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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 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
NASA NTRS2006

Electrical Arc Ignition Testing of Spacesuit Materials

A viewgraph presentation on electrical arc ignition testing of spacesuit materials is shown. The topics include: 1) Background; 2) Test Objectives; 3) Test Sample Materials; 4) Test Methods; 5) Scratch Test Objectives; 6) Cotton Scratch Test Video; 7) Scratch Test Results; 8) Entire Date Plot; 9) Closeup Data Plot; 10) Scratch Test Problems; 11) Poke Test Objectives; 12) Poke Test Results; 13) Poke Test Problems; 14) Wire-break Test Objectives; 15) Cotton Wire-Break Test Video; 16) High Speed Cotton Wire-break Test Video; 17) Typical Data Plot; 18) Closeup Data Plot; 19) Wire-break Test Results; 20) Wire-break Tests vs. Scratch Tests; 21) Urethane-coated Nylon; and 22) Moleskin.

Smith, Sarah↗
NASA NTRS2018

Channel Wall Nozzle Manufacturing and Hot-Fire Testing using a Laser Wire Deposition Closeout Technique for Liquid Rocket Engines

A regeneratively-cooled nozzle for liquid rocket engine applications is a significant cost of the overall engine due to the complexities of manufacturing a large thin-walled structure that must operate in extreme temperature and pressure environments. NASA has been investigating and advancing methods for fabrication of liquid rocket engine channel wall nozzles to realize further cost and schedule improvements. The methods being evaluated are targeting increased scale required for current NASA and commercial space programs. Several advanced rapid fabrication methods are being investigated for forming of the inner liner, producing the coolant channels, closeout of the coolant channels, and fabrication of the manifolds. NASA Marshall Space Flight Center (MSFC) completed process development and subscale hot-fire testing of a series of these advanced fabrication channel wall nozzle technologies to gather performance data in a relevant environment. The primary fabrication technique being discussed in this paper is Laser Wire Deposition Closeout (LWDC). This process has been developed to significantly reduce time required for closeouts of regeneratively-cooled slotted liners. It allows for channel closeout to be formed in place in addition to the structural jacket without the need for channel fillers or complex tooling. Additional technologies were also tested as part of this program including water jet milling and arc-based additive manufacturing deposition. Each nozzle included different fabrication features, materials, and methods to demonstrate durability in a hot-fire environment. The results of design, fabrication and hot-fire testing performance is discussed in this paper.

Gradl, Paul R.↗
NASA NTRS2018

Channel Wall Nozzle Manufacturing and Hot-Fire Testing Using a Laser Wire Direct Closeout Technique for Liquid Rocket Engines

A regeneratively-cooled nozzle for liquid rocket engine applications is a significant cost of the overall engine due to the complexities of manufacturing a large thin-walled structure that must operate in extreme temperature and pressure environments. The National Aeronautics and Space Administration (NASA) has been investigating and advancing methods for fabrication of liquid rocket engine channel wall nozzles to realize further cost and schedule improvements over traditional techniques. The methods being evaluated are targeting increased scale required for current NASA and commercial space programs. Several advanced rapid fabrication methods are being investigated for forming of the inner liner, producing the coolant channels, closeout of the coolant channels, and fabrication of the manifolds. NASA's Marshall Space Flight Center (MSFC) has completed process development and subscale hot-fire testing of a series of these advanced fabrication channel wall nozzle technologies to gather performance data in a relevant environment. The primary fabrication technique being discussed in this paper is Laser Wire Direct Closeout (LWDC). This process has been developed to significantly reduce the time required for closeouts of regeneratively-cooled slotted liners. It allows for channel closeout to be formed in place in addition to the structural jacket without the need for channel fillers or complex tooling. Additional technologies were also tested as part of this program including water jet milling and arc-based additive manufacturing deposition. Each nozzle included different fabrication features, materials, and methods to demonstrate durability in a hot-fire environment. The results of design, fabrication, and hot-fire testing are discussed in this paper.

