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A review was made of lightweight mobile nuclear power systems (LMNPS). Data cover technical feasibility studies of LMNPS and airborne vehicles, mission studies, and non-technical conditions that are required to develop and use LMNPS.
Six liquid hydrogen feedline design concepts were developed for the cryogenic space tug. The feedlines include composite and all-metal vacuum jacketed and non-vacuum jacketed concepts, and incorporate the latest technology developments in the areas of thermally efficient vacuum jacket end closures and standoffs, radiation shields in the vacuum annulus, thermal coatings, and lightweight dissimilar metal flanged joints. The feedline design concepts were evaluated on the basis of thermal performance, weight, cost, reliability, and reusability. It is shown that composite tubing provides improved thermal performance and reduced weight for each design concept considered. Approximately 12 kg (26 lb.) can be saved by the use of composite tubing for the LH2 feedline and the other propulsion lines in the space tug.
After nearly two decades of study, analysis, and experiments relating to lightweight mobile nuclear power systems (LMNPS), it seems fitting to report the status and to assess some options for the future of this technology. This report: (1) reviews the technical feasibility studies of LMNPS and airborne vehicles; (2) identifies what remains to be done to demonstrate technical feasibility of LMNPS; (3) reviews missions studies and identifies particular missions that could justify renewed support for such technology; and (4) identifies some of the nontechnical conditions that will be required for the development and eventual use of LMNPS.
Method has been developed for fabrication of lightweight ducts that are three times stronger than aluminum ducts. Method can be used to produce either flexible or rigid ducts.
System is composed of three interwoven fiberglass bands that encircle tank surface in basketweave configuration. Fiberglass support is lightweight with low thermal conductivity.
The feasibility of producing a lightweight vacuum jacket using state-of-the-art technology and materials was examined. Design and analytical studies were made on a full-scale, orbital maneuvering system fuel tank. Preliminary design details were made for the tank assembly, including an optimized vacuum jacket and multilayer insulation system. A half-scale LH2 test model was designed and fabricated, and a force/stiffness proof test was conducted on the vacuum jacket. A vacuum leak rate of .000001 atmosphere ml of helium per second was measured, approximately 1500 hours of vacuum pressure were sustained, and 29 vacuum-pressure cycles were experienced prior to failure.
Six liquid hydrogen feedline design concepts were developed for the cryogenic space tug. The feedlines include composite and all-metal vacuum jacketed and nonvacuum jacketed concepts, and incorporate the latest technological developments in the areas of thermally efficient vacuum jacket end closures and standoffs, radiation shields in the vacuum annulus, thermal coatings, and lightweight dissimilar metal flanged joints. The feedline design concepts are evaluated on the basis of thermal performance, weight, cost, reliability, and reusability. Design concepts were proved in a subscale test program. Detail design was completed on the most promising composite feedline concept and an all-metal feedline. Three full scale curved composite feedlines and one all-metal feedline assembly were fabricated and subjected to a test program representative of flight hardware qualification. The test results show that composite feedline technology is fully developed. Composite feedlines are ready for space vehicle application and offer significant reduction in weights over the conventional all-metal feedlines presently used.
The feasibility is demonstrated of producing a lightweight vacuum jacket using state-of-the-art technology and materials. Design and analytical studies were made on an orbital maneuvering system fuel tank. Preliminary design details were completed for the tank assembly which included an optimized vacuum jacket and multilayered insulation system. A half-scale LH2 test model was designed and fabricated and a force/stiffness proof test was conducted on the vacuum jacket. A vacuum leak rate of 0.00001 was measured, approximately 1500 hours of vacuum pressure was sustained, and 29 vacuum pressure cycles were experienced prior to failure. For vol. 1, see N75-26192.
The present work describes the characteristics and design criteria for components and materials used in lightweight substrate solar arrays. This includes descriptions of wraparound-electrode solar cells, cell covers, and cell interconnects. Cell cover systems briefly discussed are fused silica, cerium stabilized glass, microsheet, FEP (tape, heat laminated, and spray on), and ESB 7070 glass integral covers. The majority of solar arrays orbited have used either silver, Kovar, copper, or molybdenum as interconnect metals. Data are presented comparing the Young's modulus E, ultimate tensile strength, coefficient of expansion, thermal conductivity, and percent elongation of these and other interconnect candidate materials. Guidelines for the use of end tab wraparound cells are listed.
