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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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At least 271 records · Page 15

Making Nozzles From Hard Materials

Proposed method of electrical-discharge machining (EDM) cuts hard materials like silicon carbide into smoothly contoured parts. Concept developed for fabrication of interior and exterior surfaces and internal cooling channels of convergent/divergent nozzles. EDM wire at skew angle theta creates hyperboloidal cavity in tube. Wire offset from axis of tube and from axis of rotation by distance equal to throat radius. Maintaining same skew angle as that used to cut hyperboloidal inner surface but using larger offset, cooling channel cut in material near inner hyperboloidal surface.

Wells, Dennis L.↗

Design, Fabrication, Optical Testing, and Performance of Diamond Machined Aspheric Mirrors for Ground-Based Near-IR Astronomy

Challenges in fabrication and testing have historically limited the choice of surfaces available for the design of reflective optical instruments. Spherical and conic mirrors are common, but, for future science instruments, more degrees of freedom are necessary to meet challenging performance and packaging requirements. These instruments will be composed of unusual aspheres located far off-axis with large spherical departure, and some designs will require asymmetric surface profiles. In particular, single-surface astigmatism correction in spectrographs necessitates a toroidal surface, which lacks an axis of rotational symmetry. We describe the design, fabrication, optical testing, and performance of three rotationally symmetric, off-axis, aspheric mirrors and one toroidal, off-axis, biconic camera mirror on aluminum substrates for the Infrared Multi-Object Spectrograph (IRMOS) instrument. IRMOS is a facility instrument for the Kitt Peak National Observatory's Mayall Telescope (3.8 m) and an engineering prototype for a possible design of the Next Generation Space Telescope/Multi-Object Spectrograph. The symmetric mirrors range in aperture from 94x86 mm to 286x269 mm and in f-number from 0.9 to 2.4. They are various off-axis, convex and concave, prolate and oblate ellipsoids. The concave biconic mirror has a 94x76 mm aperture, Rx=377 mm, kx=0.0778, Ry=407 mm, and ky=0.1265 and is decentered. by -2 mm in x and 227 mm in y. The mirrors have an aspect ratio of approximately 4:1. The surface error fabrication tolerances are less than 63.3 nm RMS figure error and less than 10 nm RMS microroughness. The mirrors are attached to the instrument bench via a semi-kinematic, integral flexure mount. We describe mirror design, diamond machining, the results of figure testing using computer-generated holograms, and imaging and scattered light modeling and performance.

Ohl, Raymond G.↗

Design and Development of Modules to Support Live Microscopic Imaging on Ground-Based Microgravity Simulators

In space, astronauts are exposed to environmental stressors that often result in physiological changes. One prominent stressor in spaceflight is microgravity, and research has shown that long term microgravity exposure causes muscle atrophy, bone loss, cardiovascular concerns, and vision impairment. It is critical to understand how altered gravity affects physiology on the cellular, molecular, and gene level in order to accurately assess health risks and to develop effective countermeasures. Ground-based microgravity simulators such as random positioning machines (RPMs) are used to produce some of the biological effects of altered gravity on different cell types and organisms. Real-time imaging during simulations are of particular interest as we can study how basic cell functions such as cell division, cell migration, and proliferation progress under microgravity conditions. However, design limitations of present microgravity simulators such as susceptibility to parasitic vibration and displacement of the sample from the center of rotation challenge the accuracy of experiment results and live images. We have developed a cell culture sample holder module suitable for live microscopic imaging on an RPM. CAD modeling and 3D printing technology were used to implement modifications to the sample holder and to install a digital microscope to perform live bright-field and fluorescent imaging. Vibration damping materials were also investigated to allow for stable imaging while the microgravity simulator was within a cell culture incubator. Novel methods and hardware modifications for improving live cell imaging on ground-based microgravity simulators were proposed and discussed.

