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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 289 records · Page 16
All sourcesNASA NTRSDOE OSTI
NASA NTRS2005

Thermal Protection Materials Technology for NASA's Exploration Systems Mission Directorate

To fulfill the President s Vision for Space Exploration - successful human and robotic missions between the Earth and other solar system bodies in order to explore their atmospheres and surfaces - NASA must reduce trip time, cost, and vehicle weight so that payload and scientific experiment capabilities are maximized. As a collaboration among NASA Centers, this project will generate products that will enable greater fidelity in mission/vehicle design trade studies, support risk reduction for material selections, assist in optimization of vehicle weights, and provide the material and process templates for development of human-rated qualification and certification Thermal Protection System (TPS) plans. Missions performing aerocapture, aerobraking, or direct aeroentry rely on technologies that reduce vehicle weight by minimizing the need for propellant. These missions use the destination planet s atmosphere to slow the spacecraft. Such mission profiles induce heating environments on the spacecraft that demand thermal protection heatshields. This program offers NASA essential advanced thermal management technologies needed to develop new lightweight nonmetallic TPS materials for critical thermal protection heatshields for future spacecraft. Discussion of this new program (a December 2004 new start) will include both initial progress made and a presentation of the work to be preformed over the four-year life of the program. Additionally, the relevant missions and environments expected for Exploration Systems vehicles will be presented, along with discussion of the candidate materials to be considered and of the types of testing to be performed (material property tests, space environmental effects tests, and Earth and Mars gases arc jet tests).

Valentine, Peter G.↗
NASA NTRS2018

Boeing: Arc Jet Exposure of Ablative Non-Oxide CMC TPS for Planetary Probe and Sample Return Applications

NASA Game Changing Development (GCD) provided Boeing support under a Space Act Agreement (SAA) for arc jet sample design, CFD support and arc jet test time of stagnation and shear models for 3 Boeing TPS materials: BLA (Boeing Lightweight Ablator, 18, 21 and 22 densities), BPA (Boeing Phenolic Ablator, standard, graded density, or without reinforcement) and Non-oxide high temperature ceramic composite for structurally integrated TPS (SITPS). Results: For BLA, tested successfully to 500 W/cm² heat flux and heat loads up to 12 kJ/cm² with shear loads up to 370 Pa. The BPA 2017 formulation tested successfully to 1500 W/cm² and 80 kJ/cm², with shear loads up to 250 Pa. For SITIPS, Boeing fabricated C/SiC laminate materials survived testing in shear.

commercial space↗
DOE OSTI2025

Aerogel with Unparalleled Performance and Cost-Effectiveness for All Insulation Needs (CRADA Final Report)

Westwood Aerogel investigated the reproducible production of an ambiently or electromagnetic spectrum assisted drying of extremely porous aerogel materials. Traditional aerogel processing is limited by low throughput and scalability due to supercritical drying. Westwood Aerogel’s advanced manufacturing process enables commercialization and deployment at scale, making aerogel materials more accessible to a range of industries and applications. We focused on shifting from the lab scale environment to manufacturing prototypes. The initial manufacturing model is based on the float glass process, which is the industry standard for glass window production, and the paper drying process. By incorporating an ambient drying process a continuous line model can be used from start to finish. The project team worked to develop a continuous manufacturing system to scale-up and reduce costs while maintaining the lightweight and insulative properties of aerospace-grade aerogel. While aerogels are extremely insulative, lightweight, and thin materials (making them ideal insulators across application spaces), high costs and stagnant innovation have hampered their wider adoption. Traditional manufacturing of aerogel requires supercritical extraction of pore fluid to obtain highly insulating materials, which is an energy intensive batch process and limits aerogel production output. Westwood Aerogel’s proprietary ambient drying process enables the continuous production of highly insulative aerogel materials without the use of supercritical extraction.