With the advent of the age of flight and specifically space flight, a major effort was devoted to the development of lightweight metallic flight hardware. The paper deals with metallic pressure vessels designed to hold liquids or gases under pressure and with the methods for assuring safety through elimination of failures. The consequences of discontinuity stress failures range from leakage, bursting, and detrimental deformation to catastrophic failure, or literally, an explosion of the vessel. Controls, system design, protective devices and tests are discussed.
Lightweight, Kevlar - reinforced laminating systems that are non-burning, generate little smoke in the space shuttle environment, and are physically equivalent to the fiberglass/polyimide system used in the Apollo program for non-structural cabin panels, racks, etc. Resin systems representing five generic classes were screened as matrices for Kevlar 49 reinforced laminates. Of the systems evaluated, the polyimides were the most promising with the phenolics a close second. Skybond 703 was selected as the most promising resin candidate. With the exception of compression strength, all program goals of physical and mechanical properties were exceeded. Several prototype space shuttle mobility and translation handrail segments were manufactured using Kevlar/epoxy and Kevlar-graphite/epoxy. This application shows significant weight savings over the baseline aluminum configuration used previous. The hybrid Kevlar-graphite/epoxy is more suitable from a processing standpoint.
Contemporary lightweight headsets were evaluated for: intelligibility, frequency response, sensitivity, distortion, noise isolation, acoustic quality, weight, and wearer comfort.
An inexpensive, lightweight reflective assembly member having good optical quality and particularly adaptable to accommodating temperature variations without providing destructive thermal stresses and reflective slope errors is described. The reflective assembly consists of a thin sheet of glass with appropriate reflective coating and a cellular glass block substrate bonded together. The method of fabrication includes abrading the cellular substrate with an abrasive master die to form an appropriate concave surface. An adhesive is applied to the abraded surface and a lamina reflective surface is placed under a uniform pressure to conform the reflective surface onto the desired abraded surface of the substrate.
A review of recent advances is presented for lightweight, high performance composite pressure vessel technology that covers the areas of design concepts, fabrication procedures, applications, and performance of vessels subjected to single cycle burst and cyclic fatigue loading. Filament wound fiber/epoxy composite vessels were made from S glass, graphite, and Kevlar 49 fibers and were equipped with both structural and nonstructural liners. Pressure vessels structural efficiencies were attained which represented weight savings, using different liners, of 40 to 60 percent over all titanium pressure vessels. Significant findings in each area are summarized.
Progress is reported in the construction of lightweight orthogrid shells. Graphite/epoxy panels are being used in the fabrication. The shell structure is diagramed in detail. Panel laminates, and panel stiffener flanges are described while illustrations delineate panel assembly procedures.
A review of recent advances is presented for lightweight, high-performance composite pressure vessel technology that covers the areas of design concepts, fabrication procedures, applications, and performance of vessels subjected to single-cycle burst and cyclic fatigue loading. Filament-wound fiber/epoxy composite vessels were made from S-glass, graphite, and Kevlar 49 fibers and were equipped with both structural and nonstructural liners. Pressure vessel structural efficiencies were attained which represented weight savings, using different liners, of 40 to 60 percent over all-titanium pressure vessels. Significant findings in each area are summarized including data from current NASA-Lewis Research Center contractual and in-house programs.
Cross-layered woven or unwoven yarns are used to provide an active thermal control mechanism for spacecraft use. One set of yarns is composed of flexible electrically conductive metal fibers which are capable of being resistance heated by the application of voltage. Another set of yarns, nonconductive and flexible, provides mechanical strength and precludes the passage of electrical current between the metal yarns by virtue of the spacing between them. A lightweight, electrically nonconductive film is bonded to the cross-layered yarns to protect the metal yarns from the elements (minimize electrical shorts from moisture such as rain), to provide additional strength to the fabric, and to prevent conductive loss of heat in nonvacuum applications. The nonconductive film is metalized on its obverse side to provide a more uniform heat load distribution.
The fabrication of a lightweight composite nickel hydroxide electrode based on nickel-coated graphite is described and its effect on the load to failure and electrical resistivity of nickel cadmium and nickel zinc systems was evaluated. The use pure lead in lead acid batteries for submarines is also discussed.