3D printing↗

The Manned Maneuvering Unit - 'A nice flying machine'

The need for untethered maneuvers in extravehicular space was recognized early in the NASA manned spaceflight program, leading to experiments during the Gemini flights. The Space Shuttle crews are now equipped with a Manned Maneuvering Unit (MMU) which employs 24 gaseous nitrogen thrusters to furnish six-degree-of-freedom mobility and is fitted with fully redundant electronics, electrical, and propulsion subsystems. The MMU thrusters are operated with translational and rotational hand controllers at the ends of the MMU arms.

Bollendonk, W. W.↗

Grinding Glass Disks On A Belt Sander

Small machine attached to table-top belt sander makes possible to use belt sander to grind glass disk quickly to specified diameter within tolerance of about plus or minus 0.002 in. Intended to be used in place of production-shop glass grinder. Held on driveshaft by vacuum, glass disk rotated while periphery ground by continuous sanding belt.

Lyons, James J., III↗

Applied Operations Research: Augmented Reality in an Industrial Environment

Augmented reality is the application of computer generated data or graphics onto a real world view. Its use provides the operator additional information or a heightened situational awareness. While advancements have been made in automation and diagnostics of high value critical equipment to improve readiness, reliability and maintenance, the need for assisting and support to Operations and Maintenance staff persists. AR can improve the human machine interface where computer capabilities maximize the human experience and analysis capabilities. NASA operates multiple facilities with complex ground based HVCE in support of national aerodynamics and space exploration, and the need exists to improve operational support and close a gap related to capability sustainment where key and experienced staff consistently rotate work assignments and reach their expiration of term of service. The initiation of an AR capability to augment and improve human abilities and training experience in the industrial environment requires planning and establishment of a goal and objectives for the systems and specific applications. This paper explored use of AR in support of Operation staff in real time operation of HVCE and its maintenance. The results identified include identification of specific goal and objectives, challenges related to availability and computer system infrastructure.

Cole, Stuart K.↗

Parametric Mechanism Design Through Numerical Optimization and Physics Simulation

Design-Build-Test approaches for developing spaceflight hardware are prohibitively time and cost intensive and often lead to suboptimal mechanism designs. Approaches that couple machine learning and high-fidelity physics simulation could eliminate the need for hardware prototyping and dramatically accelerate the engineering design cycle, ultimately reducing cost. This work presents a modular NASA-developed toolchain to optimize hardware mechanisms in a virtual environment using numerical optimization and multi-body physics simulation. The toolchain enables multi-objective optimization, generates parametric CAD files that can be further post-processed by an end user, and can be expanded to optimize full systems and non-mechanical parameters such as feedback control variables. We demonstrate the toolchain through an independently verifiable design problem that optimizes wheel radius to achieve a desired linear velocity in a rigid-body physics environment when the wheel rotates at a constant angular speed, and then post-process the parametric CAD file of the optimal design generated by the tool before ultimately manufacturing it via 3D printing. We end with a discussion of how the toolchain can incorporate other analysis tools, including finite element analysis, computational fluid dynamics, and granular media simulations.

Optimization↗

An Optimization-Based Toolchain for Parametric Mechanism Design

Design-Build-Test approaches for developing spaceflight hardware are prohibitively time and cost intensive and often lead to suboptimal mechanism designs. Approaches that couple machine learning and high-fidelity physics simulation could eliminate the need for hardware prototyping and dramatically accelerate the engineering design cycle, ultimately reducing cost. This work presents a modular NASA-developed toolchain to optimize hardware mechanisms in a virtual environment using numerical optimization and multi-body physics simulation. The toolchain enables multi-objective optimization, generates parametric CAD files that can be further post-processed by an end user, and can be expanded to optimize full systems and non-mechanical parameters such as feedback control variables. We demonstrate the toolchain through an independently verifiable design problem that optimizes wheel radius to achieve a desired linear velocity in a rigid-body physics environment when the wheel rotates at a constant angular speed, and then post-process the parametric CAD file of the optimal design generated by the tool before ultimately manufacturing it via 3D printing. We end with a discussion of how the toolchain can incorporate other analysis tools, including finite element analysis, computational fluid dynamics, and granular media simulations.

