Search NASA⌕ Search

SEARCH · Search NASA

Results for “Novel Processing”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 253 records · Page 14

Material processing with hydrogen and carbon monoxide on Mars

Several novel proposals are examined for propellant production from carbon dioxide and monoxide and hydrogen. Potential uses were also examined of CO as a fuel or as a reducing agent in metal oxide processing as obtained or further reduced to carbon. Hydrogen can be reacted with CO to produce a wide variety of hydrocarbons, alcohols, and other organic compounds. Methanol, produced by Fischer-Tropsch chemistry may be useful as a fuel; it is easy to store and handle because it is a liquid at Mars temperatures. The reduction of CO2 to hydrocarbons such as methane or acetylene can be accomplished with hydrogen. Carbon monoxide and hydrogen require cryogenic temperatures for storage as liquids. Noncryogenic storage of hydrogen may be accomplished using hydrocarbons, inorganic hydrides, or metal hydrides. Noncryogenic storage of CO may be accomplished in the form of iron carbonyl (FE(CO)5) or other metal carbonyls. Low hydrogen content fuels such as acetylene (C2H2) may be effective propellants with low requirements for earth derived resources. The impact on manned Mars missions of alternative propellant production and utilization is discussed.

Hepp, Aloysius F.↗

Material processing with hydrogen and carbon monoxide on Mars

Several novel proposals are examined for propellant production from carbon dioxide and monoxide and hydrogen. Potential uses were also examined of CO as a fuel or as a reducing agent in metal oxide processing as obtained or further reduced to carbon. Hydrogen can be reacted with CO to produce a wide variety of hydrocarbons, alcohols, and other organic compounds. Methanol, produced by Fischer-Tropsch chemistry may be useful as a fuel; it is easy to store and handle because it is a liquid at Mars temperatures. The reduction of CO2 to hydrocarbons such as methane or acetylene can be accomplished with hydrocarbons. Carbon monoxide and hydrogen require cryogenic temperatures for storage as liquid. Noncryogenic storage of hydrogen may be accomplished using hydrocarbons, inorganic hydrides, or metal hydrides. Noncryogenic storage of CO may be accomplished in the form of iron carbonyl (FE(CO)5) or other metal carbonyls. Low hydrogen content fuels such as acetylene (C2H2) may be effective propellants with low requirements for earth derived resources. The impact on manned Mars missions of alternative propellant production and utilization is discussed.

Hepp, Aloysius F.↗

BUNDLE: A Novel Furnace for Performing Controlled Directional Solidification Experiments in a Microgravity Environment

NASA Marshall Space Flight Center has developed a novel directional solidification furnace prototype for processing metals and alloys experiments in a microgravity environment. The BUNDLE (Bridgman Unidirectional Dendrite in Liquid Experiment) furnace is intended to accommodate the science requirements of Flight Definition Principle Investigators studying cellular/dendritic growth in aluminum and lead alloys at processing temperatures up to 1200 C. The furnace implements a number of innovative features to achieve high thermal gradients and quench rates in a low-power, light-weight design. These include a pyrolytic boron nitride/graphite composite heating element surrounded by layers of self-supporting refractory metal shielding, and a graphite fiber enhanced cold zone allowing high levels of heat extraction from the sample crucible. Novel to the BUNDLE design is an in-situ helium gas quench capability that ensures rapid freezing of the solidifying region (mushy zone) of the metal sample within the furnace without sample disturbance prior to quenching; this is a stringent requirement for subsequent analysis and understanding of microstructural development. The experiment hardware concept features multiple furnaces that may be "bundled" together so many samples, currently up to eight, can be processed at one time. The design of BUNDLE is flexible enough to be implemented on the Shuttle and Space Station in a number of locations (SpaceHab, Express Rack, MPESS, ISPR, etc). BUNDLE prototype furnaces have directionally solidified and quenched 1cm diameter lead - 5.8 weight percent antimony and aluminum - 4 weight percent copper alloys. Quenching of the mushy zone, as recorded by in-situ thermocouples, occurred on the order of 0.5 seconds or less, a rate within the PI's requirements. Subsequent metallographic examination revealed the solidified microstructure to be, as expected, unidirectional. Both the dendrite tips and the eutectic reaction were planar in nature indicating uniform axial heat flow. Delineation between the growing dendrites and eutectic structure with the "quenched-in" liquid was sharp, attesting to the efficacy of the helium quench. BUNDLE's conception, development, capability, and adaptability are presented (in view of Flight PI's needs and science requirements) through viewgraphs depicting actual hardware, generated thermal analysis, and micrographs prepared from BUNDLE processed, flight-like samples.