Gradl, Paul R.↗
NASA NTRS1994

ESTEC wiring test programme materials related properties

Electrical wires are considered as EEE parts and are covered within the ESA SCC specification series (ESA SCC 3901/XXX). This specification defines the principal properties of the wires including insulation/lay-up and electrical properties. Some additional space related materials requirements are also included, requirements such as outgassing and silver plating thickness. If a project has additional materials requirements over and above those covered by the relevant SCC specification, then additional testing is required. This is especially true for crewed spacecraft. The following topics are discussed in this context: additional requirements for manned spacecraft; flammability; arc tracking; thermal decomposition; microbial surface growth; and ageing.

Judd, M. D.↗
NASA NTRS2024

Welding of Crack Sensitive Aluminum Alloys for Liquid Rocket Propulsion Applications

In this welding test campaign, electron beam welding (EBW) and manual gas tungsten arc welding (GTAW) processes were utilized to join an additively manufactured aluminum alloy nozzle to a wrought aluminum flange. Both aluminum alloys were 6061, which in their conventional form are susceptible to solidification cracking issues. The AM nozzle utilized a novel high-performance modified version of 6061 which exhibits crack resistant properties during the AM process and during welding. When manually conducting GTAWs a filler wire with the same modified version of 6061 was utilized to weld different combinations of 6061 coupons (either modified or unmodified). Due to the grain refinement technology in the modified 6061, either as filler material or base material, there was complete elimination of weld solidification cracking. During EBW development a combination of wrought 6061 with a modified and additively manufactured 6061 was investigated. The EBWs developed exhibited no crack like defects. Each weld development program utilized non-destructive evaluation, metallography, and mechanical testing to determine the final weld acceptance. Mechanical testing involved hardness evaluation and tension testing on welded coupons. Both welding techniques were successfully developed and exhibited adequate properties for the final test articles and met all requirements of the development campaign. These welds were ultimately developed to be utilized on a set of all-aluminum liquid rocket nozzles to demonstrate additively manufactured aluminum alloys for propulsion applications. These aluminum nozzles were tested at NASA Marshall Space Flight Center’s hot fire test facility and subsequently underwent a test campaign involving a variety of chamber pressures and liquid propellant combinations. Following the hot fire test campaign each weldment was investigated for post operation performance and any defects that may have evolved during testing.

Welding↗
NASA NTRS2000

Increasing Importance of Material Electrical Interaction with the Space Environment

The electrical properties of materials have always been important for spacecraft in charging environments. However, in recent years consideration of interactions of materials and systems with the plasma environment has become more and more important in spacecraft design. This has primarily been driven by independent factors including increase in power and high voltage power systems, operation of tethered satellites, and science requirements for electrostatic clean spacecraft. Increased need for power has led to increased operating voltages for spacecraft. The Upper Atmospheric Research Satellite (UARS) was one of the first to operate at near 100 V solar array potential and demonstrate that the spacecraft floated nearly the entire voltage negative of the ionospheric plasma. The high voltage, 160 V, of the solar arrays on the International Space Station (ISS) led to the requirement to have a plasma contactor to control structure potential relative to the local plasma. Issues such as sputtering, dielectric breakdown, capacitive energy storage in the structure, space debris impact induced arcs and other arcing mechanisms had to be addressed. Recently commercial satellites, driven to higher voltages for efficiency, have experienced arcing problems which led to severe, permanent power degradation. The first tethered satellite, Tethered Satellite System (TSS), was deployed from the Space Shuttle. A conductive coating was developed which provided a low resistivity and also the required solar absorptivity and emittance. Other tether systems are being designed which will have similar requirements but also long life and "bare tether" designs are also being built for flight experiments. The wire requires an electrically conductive coating with proper thermal control properties, which a bare wire doesn't possess. Increasing sophistication of scientific instruments and measurements which scientists want to make have led to increasing requirements for conducting thermal control coatings to provide electrostatic cleanliness. These issues, which are increasing the importance of electrical interaction of materials to the space environment, will be discussed in this paper as well as research into material development to meet thermal and electrical requirements and research to understand phenomena regarding such interactions.

