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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
DOE OSTI2023

Characterization of Additive Manufacturing Materials for String Assembly in Cleanroom

Beamline components, such as superconducting radio frequency cavities and focusing lenses, need to be assembled together in a string while in a cleanroom environment. The present contribution identifies and characterizes materials for additive manufacturing that can be used in a cleanroom. The well known advantages of additive manufacturing processes would highly benefit the design and development of tooling needed for the mechanical support and alignment of string components. Cleanliness, mechanical properties, and leak tightness of the chosen materials are the main focus of this contribution, which also paves the way for the integration of such materials in cryomodule assemblies. Results reported here were obtained in the framework of the PIP-II project at Fermilab.

43 PARTICLE ACCELERATORS↗
DOE OSTI2026

Bent Crystal Channeling for Optimized Beam Shadowing and Proton Extraction at Mu2e

The Mu2e experiment is designed to investigate the CLFV through the observation of a neutrinoless muon-to-electron conversion in the field of an Al nucleus. The observation of such a process would be clear evidence of physics beyond the standard model. Due to the rarity of this process, a cutting-edge, intense muon beam is required to achieve an improvement of the current single-event sensitivity by 4 orders of magnitude. To achieve this goal, a primary proton beam with 8 GeV is extracted from the Fermilab Delivery Ring using the slow resonant extraction technique. Mu2e requires ~3.6x10$^{20}$ protons-on-target to meet its goal; hence, it is crucial to minimize the extraction losses. An important source of such losses are the particles impacting on the electrostatic septum blade. A very promising solution to the problem lies in the beam shadowing scheme tested at CERN SPS. In this approach, a bent crystal is strategically placed upstream of the septum, deflecting particles from the blade at a precise angle via the phenomenon of channeling. As a result, a zone with reduced particle flux is created downstream of the crystal, safeguarding the septum anode by minimizing interactions with the beam. This work explores the optimization of beam shadowing design and the process in the manufacturing and characterization of the bent crystal sample. It emphasizes the promising role of channeling in bent crystals, and it underscores the significant potential of channeling in bent crystals to assist the Mu2e experiment.

Fedeli, Pierluigi [Ferrara U.; INFN, Ferrara] (ORC↗
DOE OSTI2026

Tandem Photovoltaics Core Program Final Technical Report

The Tandem Photovoltaics Core Program was a multi-year initiative aimed at advancing hybrid tandem solar cell technologies to enhance solar module efficiency beyond the limits of single junction devices. This project focused on the development, testing, and scaling of prototype photovoltaic devices, with the goal of achieving commercial relevance and driving industry adoption. The work was divided into three tasks: 1) Comparative Analysis of Tandem Technologies: This task focused on quantifying energy yield under real-world conditions and assessing economic viability of tandems relative to silicon-based modules. The project's modeling framework incorporated performance data, cost of materials, and manufacturing process impacts to optimize tandem designs 2) Tandem Integration and Prototyping: In this task, we developed innovative tandem designs by combining metal halide perovskite (MHP) top cells and silicon (Si) bottom cells. The project focuses on both mechanical integration and direct deposition techniques to enable compatibility with commercially relevant Si technologies, such as passivated contact or PERC cells. 3) Scale-up and Reliability: This task addressed the challenges of large-area fabrication by developing scalable deposition methods and robust interconnection schemes for tandems. The project looked at different accelerated testing such as thermal cycling, damp heat exposure, and potential induced degradation, to ensure long-term stability of devices in field conditions. Tandem solar cells can greatly increase module efficiency beyond conventional single junction (SJ) devices, which are approaching their theoretical limit. There are many ways to fabricate a tandem cell or module in terms of materials used, configuration, and terminal connection. This SETO core project focused critical factors in enabling tandems to enter the market, including hardware integration, technoeconomic analysis (TEA), and energy yield analysis. We focused on MHP/Si hybrid tandem solar cells and modules as a model system for their versatility in module design comparisons, providing valuable insights for other tandem options. While champion cells with areas <1cm2 are regularly demonstrated by groups around the world, it is significantly more challenging to translate these advances into modules, and fewer institutions and companies are working at the module level. This project addressed questions about module fabrication, testing, and reliability that are hard to answer without actually fabricating prototypes. We also performed analysis and road-mapping activities to understand the potential for a wider variety of tandems, including all-perovskite tandems fabricated in collaboration with the Perovskite PV core program. Detailed technical results from this project are described for each task in Section 7.