Carrasquillo, Edgar J.↗

BUNDLE - A Novel Furnace for Performing Controlled Directional Solidification Experiments in a Microgravity Environment

NASA Marshall Space Flight Center has developed a novel directional solidification furnace prototype for processing metals and alloys experiments in a microgravity environment. The BUNDLE (Bridgman Unidirectional Dendrite in Liquid Experiment) furnace is intended to accommodate the science requirements of Flight Definition Principle Investigators studying cellular/dendritic growth in aluminum and lead alloys at processing temperatures up to 1200 C. The furnace implements a number of innovative features to achieve high thermal gradients and quench rates in a low-power, light-weight design. These include a pyrolytic boron nitride/graphite composite heating element surrounded by layers of self-supporting refractory metal shielding, and a graphite fiber enhanced cold zone allowing high levels of heat extraction from the sample crucible. Novel to the BUNDLE design is an in-situ helium gas quench capability that ensures rapid freezing of the solidifying region (mushy zone) of the metal sample within the furnace without sample disturbance prior to quenching; this is a stringent requirement for subsequent analysis and understanding of microstructural development. The experiment hardware concept features multiple furnaces that may be "bundled" together so many samples, currently up to eight, can be processed at one time. The design of BUNDLE is flexible enough to be implemented on the Shuttle and Space Station in a number of locations (SpaceHab, Express Rack, MPESS, ISPR, etc). BUNDLE prototype furnaces have directionally solidified and quenched 1cm diameter lead - 5.8 weight percent antimony and aluminum - 4 weight percent copper alloys. Quenching of the mushy zone, as recorded by in-situ thermocouples, occurred on the order of 0.5 seconds or less, a rate within the PI's requirements. Subsequent metallographic examination revealed the solidified microstructure to be, as expected, unidirectional. Both the dendrite tips and the eutectic reaction were planar in nature indicating uniform axial heat flow. Delineation between the growing dendrites and eutectic structure with the "quenched-in" liquid was sharp, attesting to the efficacy of the helium quench. BUNDLE's conception, development, capability, and adaptability are presented (in view of Flight PI's needs and science requirements) through viewgraphs depicting actual hardware, generated thermal analysis, and micrographs prepared from BUNDLE processed, flight-like samples.

Carrasquillo, Edgar J.↗

Review and evaluation of space processing applications

Materials research in space which offers advantages in studying phenomena and preparing materials under conditions which cannot be realized in the gravity field of the Earth is discussed. Many techniques were developed to improve processing systems and reduce the effect of gravitationally induced restrictions. The space-based devices take advantage of a wide range of low-gravity facilities including drop towers and tubes, aircraft and sounding rocket parabolic trajectories, simple materials experiment accommodations in the Space Shuttle, and more complex capabilities in Spacelab. All these systems are used to produce novel materials and to study material processing under unique conditions.