36 MATERIALS SCIENCE↗
NASA NTRS1990

NDE of thermal protection system for space shuttle solid rocket booster

Potential nondestructive test (NDE) methods were evaluated for detecting debonds and weak bonds in the thermal protection system (TPS) for the space shuttle solid rocket boosters. The primary thermal protection material is a sprayable, thick epoxy coating that is filled with lightweight and thermal insulating materials. Test panels were fabricated with a wide variety of hidden realistic defects, including contact debonds and weak bonds. Nondestructive test results were obtained. Candidate NDE methods evaluated for booster production applications include laser interferometry (e.g., electronic shearography), infrared thermography, radiography (e.g., computed tomography), acousto-ultrasonics, mechanical/acoustic impedance, ultrasonics, acoustic emission, and the tap test. Capabilities, advantages, disadvantages, and relative performances in defect detection of each test method for TPS bonding applications are reported. Electronic shearography NDE was technically the superior method for detecting debonds.

Myers, R. S.↗
DOE OSTI2025

Lightweight Metal Stamping Optimization Enabled by Artificial Intelligence

Successfully manufacturing an automotive body structure made via the sheet metal stamping process depends upon simultaneous consideration of component design, tooling design, stamping process control, and material properties. In many cases, introducing lightweight sheet materials (e.g., aluminum alloys, magnesium alloys, advanced high strength steels) holds the potential to significantly reduce vehicle weight, but challenges the stamping process by introducing materials with inherently less ductility. Successful and repeatable applications require co-developing the stamping process controls with the varying material properties, including formability. During the stamping process, as soon as the forming limit of the sheet is exceeded, the material shows localized necking which quickly leads to splits. Controlling process variability to avoid these material splits will enable deployment of less formable, lighter, and stronger materials for stamped automotive components. A typical optimization procedure for manufacturing requires an iterative process involving parameter setting, execution of computational simulations, and modifying the parameters. The entire process demands substantial computational time, making it impractical for real-time feedback towards rapid corrective actions required for in-line control for running production processes. To overcome this challenge, artificial intelligence (AI) can be leveraged to determine optimal manufacturing parameters within a single manufacturing cycle time. This research proposes an in-line optimization framework incorporating a trained AI model to predict kidney-shaped die forming. Preliminary results indicate that the AI framework can accurately predict draw-in values based on a given parameter set, a process referred to as forward prediction. Furthermore, the AI framework can also predict the optimal parameter set that leads to the desired draw-in values, referred to as inverse optimization (or backward prediction). This research has been performed in collaborations with USCAR (US Council for Automotive Research) and AutoForm. The members of USCAR are Ford, GM, and Stellantis.

36 MATERIALS SCIENCE↗
NASA NTRS1971

Heat shields for aircraft - A new concept to save lives in crash fires.

A passenger compartment surrounded by a fire-retardant shell, to protect the occupants long enough for the fire to burn out or for fire-fighting equipment to reach the aircraft and extinguish it, is proposed as a new concept for saving lives in crash fires. This concept is made possible by the recent development of two new fire-retardant materials: a very lightweight foam plastic, called polyisocyanurate foam, and an intumescent paint. Exposed to heat, the intumescent paint expands to many times its original thickness and insulates the surface underneath it. Demonstration tests are illustrated, described and discussed. However, some problems, such as preventing fuselage rupture and protecting windows, must be solved before such a system can be used.

Neel, C. B.↗
NASA NTRS1983

Low-Weight Inserts for Aluminum Honeycomb Panels

Fiber/epoxy composites used in place of solid aluminum. New proposal suggests to make inserts out of such lightweight, high strength materials as fiber/epoxy composites or high density aluminum honeycomb. Composite insert is same size and shape as aluminum insert it replaces.

Bumgarner, G. S.↗
NASA NTRS1985

Lightweight Electrical Insulation

Hollow plastic spheres expanded and fused together. Hollow, gasfilled plastic spheres piled in mold. Heating in vacuum softens and expands spheres, forcing them together into nearly regular hexagonal close packing. Foam used as lightweight, electrically insulating material in place of solid ceramic, glass, or polymer. Padding to protect against mechanical shocks another application for such dense, regular foam.