Optimization↗

Touchdown Ball-Bearing System for Magnetic Bearings

The torque-limited touchdown bearing system (TLTBS) is a backup mechanical-bearing system for a high-speed rotary machine in which the rotor shaft is supported by magnetic bearings in steady-state normal operation. The TLTBS provides ball-bearing support to augment or supplant the magnetic bearings during startup, shutdown, or failure of the magnetic bearings. The TLTBS also provides support in the presence of conditions (in particular, rotational acceleration) that make it difficult or impossible to control the magnetic bearings or in which the magnetic bearings are not strong enough (e.g., when the side load against the rotor exceeds the available lateral magnetic force).

Kingsbury, Edward P.↗

A first interpretation of East African swiddening via computer-assisted analysis of 3 Landsat tapes

A preliminary application of the machine processing of Landsat data for the identification of swidden farming in East Africa is discussed. Three sets of Landsat data were analyzed: the 1972 mid-dry season, the 1973 late dry season, and the 1975 early wet season. The analysis procedure consisted of: (1) a preprocessing step to de-skew, rotate, and rescale the data, (2) a geometric correction process, (3) photographic enlargement, and (4) a procedure to obtain spectral response values for training the classification algorithm.

Conant, F. P.↗

Surface texture characterization by angular distributions of scattered light

Work at the National Bureau of Standards to develop an on-line optical measurement device and attendant algorithms for automated optical scattering measurements of machined metal surfaces are described. The surfaces could be milled, ground or lapped, and the system is intended to categorize the resulting surface characteristics. The optical device consists of a He-Ne laser which is shone on a surface. The scattered light is captured by a semicircular array of 87 detector elements rotated over the scanned area. The light signals are processed through a digital voltmeter and then an A/D converter. The signals are then stored for later comparisons with optical scattering data obtained by optical instruments used with stylus instruments for characterizing surface topographies. A theoretical model has been defined which relates light scattering and the characteristics of the surface roughness. Initial experimental results with a sinusoidal surface have indicated that although the system can follow the trend of the roughness, the roughness amplitude is as yet uncertainly defined and the computations require excessive time.

Gilsinn, D. E.↗

Exploring the Capabilities of a Machine Learning Algorithm to Detect Space Weather-Significant Emerging Active Regions

Active regions are a source of various phenomena responsible for Space Weather disturbances; therefore, developing a technology for early warning about upcoming magnetic activity is crucial to mitigate its impact. However, observational limitations and the high nonlinearity of processes associated with the accumulation of magnetic flux and its interaction with the surrounding plasma during the emergence through the convection zone make early activity detection a challenging problem. To address these challenges, we developed a physics-driven machine learning model that allows us to detect active regions (ARs) before they become visible on the solar surface by analyzing the power spectra of acoustic oscillations observed by the SDO/HMI instrument. This study is based on a time series of Doppler shift maps of 31x31-degree areas tracked with the Carrington rotation rate for four days before and after the emergence. The Doppler shift time series are processed into the oscillation power maps for four frequency ranges and accompanied by line-of-sight magnetograms and the continuum intensity maps from SDO/HMI. The resulting data are converted into a 1D time series representing the mean temporal variations of these quantities. The redacted time series are used as input to predict AR emergence using the Long Short Term Memory (LSTM) method. The training of the LSTM model is based on 40 ARs, which includes an independent analysis for each sub region that exhibits AR emergence or remains quiet. The emergence of magnetic flux (defined as a decrease of the continuum intensity) was detected with the developed LSTM algorithm from 5 to 48 hours before the reported time by NOAA. The developed model is capable of pointing to the time and location of active region formation. In this presentation, we discuss reasons that impact how early in advance the model can identify the upcoming activity and the possibility of improving the current predictive skills and steps to transition to the operational forecast.