14 SOLAR ENERGY↗
NASA NTRS1967

Electronics parts engineering

Identification of designs, materials, and processes used in manufacturing of electronic equipment

ELECTRONIC EQUIPMENT↗
NASA NTRS1972

Investigation of low-cost ablative heat shield fabrication for space shuttles

Improvements in the processes and design to reduce the manufacturing costs for low density ablative panels for the space shuttle are discussed. The areas that were studied included methods of loading honeycomb core, alternative reinforcement concepts, and the use of reusable subpanels. A review of previous studies on the fabrication of low-cost ablative panels and on permissible defects that do not affect thermal performance was conducted. Considerable differences in the quoted prices for ablative panels, even though the various contractors had reported similar fabrication times were discovered. How these cost differences arise from different estimating criteria and which estimating assumptions and other costs must be included in order to arrive at a realistic price are discussed.

Chandler, H. H.↗
NASA NTRS1972

FCC in Viking articulated boom

The application requirements and manufacturing techniques for the flat conductor cable used in the Viking Lander Articulated Boom Unit are described. The Viking Boom is a 3-axis device utilized to position a soil sampler and provide digging forces. This application imposed severe restrictions on size, weight, materials, and choice of manufacturing processes. The final cable assembly design resulted in a combination of collated cable and flexible circuits assembled by resistance welding techniques.

Hawkins, E. S.↗
NASA NTRS1975

The solidification under zero gravity conditions of binary alloys exhibiting solid state immiscibility

The solidification behavior of gold-silicon alloys containing up to 25 at. % silicon was studied, and a mathematical model of gravity segregation during solidification was developed. A background of knowledge is provided which can be used in the design of zero gravity solidification experiments to be carried out in the 300-ft drop tower, in Aerobee rockets and in future space missions. Such experiments are needed to develop the basic scientific knowledge required for the design of economically viable space manufacturing processes. Some preliminary zero gravity experiments were carried out on a gold-25 at. % silicon alloy using the drop tower facility.

Johnson, A. A.↗
NASA NTRS1979

Technology for future air transports

The requirements and opportunities for technological development in transport aircraft of the next generation are reviewed, focusing primarily on conventional, subsonic aircraft. Advances in computational aerodynamics and computer-aided design and manufacturing (in numerically controlled processes) are noted as well as improved wind tunnel testing and drag reduction techniques. Advances in aeroelasticity prediction have made it possible to use flexible, high-aspect-ratio wings without large weight penalties. Weight reduction may be achieved by the use of composite aircraft structures and superplastic forming combined with diffusion bonding, however composites require improvement in manufacturing techniques and mechanical properties in order to gain general acceptance. Propulsion systems can be improved in engine fuel efficiency, control, durability, environmental compatibility (exhaust and noise emissions), and fuel specifications. In avionics, due to the growth of low-cost, miniaturized packages, opportunities exist in the fields of digital controls, navigation, guidance and communication. Applications of new technologies to various aspects of flight safety are also outlined.

Klineberg, J. M.↗
NASA NTRS1980

The Voyager spacecraft /James Watt International Gold Medal Lecture/

The Voyager Project background is reviewed with emphasis on selected features of the Voyager spacecraft. Investigations by the Thermo-electric Outer Planets Spacecraft Project are discussed, including trajectories, design requirements, and the development of a Self Test and Repair computer, and a Computer Accessed Telemetry System. The design and configuration of the spacecraft are described, including long range communications, attitude control, solar independent power, sequencing and control data handling, and spacecraft propulsion. The development program, maintained by JPL, experienced a variety of problems such as design deficiencies, and process control and manufacturing problems. Finally, the spacecraft encounter with Jupiter is discussed, and expectations for the Saturn encounter are expressed.