Source record↗

Advancement of Extreme Environment Additively Manufactured Alloys for Next Generation Space Propulsion Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into propulsion development and flight applications. NASA matured commonly used aerospace alloys from various alloy families (Nickel, Copper, Stainless and Steel, Aluminum, and Titanium-based) through detailed AM process and heat treatment characterization, in addition to mechanical and thermophysical testing. While these alloys are actively used in many propulsion applications, there is a need for ongoing AM optimized alloys using integrated computational materials engineering (ICME) and process development for high performance applications. The applications targeted are liquid rocket engines; advanced propulsion systems; and in-space propulsion with high heat fluxes, high pressure, and/or that use propellants that can degrade alloys (e.g., hydrogen). This paper highlights the characterization and physical properties of the more common AM alloys using laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Additionally, this paper discusses some of the ongoing novel alloy development and maturation using AM for use in these harsh environments, such as GRCop42, GRCop-84, NASA HR-1, GRX-810, and C-103. The results from these processes demonstrated that AM could enable rapid development and ongoing efforts for optimized alloys using ICME, yielding higher performances. These alloys have undergone modeling, fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing campaigns. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL) through high duty-cycle testing. A background and overview of these novel AM-enabled alloys and AM processing developments including metallurgical and mechanical property studies is presented here. The latest advancement in the parallel component development and hot-fire testing and future developments for these alloys is also discussed.

Additive Manufacturing↗

Advancement of Extreme Environment Additively Manufactured Alloys for Next Generation Space Propulsion Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into propulsion development and flight applications. NASA matured commonly used aerospace alloys from various alloy families (Nickel, Copper, Stainless and Steel, Aluminum, and Titanium-based) through detailed AM process and heat treatment characterization, in addition to mechanical and thermophysical testing. While these alloys are actively used in many propulsion applications, there is a need for ongoing AM optimized alloys using integrated computational materials engineering (ICME) and process development for high performance applications. The applications targeted are liquid rocket engines; advanced propulsion systems; and in-space propulsion with high heat fluxes, high pressure, and/or that use propellants that can degrade alloys (e.g., hydrogen). This paper highlights the characterization and physical properties of the more common AM alloys using laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Additionally, this paper discusses some of the ongoing novel alloy development and maturation using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, GRX-810, and C-103. The results from these processes demonstrated that AM could enable rapid development and ongoing efforts for optimized alloys using ICME, yielding higher performances. These alloys have undergone modeling, fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing campaigns. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL) through high duty-cycle testing. A background and overview of these novel AM-enabled alloys and AM processing developments including metallurgical and mechanical property studies is presented here. The latest advancement in the parallel component development and hot-fire testing and future developments for these alloys is also discussed.

Additive Manufacturing↗

Developments on Reusable TPS Materials Based Upon Shuttle Tile

The insulating tiles used on the Space Shuttler Orbiter, principally AETB (Alumina Enhanced Thermal Barrier), have been seen by new vehicle developers in the aerospace industry as a fast-track approach for fielding a reusable thermal protection system (TPS) given the extensive use by both the Orbiter program and the current Orion vehicle. NASA has, and is, supporting the industry through technology transfer and commercial crew and payloads programs. However, the reusable TPS community is rapidly encountering challenges rooted in Orbiter’s and Orion’s dependence on legacy material and processes. With the aim of alleviating these issues, improving availability of reusable TPS, and strengthening the nation’s space economy, ongoing efforts at NASA Ames have focused on understanding process-property relationships in AETB as well as novel materials and technologies for reusable TPS. The first portion of this talk will address the effects of raw materials and processing conditions on the properties of AETB-8, including the raw materials used, mixing and casting parameters, and thermal history. Understanding these relationships, and how they extend to aerothermal performance, is instrumental in alleviating supply chain constraints and improving manufacturability. The implications of these finding on development of novel TPS materials and systems will be discussed. AETB will likely continue to fill a niche of relatively high performance with associated costs. There exists, therefore, a gap in developed reusable TPS for a lower cost, moderate performing material system. The later portion of this talk will touch on current development efforts at Ames focusing on reduced cost and ease of integration, which are being pursued in addition to AETB and higher performing systems. In addition to summarizing these efforts, an outlook for these projects and collaborations will be given.