Carruth, M. R., Jr.↗
NASA NTRS2000

Investigation of Electromagnetic Field Threat to Fuel Tank Wiring of a Transport Aircraft

National Transportation Safety Board investigators have questioned whether an electrical discharge in the Fuel Quantity Indication System (FQIS) may have initiated the TWA-800 center wing tank explosion. Because the FQIS was designed to be incapable of producing such a discharge on its own, attention has been directed to mechanisms of outside electromagnetic influence. To support the investigation, the NASA Langley Research Center was tasked to study the potential for radiated electromagnetic fields from external radio frequency (RF) transmitters and passenger carried portable electronic devices (PEDs) to excite the FQIS enough to cause arcing, sparking or excessive heating within the fuel tank.

Ely, Jay J.↗
NASA NTRS2006

Using Electrostriction to Manipulate Ullage in Microgravity

A report proposes to use electrostriction to manipulate the ullage in a tank containing a dielectric liquid in a microgravitational environment. In the original intended application, the liquid would be a spacecraft propellant and the goal would be to force the ullage (comprising bubbles of noncondensible gas) to coalesce at one end of the tank, to enable use of one of the established means of (1) measuring the position of the gas/liquid interface and (2) inferring the quantity of liquid from the measurement. Electrically insulated wires would be installed in the tank, shaped and positioned so that application of a suitably high potential (e.g., 1 kV) between adjacent wires in successive pairs would give rise to a sufficient electric field gradient along the tank. The resulting electrostriction in the liquid would give rise to a pressure gradient that would force the ullage toward the low-electric-field-magnitude end of the tank. The feasibility of this proposal was demonstrated in an experiment in a tank containing liquid helium aboard an airplane flying a low-gravity arc. The ullage-segregating electrostrictive effect is expected to be considerably greater in other liquids.

Chui, Talso↗
NASA NTRS2011

Lockout/Tagout (LOTO) Simulator

The Lockout/Tagout (LOTO) Simulator is a portable training aid, or demonstration tool, designed to physically illustrate real-time critical-safety concepts of electrical lockout/tagout. The objective is to prevent misinterpretations of what is off and what is on during maintenance and repair of complex electrical systems. The simulator is designed in the form of a hinged box that opens up and stands on its own as an easel for demonstrations. On the outer face of the unit is a simulated circuit breaker box housing the switches. The breakers control the main power to the unit, a light bulb, and an electrical control cabinet. The light bulb is wired so that either of two breakers can provide power to it. When power is sent to the electrical control cabinet, a red indicator light illuminates. Inside the cabinet is the power supply from a personal computer. The power supply produces a 12-V dc output that is sent over to a small fan next to it, also from a computer, and an amber light on the front of the cabinet illuminates. A separate switch powers the fan on and off. The power supply is behind a plastic shield to protect against exposure to live conductors. Electrical banana jacks are mounted in the plastic shield to allow a voltmeter to be connected safely when opening the cabinet and taking a meter reading to verify de-energization as part of a simulation exercise. This LOTO simulator prototype is designed and fabricated as an all-in-one unit. All accessories can be stored inside the hinged case, and there is a handle on top for ease of transport. The circuit breaker labels attach with hook and loop fasteners so that they may be moved and changed to fit the training or demonstration scenario. The warning signs and labels on the electrical control box are magnetic, allowing for easy reconfiguration to emulate different equipment setups. A specially designed magnetic cover was made to disguise the indicator lights for demonstrations when these indicators are not used. The cover is disguised as an arc flash safety label that would typically be found on such a cabinet. One indicator light has a separate switch that can take it offline. This is to allow for demonstration to trainees on why it is important not to completely rely on indicator lights, but that they should always take a meter reading at the exposed conductors to absolutely verify de-energization before exposure. A clear plastic barrier and banana jacks inside the cabinet provide a safe way to plug in a voltmeter for demonstrations without exposure to the hazards of energized equipment. A small remote control unit is wired into the fan circuit. The remote allows the demonstrator to turn the fan on and off, provided that all of the breakers and switches leading to it are configured on as well. The remote feature was added in order to demonstrate the importance of starting the lockout/tagout task with energized equipment, then powering it down, isolating it, and locking it out to ensure that the correct breakers have been locked out.