Schroeder, J. E.↗
NASA NTRS1986

The large deployable reflector: A NASA submillimeter-infrared orbiting observatory

The Large Deployable Reflector (LDR) concept is outlined. The LDR telescope is based on a 20-m diameter reflector. The primary mirror is a filled aperture made up of 84 hexagonal panels, each 2 m edge-to-edge. The panels are based on lightweight structural composite materials. The optical configuration is a four mirror two stage system. The primary mirror is passive. The active optical elements for figure control are at the quaternary mirror. The primary mirror panels are supported by a deployable PAC truss backup structure at the vertices of each hexagon. The four focal plane instruments covering the range of 30 to 1000 microns are located near the vertex of the primary mirror. Some instruments will be cooled with stored cryogens to liquid helium temperatures, others to liquid nitrogen temperatures. The spacecraft functions will be located in a resource module behind the primary mirror. The LDR will be transferred to orbit by the space transportation system and assembled and tested at the space station. It will then be boosted to an orbit of greater than or = 700 km as a free flyer.

Swanson, Paul N.↗
NASA NTRS1987

High temperature polymer matrix composites

With the increased emphasis on high performance aircraft the need for lightweight, thermal/oxidatively stable materials is growing. Because of their ease of fabrication, high specific strength, and ability to be tailored chemically to produce a variety of mechanical and physical properties, polymers and polymer matrix composites present themselves as attractive materials for a number of aeropropulsion applications. In the early 1970s researchers at the NASA Lewis Research Center developed a highly processable, thermally stable (600 F) polyimide, PMR-15. Since that time, PMR-15 has become commercially available and has found use in military aircraft, in particular, the F-404 engine for the Navy's F/A-18 strike fighter. The NASA Lewis'contributions to high temperature polymer matrix composite research will be discussed as well as current and future directions.

Meador, Michael A.↗
NASA NTRS1991

Impact Damage In Carbon/Epoxy And Carbon/PEEK Composites

Report describes results of drop-weight impact testing of specimens of carbon-fiber/epoxy and carbon-fiber/polyetheretherketone (PEEK) composite materials. Panels made of these materials assembled into lightweight, strong, stiff structures useful in automobiles, aircraft, sporting goods, and many other products. PEEK specimens showed less delamination than epoxy specimens at given impact energy.

Nettles, A. T.↗
NASA NTRS1993

Balloonlike Shields Against Fast Projectiles

Report proposes use of flexible gas-filled or liquid-filled pouches to shield spacecraft against impacts by small meteoroids and orbiting debris traveling at speeds approximately greater than 2 km/s. Shields made in various forms reminiscent of balloons, pillows, air mattresses, or sealed-air-bubble packing material. Serve as lightweight, easily installed alternatives to heavier, rigid shields made of space aluminum sheets custom-designed and attached to spacecraft only with great difficulty and expense.

Rucker, Michelle A.↗
NASA NTRS1995

Composite Cocured Modular Eggcrate-Core Sandwich Structure

Lightweight composite-material (e.g., graphite fiber/epoxy matrix) cocured sandwich panels with eggcratelike cores developed for use as principal components of optical benches and other structures that support precise optical instruments. Structures offer greater thermal and mechanical stability. Advantages include easier fabrication and better mechanical properties.

Magurany, Charles J.↗
NASA NTRS1997

A Rocket Engine for Mars Sample Return Using In Situ Propellants

Recent studies for the planned Mars sample return mission were reviewed and modified to utilize carbon monoxide and oxygen as potential in situ propellants. Based on these studies a representative full scale engine thrust of 2225 N (500 lbf) was selected as appropriate to demonstrate performance, and the design for that engine is presented. Previous experimental results combined with parametric analyses were used to define the geometry for the engine which operates on liquid carbon monoxide and liquid oxygen. The engine was constructed using a combination of high-temperature alloys and lightweight ceramics. The materials selected were hafnium oxide, iridium, rhenium, and carbon-carbon.