Heliophysics↗

New Runtime Record Set for Free-Piston Stirling Machine

This article describes the recent progress GRC has made in the arena of long-life heat engines for power conversion. NASA has been interested in Stirling-cycle machines for power conversion since the 1970s. At that time, it was recognized that such a device could be designed to achieve long-life continuous operation with high reliability, by leveraging the free-piston configuration in favor of a kinematic engine. The free-piston variant eliminates the wear mechanisms associated with rolling-element bearings, piston rings, and connecting rods, typically found in kinematic Stirling engine designs. By restricting the moving components to linear motion only, there is no need to convert linear piston movement to rotating motion. With this, the moving components can be suspended within their cylinders by non-contacting bearings and seals can be effected with close clearances, also non-contacting. The use of a linear alternator attached directly to the piston enables direct conversion of heat, to mechanical, then to electrical energy, all in one hermetically sealed vessel, The electrical output only requires simple feedthroughs, and the complexity of sealed a rotating crankshaft is eliminated. In the free-piston variant, the displacer-to-piston phase is not implemented by a connection to a common rotating shaft. Instead, the pressure wave itself is used to drive the displacer. The displacer is designed to have a higher natural frequency of motion than the piston, which achieves a leading phase angle required for power production. The free-piston Stirling behaves like a spring-mass-damper system, with a forcing function created by the alternate heater and cooling of the working gas, and damping provided by the current flowing through the linear alternator. Two types of non-contacting bearings are available to designers: flexure and gas bearings. Flexure bearings consist of a spiral-cut disc of metal that has high radial stiffness but a deliberately engineering stiffness in the axial direction, to permit piston and displacer resonant motion. Gas bearings utilize a pressure source and precisely machined flow channels to provide a radial stiffness around the moving component. The pressure source can be supplied by the engine's pressure wave itself.

Oriti, Salvatore M.↗

Heat transfer in the tip region of a rotor blade simulator

In gas turbines, the blades of axial turbine stages rotate in close proximity to a stationary peripheral wall. Differential expansion of the turbine wheel, blades, and the shroud causes variations in the size of the clearance gap between blade tip and stationary shroud. The necessity to tolerate this differential thermal expansion dictates that the clearance gap cannot be eliminated altogether, despite accurate engine machining. Pressure differences between the pressure and suction sides of a blade drives a flow through the clearance gap. This flow, the tip leakage flow, is detrimental to engine performance. The primary detrimental effect of tip leakage flow is the reduction of turbine stage efficiency, and a second is the convective heat transfer associated with the flow. The surface area at the blade tip in contact with the hot working gas represents an additional thermal loading on the blade which, together with heat transfer to the suction and pressure side surface area, must be removed by the blade internal cooling flows. Experimental results concerned with the local heat transfer characteristics on all surfaces of shrouded, rectangular cavities are reported. A brief discussion of the mass transfer system used is given.

Chyu, M. K.↗

Sound measurements of the MOD-2 wind turbine generator

Sound measurements were made for the MOD-2 wind turbine generator for wind conditions of 7.6 to 13.4 m/sec and for output power ratings of about 1 to 2 NW. Both broad band and narrow band data wre obtained for a range of distances and azimuth angles from the machine. The rotor sound spectra are random in character and peak in the frequency ranges 30 to 50 Hz and 800 to 1300 Hz. Both peaks are predictable from experience with helicopter rotors and propellers. Results suggest that the lower frequency peak is due to the effects of inflow turbulence and the higher frequency peak is due to the interactions of the turbulent boundary layers with the trailing edges of the blades. The boundary layer related sound is the dominant component in the audible frequency range and determines the detectability of the machine. It could be detected at a distance of 1350 m in the upwind direction where the background noise was 30 dB (A) and at distances in excess of 2100 m in the downwind direction. Discrete frequency sound components associated with the power generation equipment are measurable in the direction normal to the axis of rotation but are not believed to be significant for detection or community response.