Heacock, R. L.↗
NASA NTRS1990

Space shuttle redesigned solid rocket motor Certificate of Qualification (COQ) data report

The Space Shuttle Redesigned Solid Rocket Motor (RSRM) Certification Program provides confidence that the RSRM and its components/subsystems meet or exceed Mission Oriented Requirements when manufactured per design requirements and specified/approved processes. Certification is based on documented results of tests, analyses, inspections, similarity, and demonstrations. Evidencing information is provided to certify that each RSRM component/subsystem satisfies design, mission related requirements and objectives.

Duersch, Fred, Jr.↗
NASA NTRS1991

Space Shuttle Solid Rocket Motor Program - Lessons learned

An evaluation is given of the most important lessons learned concerning the Space Shuttle's Solid Rocket Motors with respect to flight safety, reuse requirements, system reliability, structural integrity, and hardware damage due to reentry, water impact, and retrieval. Within the major categories of flight safety, performance, and reuse/cost, priorities are identified for implementation of envisioned improvements; schedule and cost considerations are noted to have been substantially downgraded in favor of flight safety. The consequences of the primacy of flight safety are discussed in the areas of primary systems design, redundant systems, manufacturing and assembly processing, and launch constraints.

Mccool, A. A.↗
NASA NTRS1994

Linear Proof Mass Actuator

This paper describes the mechanical design, analysis, fabrication, testing, and lessons learned by developing a uniquely designed spaceflight-like actuator. The linear proof mass actuator (LPMA) was designed to attach to both a large space structure and a ground test model without modification. Previous designs lacked the power to perform in a terrestrial environment while other designs failed to produce the desired accelerations or frequency range for spaceflight applications. Thus, the design for a unique actuator was conceived and developed at NASA Langley Research Center. The basic design consists of four large mechanical parts (mass, upper housing, lower housing, and center support) and numerous smaller supporting components including an accelerometer, encoder, and four drive motors. Fabrication personnel were included early in the design phase of the LPMA as part of an integrated manufacturing process to alleviate potential difficulties in machining an already challenging design. Operating testing of the LPMA demonstrated that the actuator is capable of various types of load functions.

Holloway, Sidney E., III↗
NASA NTRS1995

Linear Proof Mass Actuator

This paper describes the mechanical design, analysis, fabrication, testing, and lessons learned by developing a uniquely designed spaceflight-like actuator. The Linear Proof Mass Actuator (LPMA) was designed to attach to both a large space structure and a ground test model without modification. Previous designs lacked the power to perform in a terrestrial environment while other designs failed to produce the desired accelerations or frequency range for spaceflight applications. Thus, the design for a unique actuator was conceived and developed at NASA Langley Research Center. The basic design consists of four large mechanical parts (Mass, Upper Housing, Lower Housing, and Center Support) and numerous smaller supporting components including an accelerometer, encoder, and four drive motors. Fabrication personnel were included early in the design phase of the LPMA as part of an integrated manufacturing process to alleviate potential difficulties in machining an already challenging design. Operational testing of the LPMA demonstrated that the actuator is capable of various types of load functions.