Scheer, Jennifer↗
NASA NTRS2006

Analysis of ISS Plasma Interaction

To date, the International Space Station (ISS) has been one of the largest objects flown in lower earth orbit (LEO). The ISS utilizes high voltage solar arrays (160V) that are negatively grounded leading to pressurized elements that can float negatively with respect to the plasma. Because laboratory measurements indicate a dielectric breakdown potential difference of 80V, arcing could occur on the ISS structure. To overcome the possibility of arcing and clamp the potential of the structure, two Plasma Contactor Units (PCUs) were designed, built, and flown. Also a limited amount of measurements of the floating potential for the present ISS configuration were made by a Floating Potential Probe (FPP), indicating a minimum potential of 24 Volts at the measurement location. A predictive tool, the ISS Plasma Interaction Model (PIM) has been developed accounting for the solar array electron collection, solar array mast wire and effective conductive area on the structure. The model has been used for predictions of the present ISS configuration. The conductive area has been inferred based on available floating potential measurements. Analysis of FPP and PCU data indicated distribution of the conductive area along the Russian segment of the ISS structure. A significant input to PIM is the plasma environment. The International Reference Ionosphere (IRI 2001) was initially used to obtain plasma temperature and density values. However, IRI provides mean parameters, leading to difficulties in interpretation of on-orbit data, especially at eclipse exit where maximum charging can occur. This limits our predicative capability. Satellite and Incoherent Scatter Radar (ISR) data of plasma parameters have also been collected. Approximately 130,000 electron temperature (Te) and density (Ne) pairs for typical ISS eclipse exit conditions have been extracted from the reduced Langmuir probe data flown aboard the NASA DE-2 satellite. Additionally, another 18,000 Te and Ne pairs of ISR data from several radar locations around the globe were used to assure consistency of the satellite data. PIM predictions for ISS charging made with this data correlated very well with FPP data, indicating that the general physics of spacecraft charging with high voltage solar arrays have been captured. The predictions also provided the probabilities of occurrences for ISS charging. These probabilities give a numerical measure of the number of times when the ISS will approach or exceed the vehicle plasma hazard conditions for each configuration. In this paper we shall present the interaction mechanisms between the ISS and the surrounding plasma and give an overview of the PIM components. PIM predictions are compared with available data followed by a discussion of the variability of plasma parameters and the conductive area on the ISS. The ISS PIM will be further tested and verified as data from the Floating Potential Measurement Unit become available, and construction of the ISS continues.

Reddell, Brandon↗
NASA NTRS2014

High Current ESD Test of Advanced Triple Junction Solar Array Coupon

A test was conducted on an Advanced Triple Junction (ATJ) coupon that was part of a risk reduction effort in the development of a high-powered solar array design by SSL. The ATJ coupon was a small, 4-cell, two-string configuration that has served as the basic test coupon design used in previous SSL environmental aging campaigns. The coupon has many attributes of the flight design; e.g., substrate structure with graphite face sheets, integrated by-pass diodes, cell interconnects, RTV grout, wire routing, etc. The objective of the present test was to evaluate the performance of the coupon after being subjected to induced electrostatic discharge testing at two string voltages (100 V, 150 V) and four array current (1.65 A, 2.0 A, 2.475 A, and 3.3 A). An ESD test circuit, unique to SSL solar array design, was built that simulates the effect of missing cells and strings in a full solar panel with special primary arc flashover circuitry. A total of 73 primary arcs were obtained that included 7 temporary sustained arcs (TSA) events. The durations of the TSAs ranged from 50 μs to 2.9 ms. All TSAs occurred at a string voltage of 150 V. Post-test Large Area Pulsed Solar Simulator (LAPSS), Dark I-V, and By-Pass Diode tests showed that no degradation occurred due to the TSA events. In addition, the post-test insulation resistance measured was > 50 G-ohms between cells and substrate. These test results indicate a robust design for application to a high-current, high-power mission application.