Hubbard, H. H.↗

Progress Toward the Critical Design of the Superconducting Rotor for NASA's 1.4 MW High-Efficiency Electric Machine

NASA Glenn Research Center is developing a 1.4 MW high-efficiency electric machine for future electrified aircraft to reduce energy consumption, emissions, and noise. This wound-field, synchronous machine employs a self-cooled, superconducting rotor to achieve excellent specific power and efficiency. This paper presents the progress made over the past year toward a critical design of the superconducting rotor, including refined analysis and risk reduction testing on prototype superconducting coils. A 3D finite element model of the rotor is developed to simulate the combined loading imposed by the initial cool down of the rotor from room temperature to cryogenic temperature and the subsequent rotation of the rotor up to the design speed. The model is evaluated to better predict the stress state in the critical components and the reduction in physical gap between the stator and rotor due to the resulting radial deflections. This model includes an enhanced model of the superconducting coil that considers the coil as an assembly of four individual coil layers. An improved coil fabrication process is described in detail. Two sub-scale test coils are fabricated and then tested under repeated thermal cycling between room temperature and liquid nitrogen temperature (77 K). It is demonstrated that the proposed coil fabrication procedure can produce no-insulation, high temperature superconducting coils that can survive several thermal cycles without apparent degradation.

electric machines↗

Intermetallic Nickel-Titanium Alloys for Oil-Lubricated Bearing Applications

An intermetallic nickel-titanium alloy, NITINOL 60 (60NiTi), containing 60 wt% nickel and 40 wt% titanium, is shown to be a promising candidate material for oil-lubricated rolling and sliding contact applications such as bearings and gears. NiTi alloys are well known and normally exploited for their shape memory behavior. When properly processed, however, NITINOL 60 exhibits excellent dimensional stability and useful structural properties. Processed via high temperature, high-pressure powder metallurgy techniques or other means, NITINOL 60 offers a broad combination of physical properties that make it unique among bearing materials. NITINOL 60 is hard, electrically conductive, highly corrosion resistant, less dense than steel, readily machined prior to final heat treatment, nongalling and nonmagnetic. No other bearing alloy, metallic or ceramic encompasses all of these attributes. Further, NITINOL 60 has shown remarkable tribological performance when compared to other aerospace bearing alloys under oil-lubricated conditions. Spiral orbit tribometer (SOT) tests were conducted in vacuum using NITINOL 60 balls loaded between rotating 440C stainless steel disks, lubricated with synthetic hydrocarbon oil. Under conditions considered representative of precision bearings, the performance (life and friction) equaled or exceeded that observed with silicon nitride or titanium carbide coated 440C bearing balls. Based upon this preliminary data, it appears that NITINOL 60, despite its high titanium content, is a promising candidate alloy for advanced mechanical systems requiring superior and intrinsic corrosion resistance, electrical conductivity and nonmagnetic behavior under lubricated contacting conditions.

DellaCorte, C.↗

Beam Steering Devices Reduce Payload Weight

Scientists have long been able to shift the direction of a laser beam, steering it toward a target, but often the strength and focus of the light is altered. For precision applications, where the quality of the beam cannot be compromised, scientists have typically turned to mechanical steering methods, redirecting the source of the beam by swinging the entire laser apparatus toward the target. Just as the mechanical methods used for turning cars has evolved into simpler, lighter, power steering methods, so has the means by which researchers can direct lasers. Some of the typical contraptions used to redirect lasers are large and bulky, relying on steering gimbals pivoted, rotating supports to shift the device toward its intended target. These devices, some as large and awkward as a piece of heavy luggage, are subject to the same issues confronted by mechanical parts: Components rub, wear out, and get stuck. The poor reliability and bulk not to mention the power requirements to run one of the machines have made mechanical beam steering components less than ideal for use in applications where weight, bulk, and maneuverability are prime concerns, such as on an unmanned aerial vehicle (UAV) or a microscope. The solution to developing reliable, lighter weight, nonmechanical steering methods to replace the hefty steering boxes was to think outside the box, and a NASA research partner did just that by developing a new beam steering method that bends and redirects the beam, as opposed to shifting the entire apparatus. The benefits include lower power requirements, a smaller footprint, reduced weight, and better control and flexibility in steering capabilities. Such benefits are realized without sacrificing aperture size, efficiency, or scanning range, and can be applied to myriad uses: propulsion systems, structures, radiation protection systems, and landing systems.

Source record↗