Holloway, S. E., III↗
NASA NTRS1993

Role of strategic planning in engineering management

Today, more than ever before, engineers are faced with uncertain and sometimes chaotic environments in which to function. The traditional roles of an engineer to design, develop, and streamline a manufacturing process for a product are still valued and relevant. However, the need for an engineer to participate in the process of identifying the product to be developed, the schedule and resources required, and the goal of satisfying the customer, has become paramount to achieving the success of the enterprise. When we include these endeavors in the functions of an engineer, management of 'engineering' takes on a new dimension. In this paper, the ramifications of the changing and increased functions of an engineer and consequent impacts on engineering management are explored. The basic principles which should be invoked in order to embrace the new environment for engineering management are outlined. The ultimate finding of this study is that the enterprise strategic plan should be developed in such a way as to allow engineering management to encompass the full spectrum of the responsibilities of engineers. A consequence of this is that the fundamental elements of the strategic process can best be implemented through a project team or group approach. The paper thus concentrates on three areas: evolving environment, strategic plan, and ways to achieve enterprise success.

Krishen, Kumar↗
NASA NTRS2019

3D Printing Heat Shields

Heat shields that protect spacecraft from the heat of entering a planet's atmosphere are labor intensive to manufacture, cost prohibitive and the heat shield design is constrained by the manufacturing process. Little, if any, automation is used to manufacture and install the thermal protection system (TPS) on the vehicles and most heat shields are segmented with many seams and gaps. The goal of this project is to change this paradigm by developing new TPS materials and taking advantage of additive manufacturing technology to automate the processes for making and installing monolithic, ablative TPS on large entry vehicles.

Bouslog, Stan↗
NASA NTRSDate not supplied

Assured Performance of Additively Manufactured and Composite Parts through Embedded Sensing and Life Cycle Monitoring: An Enabler for in-Space Use

Lightweight composites have a range of applications in aerospace where operational costs and mission (payload) capabilities depend significantly on component weight. Additive manufacturing of the composite components expands the design and production space allowing for complex part geometries. A limiting factor to the utilization of the composites in high value applications, such as aerospace generally, and particularly for in-space applications, is the ability to determine the part quality both at the time of production as well as through the lifetime of the component. Work on monitoring the performance of additively manufactured and autoclaved composites that encompasses the design and manufacturing as well as use in operational environments will be discussed. Optimization of the component design for manufacturability, the use of process monitoring sensors during the component build as well as embedding of carbon nanotube yarn based structural sensors will be described.

Additive Manufacturing↗
NASA NTRS2001

Single-event upset in the PowerPC750 microprocessor

In this paper we report results of single-event tests of the PowerPC750 from Motorola and IBM, which are identical designs which are manufactured with advanced processes that uses a minimum feature size of 0.29 and 0.28 mu m, respectively.

single↗
NASA NTRS2016

The "Puck" Energetic Charged Particle Detector: Design, Heritage, and Advancements

Energetic charged particle detectors characterize a portion of the plasma distribution function that plays critical roles in some physical processes, from carrying the currents in planetary ring currents to weathering the surfaces of planetary objects. For several low-resource missions in the past, the need was recognized for a low-resource but highly capable, mass-species-discriminating energetic particle sensor that could also obtain angular distributions without motors or mechanical articulation. This need led to the development of a compact Energetic Particle Detector (EPD), known as the "Puck" EPD (short for hockey puck), that is capable of determining the flux, angular distribution, and composition of incident ions between an energy range of approximately 10 kiloelectronvolts to several megaelectronvolts. This sensor makes simultaneous angular measurements of electron fluxes from the tens of kiloelectronvolts to about 1 megaelectronvolt. The same measurements can be extended down to approximately 1 kiloelectronvolt per nucleon,with some composition ambiguity. These sensors have a proven flight heritage record that includes missions such as MErcury Surface, Space ENvironment, GEochemistry, and Ranging (MESSENGER) and New Horizons, with multiple sensors on each of Juno, Van Allen Probes, and Magnetospheric Multiscale. In this review paper we discuss the Puck EPD design, its heritage, unexpected results from these past missions and future advancements. We also discuss high-voltage anomalies that are thought to be associated with the use of curved foils, which is a new foil manufacturing processes utilized on recent Puck EPD designs. Finally, we discuss the important role Puck EPDs can potentially play in upcoming missions.

Clark, G.↗