Peter Edward Marshall↗

Developments on Reusable TPS Materials Based Upon Shuttle Tile

The insulating tiles used on the Space Shuttler Orbiter, principally AETB (Alumina Enhanced Thermal Barrier), have been seen by new vehicle developers in the aerospace industry as a fast-track approach for fielding a reusable thermal protection system (TPS) given the extensive use by both the Orbiter program and the current Orion vehicle. NASA has, and is, supporting the industry through technology transfer and commercial crew and payloads programs. However, the reusable TPS community is rapidly encountering challenges rooted in Orbiter’s and Orion’s dependence on legacy material and processes. With the aim of alleviating these issues, improving availability of reusable TPS, and strengthening the nation’s space economy, ongoing efforts at NASA Ames have focused on understanding process-property relationships in AETB as well as novel materials and technologies for reusable TPS. The first portion of this talk will address the effects of raw materials and processing conditions on the properties of AETB-8, including the raw materials used, mixing and casting parameters, and thermal history. Understanding these relationships, and how they extend to aerothermal performance, is instrumental in alleviating supply chain constraints and improving manufacturability. The implications of these finding on development of novel TPS materials and systems will be discussed. AETB will likely continue to fill a niche of relatively high performance with associated costs. There exists, therefore, a gap in developed reusable TPS for a lower cost, moderate performing material system. The later portion of this talk will touch on current development efforts at Ames focusing on reduced cost and ease of integration, which are being pursued in addition to AETB and higher performing systems. In addition to summarizing these efforts, an outlook for these projects and collaborations will be given.

Thermal Protection Systems↗

The impact crater as a habitat: effects of impact processing of target materials

Impact structures are a rare habitat on Earth. However, where they do occur they can potentially have an important influence on the local ecology. Some of the types of habitat created in the immediate post-impact environment are not specific to the impact phenomenon, such as hydrothermal systems and crater lakes that can be found, for instance, in post-volcanic environments, albeit with different thermal characteristics than those associated with impact. However, some of the habitats created are specifically linked to processes of impact processing. Two examples of how impact processing of target materials has created novel habitats that improve the opportunities for colonization are found in the Haughton impact structure in the Canadian High Arctic. Impact-shocked rocks have become a habitat for endolithic microorganisms, and large, impact-shattered blocks of rock are used as resting sites by avifauna. However, some materials produced by an impact, such as melt sheet rocks, can make craters more biologically depauperate than the area surrounding them. Although there are no recent craters with which to study immediate post-impact colonization, these data yield insights into generalized mechanisms of how impact processing can influence post-impact succession. Because impact events are one of a number of processes that can bring localized destruction to ecosystems, understanding the manner in which impact structures are recolonized is of ecological interest. Impact craters are a universal phenomenon on solid planetary surfaces, and so they are of potential biological relevance on other planetary surfaces, particularly Mars.

Environment↗

Telerobotic Surgery: An Intelligent Systems Approach to Mitigate the Adverse Effects of Communication Delay

An extremely innovative approach has been presented, which is to have the surgeon operate through a simulator running in real-time enhanced with an intelligent controller component to enhance the safety and efficiency of a remotely conducted operation. The use of a simulator enables the surgeon to operate in a virtual environment free from the impediments of telecommunication delay. The simulator functions as a predictor and periodically the simulator state is corrected with truth data. Three major research areas must be explored in order to ensure achieving the objectives. They are: simulator as predictor, image processing, and intelligent control. Each is equally necessary for success of the project and each of these involves a significant intelligent component in it. These are diverse, interdisciplinary areas of investigation, thereby requiring a highly coordinated effort by all the members of our team, to ensure an integrated system. The following is a brief discussion of those areas. Simulator as a predictor: The delays encountered in remote robotic surgery will be greater than any encountered in human-machine systems analysis, with the possible exception of remote operations in space. Therefore, novel compensation techniques will be developed. Included will be the development of the real-time simulator, which is at the heart of our approach. The simulator will present real-time, stereoscopic images and artificial haptic stimuli to the surgeon. Image processing: Because of the delay and the possibility of insufficient bandwidth a high level of novel image processing is necessary. This image processing will include several innovative aspects, including image interpretation, video to graphical conversion, texture extraction, geometric processing, image compression and image generation at the surgeon station. Intelligent control: Since the approach we propose is in a sense predictor based, albeit a very sophisticated predictor, a controller, which not only optimizes end effector trajectory but also avoids error, is essential. We propose to investigate two different approaches to the controller design. One approach employs an optimal controller based on modern control theory; the other one involves soft computing techniques, i.e. fuzzy logic, neural networks, genetic algorithms and hybrids of these.

