of such processes can dramatically reduce the extent of welding and joining needed to construct cryogenic tanks and other aerospace structures. The specific focus of this project is to successfully mature the integrally stiffened cylinder (ISC) process in which a single-piece cylinder with integral stiffeners is formed in one spin/flow forming process. Structural launch vehicle components, like cryogenic fuel tanks (e.g., space shuttle external tank), are currently fabricated via multipiece assembly of parts produced through subtractive manufacturing techniques. Stiffened structural panels are heavily machined from thick plate, which results in excessive scrap rates. Multipiece construction requires welds to assemble the structure, which increases the risk for defects and catastrophic failures.

Vickers, John↗