Wright, K. H.↗
NASA NTRS2015

High Current ESD Test of Advanced Triple Junction Solar Array Coupon

A test was conducted on an Advanced Triple Junction (ATJ) coupon that was part of a risk reduction effort in the development of a high-powered solar array design by SSL. The ATJ coupon was a small, 4-cell, two-string configuration that has served as the basic test coupon design used in previous SSL environmental aging campaigns. The coupon has many attributes of the flight design; e.g., substrate structure with graphite face sheets, integrated by-pass diodes, cell interconnects, RTV grout, wire routing, etc. The objective of the present test was to evaluate the performance of the coupon after being subjected to induced electrostatic discharge testing at two string voltages (100 V, 150 V) and four array current (1.65 A, 2.0 A, 2.475 A, and 3.3 A). An ESD test circuit, unique to SSL solar array design, was built that simulates the effect of missing cells and strings in a full solar panel with special primary arc flashover circuitry. A total of 73 primary arcs were obtained that included 7 temporary sustained arcs (TSA) events. The durations of the TSAs ranged from 50 micros to 2.9 ms. All TSAs occurred at a string voltage of 150 V. Post-test Large Area Pulsed Solar Simulator (LAPSS), Dark I-V, and By-Pass Diode tests showed that no degradation occurred due to the TSA events. In addition, the post-test insulation resistance measured was > 50 G-ohms between cells and substrate. These test results indicate a robust design for application to a high-current, high-power mission application.

Wright, Kenneth H., Jr.↗
NASA NTRS2014

High Current ESD Test of Advanced Triple Junction Solar Array Coupon

Testing was conducted on an Advanced Triple Junction (ATJ) coupon that was part of a risk reduction effort in the development of a high-powered solar array design by Space Systems/Loral, LLC (SSL). The ATJ coupon was a small, 4-cell, two-string configuration that has served as the basic test coupon design used in previous SSL environmental aging campaigns. The coupon has many attributes of the flight design; e.g., substrate structure with graphite face sheets, integrated by-pass diodes, cell interconnects, RTV grout, wire routing, etc. The objective of the present test was to evaluate the performance of the coupon after being subjected to induced electrostatic discharge (ESD) testing at two string voltages (100 V, 150 V) and four array currents (1.65 A, 2.0 A, 2.475 A, and 3.3 A). An ESD test circuit, unique to SSL solar array design, was built that simulates the effect of missing cells and strings in a full solar panel with special primary arc flashover circuitry. A total of 73 primary arcs were obtained that included 7 temporary sustained arcs (TSA) events. The durations of the TSAs ranged from 50 micro-seconds to 2.75 milli-seconds. All TSAs occurred at a string voltage of 150 V. Post-test Large Area Pulsed Solar Simulator (LAPSS), Dark I-V, and By-Pass Diode tests showed that no degradation occurred due to the TSA events. In addition, the post-test insulation resistance measured was > 50 G-ohms between cells and substrate. These test results indicate a robust design for application to a high-current, high-power mission.

Wright, Kenneth H., Jr.↗
DOE OSTI2021

Pyrolysis Vacuum-Assisted Plasma Ionization Ion Mobility–Mass Spectrometry for Insoluble Polymer Analysis

Wire-based metal additive manufacturing utilizes the ability of additive manufacturing to fabricate complex geometries with high deposition rates (above 7 kg/h), thus finding applications in the fabrication of large-scale components, such as stamping dies. Traditionally, the workhorse materials for stamping dies have been martensitic steels. However, the complex thermal gyrations induced during additive manufacturing can cause the evolution of an inhomogeneous microstructure, which leads to a significant scatter in the mechanical properties, especially the toughness. Therefore, to understand these phenomena, arc-based additive AISI 410 samples were fabricated using robotic gas metal arc welding (GMAW) and were subjected to a detailed characterization campaign. The results show significant scatter in the tensile properties as well as Charpy V-notch impact toughness data, which was then correlated to the microstructural heterogeneity and delta (δ) ferrite formation. Post-processing (austenitizing and tempering) treatments were developed and an ~70% reduction in the scatter of tensile data and a four-times improvement in the toughness were obtained. The changes in mechanical properties were rationalized based on the microstructure evolution during additive manufacturing. Based on these, an outline to tailor the composition of “printable” steels for tooling with isotropic and uniform mechanical properties is presented and discussed.