Cardullo, Frank M.↗

Investigating Morphological Stability of Faceted Interfaces with Axial Heat Processing (AHP) Technique

Successful processing of homogeneous semiconductor single crystals from their melts depends strongly on precise control of thermal and fluid flow conditions near the solid/liquid interface. In this project, we utilize a novel crystal growth technique called Axial Heat Processing (AHP) that uses a baffle, positioned inside the melt near the interface, to supply and/or conduct heat axially to the interface. The baffle, which may or may not have a heater encased in it, can promote more stable and planar growth as well as reduce buoyancy driven convection. The latter is because the baffle reduces the aspect ratio of the melt as it separates the melt into three sections, above the baffle, in the feed gap between the baffle and the crucible wall, and below the baffle between the baffle base and the interface. AHP also enables a close monitoring and/or control of thermal boundaries near the solid/liquid interface during crystal growth by means of thermocouples placed in the baffle. The interface is kept planar when a heating element in the baffle is used. However, a proper choice of melt height is necessary to keep the interface planar when using the baffle without a heater. This study addresses the influence of melt height and growth velocity on the segregation profile of AHP-grown Sb doped Ge single crystals.

Abbaschian, Reza↗

Rapid Solidification of Magnetic Oxides

The enhanced control over microstructural evolution inherent in rapid solidification processing techniques are exploited to create novel ceramic magnetic materials. The great sensitivity of magnetic properties to local structure provides a powerful probe both for the study of structure and of microscopic solidification mechanisms. The first system studied is the SrO-Fe2O3 binary, which contains the commercially important hard magnetic compound strontium hexaferrite. The products were analyzed by transmission electron microscopy, Mossbauer spectroscopy, magnetic measurements, and differential thermal analysis. As-quenched ribbons contain high concentrations of super-paramagnetic particles, 80 to 250 Angstroms in diameter, in a glassy matrix. This suggests the possibility of crystallizing monodomain strontium hexaferrite during subsequent heat treatment, with a resulting increase in coercivity over conventionally processed ferrite magnets. That magnetic properties can be controlled in solidification processing by varying the quench rate is demonstrated.

Kalonji, G.↗

Spacecraft Mission Design for the Mitigation of the 2017 PDC Hypothetical Asteroid Threat

This paper presents a detailed mission design analysis results for the 2017 Planetary Defense Conference (PDC) Hypothetical Asteroid Impact Scenario, documented at https://cneos.jpl.nasa.gov/ pd/cs/pdc17/. The mission design includes campaigns for both reconnaissance (flyby or rendezvous) of the asteroid (to characterize it and the nature of the threat it poses to Earth) and mitigation of the asteroid, via kinetic impactor deflection, nuclear explosive device (NED) deflection, or NED disruption. Relevant scenario parameters are varied to assess the sensitivity of the design outcome, such as asteroid bulk density, asteroid diameter, momentum enhancement factor, spacecraft launch vehicle, and mitigation system type. Different trajectory types are evaluated in the mission design process from purely ballistic to those involving optimal midcourse maneuvers, planetary gravity assists, and/or lowthrust solar electric propulsion. The trajectory optimization is targeted around peak deflection points that were found through a novel linear numerical technique method. The optimization process includes constrain parameters, such as Earth departure date, launch declination, spacecraft/asteroid relative velocity and solar phase angle, spacecraft dry mass, minimum/maximum spacecraft distances from Sun and Earth, and Earth/spacecraft communications line of sight. Results show that one of the best options for the 2017 PDC deflection is solar electric propelled rendezvous mission with a single spacecraft using NED for the deflection