Linne, Diane L.↗
NASA NTRS1996

Far-infrared emissivity measurements of reflective surfaces

An instrument developed to measure the emissivity of reflective surfaces by comparing the thermal emission of a test sample to that of a reference surface is reported. The instrument can accurately measure the emissivity of mirrors made from lightweight thermally insulating materials such as glass and metallized carbon fiber reinforced plastics. Far infrared measurements at a wavelength of 165 micrometers are reported. The instrument has an absolute accuracy of Delta epsilon = 9 x 10(exp -4) and can reproducibly measure an emissivity of as small as 2 x 10(exp -4) between flat reflective surfaces. The instrument was used to measure mirror samples for balloon-borne and spaceborne experiments. An emissivity of (6.05 +/- 1.24) x 10(exp -3) was measured for gold evaporated on glass, and (6.75 +/- 1.17) x 10(exp -3) for aluminum evaporated on glass.

Xu, J.↗
NASA NTRS1997

Low Cost Manufacturing Approach of High Temperature PMC Components

The overall objective is to develop a satisfactory sheet molding compound (SMC) of a high temperature polyimide, such as PMR-11-50, VCAP-75, or NB2-76, and to develop compression molding processing parameters for a random, chopped fiber, high temperature, sheet molding compound that will be more affordable than the traditional hand lay-up fabrication methods. Compression molding will reduce manufacturing costs of composites by: (1) minimizing the conventional machining required after fabrication due to the use of full 360 deg matched tooling, (2) reducing fabrication time by minimizing the intensive hand lay-up operations associated with individual ply fabrication techniques, such as ply orientation and ply count and (3) possibly reducing component mold time by advanced B-staging prior to molding. This program is an integral part of Allison's T406/AE engine family's growth plan, which will utilize technologies developed under NASA's Sub-sonic Transport (AST) programs, UHPTET initiatives, and internally through Allison's IR&D projects. Allison is aggressively pursuing this next generation of engines, with both commercial and military applications, by reducing the overall weight of the engine through the incorporation of advanced, lightweight, high temperature materials, such as polymer matrix composites. This infusion of new materials into the engine is also a major factor in reducing engine cost because it permits the use of physically smaller structural components to achieve the same thrust levels as the generation that it replaced. A lighter, more efficient propulsion system translates to a substantial cost and weight savings to an airframe's structure.

Kannmacher, Kevin↗
NASA NTRS1997

Outer Planet Mission Studies Neptune Aerocapture

Current and previous studies of orbiter missions to the outer planets have clearly identified high-energy aerocapture as a critical and enabling technology. Aerocapture involves the use of aerodynamic lift to fly a trajectory through a planet's atmosphere to sufficiently decelerate an entry vehicle to capture into planetary orbit. In the past, numerous studies of different configurations of lifting entry vehicles were studied for various planetary orbiter missions which identified aerocapture as a feasible concept yet complex and technically challenging. In order to determine the feasibility of high-speed aerocapture at the outer planets, an accurate trajectory simulation of the flight vehicle is the critical first step in the proposed research. Vehicle response to aerodynamic loading must be predicted accurately in the trajectory simulations. For several Neptune orbiter missions currently under study at the Jet Propulsion Laboratory (JPL), entry velocities relative to the rotating atmosphere ranging from 25 to 30 km/sec, are to be expected. Preliminary trajectory analysis has identified the various flow regimes the entry vehicle is expected to fly in the 8 1% H2 and 19% He atmosphere of Neptune. The size and mass of the vehicle are also determined by the launch vehicle constraints and orbiter spacecraft requirements. For a given baseline arrival conditions of an inertial entry velocity of 28 km/sec and an entry mass of 400 kg, a medium lift (L/D = 1), axisymmetric biconic shaped vehicle was selected in order to satisfy entry corridor width requirements expected for Neptune aerocapture. The analysis summarized in this study indicates that a biconic entry vehicle is a feasible concept for a Neptune aerocapture orbiter mission. The preliminary entry trajectory simulations has demonstrated adequate entry corridor control authority. Furthermore, estimates of the stagnation point heating environment has enabled the preliminary selection of candidate lightweight ceramic TPS materials.

Wercinski, Paul F.↗