36 MATERIALS SCIENCE↗
NASA NTRS1979

Sealed position sensitive hard X-ray detector having large drift region for all sky camera with high angular resolution

A sealed position sensitive proportional counter filled with two atmospheres of 95% xenon and 5% methane, and containing a drift region of 24 atm cm, has operated in a stable manner for many months. The detector contains G-10 frames to support the anode and cathode wires. The detector was sealed successfully by a combination of vacuum baking the G-10 frames at 150 C for two weeks followed by assembly into the detector in an environment of dry nitrogen, and the use of passive internal getters. The counter is intended for use with a circumferential cylindrical collimator. Together they provide a very broad field of view detection system with the ability to locate cosmic hard X-ray and soft gamma ray sources to an angular precision of a minute of arc. A set of instruments based on this principle have been proposed for satellites to detect and precisely locate cosmic gamma ray bursts.

Gorenstein, P.↗
NASA NTRS1992

757 Fly-By-Wire Demonstrator Flight Test

The Boeing Company modified a production 757-200 to emulate the 777 fly-by-wire control laws in order to evaluate the operation and performance of the 777 FBW flight control laws in flight. Following installation and checkout of the FBW system, testing began in March, 1992. Flight testing is currently planned to continue through August, 1992. The conventional 757 longitudinal flight control system is retained but controlled by only the captain’s column. The fly-by-wire system is evaluated by the pilot in the first officer’s seat and the safety pilot function is conducted from the captain’s seat. The flight test FBW longitudinal system is a 2-channel flight control system. The first officer’s column drives the current 757 left and right flight control computers (autopilots) which are modified to act as FBW computers. These FBW computers, which emulate the 777-200 FBW control laws, drive their respective autopilot actuators to control the airplane pitch axis. Directional FBW control laws arc emulated in the existing 757 yaw dampers, with corresponding modifications to the normal 757 directional control system. This paper presents a summary of the airplane FBW modifications and the flight test program to evaluate/validate the 777 FBW flight control laws.

Flight Testing↗
NASA NTRS1992

Studies of the field-of-view resolution tradeoff in virtual-reality systems

Most virtual-reality systems use LCD-based displays that achieve a large field-of-view at the expense of resolution. A typical display will consist of approximately 86,000 pixels uniformly distributed over an 80-degree by 60-degree image. Thus, each pixel subtends about 13 minutes of arc at the retina; about the same as the resolvable features of the 20/200 line of a Snellen Eye Chart. The low resolution of LCD-based systems limits task performance in some applications. We have examined target-detection performance in a low-resolution virtual world. Our synthesized three-dimensional virtual worlds consisted of target objects that could be positioned at a fixed distance from the viewer, but at random azimuth and constrained elevation. A virtual world could be bounded by chromatic walls or by wire-frame, or it could be unbounded. Viewers scanned these worlds and indicated by appropriate gestures when they had detected the target object. By manipulating the viewer's field size and the chromatic and luminance contrast of annuli surrounding the field-of-view, we were able to assess the effect of field size on the detection of virtual objects in low-resolution synthetic worlds.

Piantanida, Thomas P.↗
NASA NTRS1987

Self-clamping arc light reflector for welding torch

This invention is directed to a coaxial extending metal mirror reflector attached to the electrode housing or gas cup on a welding torch. An electric welding torch with an internal viewing system for robotic welding is provded with an annular arc light reflector to reflect light from the arc back onto the workpiece. The reflector has a vertical split or gap in its surrounding wall to permit the adjacent wall ends forming the split to be sprung open slightly to permit the reflector to be removed or slipped onto the torch housing or gas cup. The upper opening of the reflector is slightly smaller than the torch housing or gas cup and therefore, when placed on the torch housing or gas cup has that springiness to cause it to clamp tightly on the housing or gas cup. The split or gap also serves to permit the feed of weld wire through to the weld area,

Gordon, Stephen S.↗