Barbee, Brent W.↗

Alternative Processing of High Temperature Hafnium and Zirconium Based Materials

The behavior of refractory hafnium and zirconium based materials are being investigated at NASA Ames as part of ongoing research aimed at developing superior heat resistant materials for aerospace applications. Hafnium and zirconium diboride based materials have shown high temperature capabilities in simulated reentry environments indicating that these materials may successfully operate as reusable oxidation resistant components for leading edge applications. Due to the refractory nature of these materials, processing of fine-grained uniform microstructures poses a number of challenges. To better understand the process-property-microstructure relationship, processing of these materials has been carried out with conventional hot pressing in addition to the novel approach of Spark Plasma Sintering (SPS). The two processing methods are compared and contrasted in an evaluation of the sintering behavior of high temperature diboride based materials and preliminary physical and mechanical properties are presented.

Gasch, Matthew↗

Unsupervised Detection of Planetary Craters by a Marked Point Process

With the launch of several planetary missions in the last decade, a large amount of planetary images is being acquired. Preferably, automatic and robust processing techniques need to be used for data analysis because of the huge amount of the acquired data. Here, the aim is to achieve a robust and general methodology for crater detection. A novel technique based on a marked point process is proposed. First, the contours in the image are extracted. The object boundaries are modeled as a configuration of an unknown number of random ellipses, i.e., the contour image is considered as a realization of a marked point process. Then, an energy function is defined, containing both an a priori energy and a likelihood term. The global minimum of this function is estimated by using reversible jump Monte-Carlo Markov chain dynamics and a simulated annealing scheme. The main idea behind marked point processes is to model objects within a stochastic framework: Marked point processes represent a very promising current approach in the stochastic image modeling and provide a powerful and methodologically rigorous framework to efficiently map and detect objects and structures in an image with an excellent robustness to noise. The proposed method for crater detection has several feasible applications. One such application area is image registration by matching the extracted features.

Troglio, G.↗

Spacecraft Mission Design for the Mitigation of the 2017 PDC Hypothetical Asteroid Threat

This paper presents a detailed mission design analysis results for the 2017 Planetary Defense Conference (PDC) Hypothetical Asteroid Impact Scenario, documented at https:cneos.jpl.nasa.govpdcspdc17. The mission design includes campaigns for both reconnaissance (flyby or rendezvous) of the asteroid (to characterize it and the nature of the threat it poses to Earth) and mitigation of the asteroid, via kinetic impactor deflection, nuclear explosive device (NED) deflection, or NED disruption. Relevant scenario parameters are varied to assess the sensitivity of the design outcome, such as asteroid bulk density, asteroid diameter, momentum enhancement factor, spacecraft launch vehicle, and mitigation system type. Different trajectory types are evaluated in the mission design process from purely ballistic to those involving optimal midcourse maneuvers, planetary gravity assists, and/or low-thrust solar electric propulsion. The trajectory optimization is targeted around peak deflection points that were found through a novel linear numerical technique method. The optimization process includes constrain parameters, such as Earth departure date, launch declination, spacecraft, asteroid relative velocity and solar phase angle, spacecraft dry mass, minimum/maximum spacecraft distances from Sun and Earth, and Earth-spacecraft communications line of sight. Results show that one of the best options for the 2017 PDC deflection is solar electric propelled rendezvous mission with a single spacecraft using NED for the deflection.

Barbee, Brent W.↗

On the nonlinear development of three-dimensional instability waves in natural transition

The nonlinear development of a pair of symmetrical three-dimensional oblique instability waves in transitioning boundary layers is investigated based on critical-layer nonlinearity (CLN). Particular emphasis is placed on understanding the mechanisms leading to the naturally occurring transition in which the amplitudes of the plane and oblique modes can be of the same order. Results indicate that the self-interaction of the oblique waves reduces their growth rate. A relatively large oblique mode can either suppress or enhance the growth of the plane mode, depending on the initial phase difference. If the plane mode amplitude is not negligible with respect to that of the oblique modes, it causes a strong amplification of the oblique mode at the subharmonic frequency. The comparison with observations are quite encouraging and several novel features of the natural transition process are revealed.

Mankbadi, Reda R.↗