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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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Economical process produces high-purity silicon crystals suitable for use in solar cells. Reaction is strongly exothermic and can be initiated at relatively low temperature, making it potentially suitable for development into low-cost commercial process. Important advantages include exothermic character and comparatively low process temperatures. These could lead to significant savings in equipment and energy costs.
The development of the analytic capability to predict the thermal ablation response of promising low cost materials for rocket nozzles is presented.
The results of the preliminary design study for the low cost point focus solar concentrator (LCPFSC) development program are presented. A summary description of the preliminary design is given. The design philosophy used to achieve a cost effective design for mass production is described. The concentrator meets all design requirements specified and is based on practical design solutions in every possible way.
The results of the second phase of the program of developing low cost contacts to silicon solar cells using copper are presented. Phase 1 yielded the development of a plated Pd-Cr-Cu contact system. This process produced cells with shunting problems when they were heated to 400 C for 5 minutes. Means of stopping the identified copper diffusion which caused the shunting were investigated. A contact heat treatment study was conducted with Pd-Ag, Ci-Ag, Pd-Cu, Cu-Cr, and Ci-Ni-Cu. Nickel is shown to be an effective diffusion barrier to copper.
Minimum complexity satellite selection algorithms are discussed for the implementation of a low-cost GPS.
Progress made by the Low-Cost Solar Array Project during the period December 1979 to April 1980 is described. Project analysis and integration, technology development in silicon material, large area silicon sheet and encapsulation, production process and equipment development, engineering, and operation are included.
The exothermic casting process was successfully developed into a low cost nonproprietary method for producing single crystal (SC) castings. Casting yields were lower than expected, on the order of 20 percent, but it is felt that the casting yield could be significantly improved with minor modifications to the process. Single crystal Mar-M 247 and two derivative SC alloys were developed. NASAIR 100 and SC Alloy 3 were fully characterized through mechanical property testing. SC Mar-M 247 shows no significant improvement in strength over directionally solidified (DS) Mar-M 247, but the derivative alloys, NASAIR 100 and Alloy 3, show significant tensile and fatigue improvements. The 1000 hr/238 MPa (20 ksi) stress rupture capability compared to DS Mar-M 247 was improved over 28 C. Firtree testing, holography, and strain gauge rig testing were used to evaluate the effects of the anisotropic characteristics of single crystal materials. In general, the single crystal material behaved similarly to DS Mar-M 247. Two complete engine sets of SC HP turbine blades were cast using the exothermic casting process and fully machined.
The concept is advanced of carrying out space based remote missions using a cooperative of low cost robot specialists rather than monolithic, multipurpose systems. A simulation is described wherein a control architecture for such a system of specialists is being investigated. Early results show such co-ops to be robust in the face of unforeseen circumstances. Descriptions of the platforms and sensors modeled and the beacon and retriever creatures that make up the co-op are included.
Superplastic forming of advanced aluminum alloys is being evaluated as an approach for fabricating low-cost, light-weight, cryogenic propellant tanks. Built-up structure concepts (with inherent reduced scrap rate) are under investigation to offset the additional raw material expenses incurred by using aluminum lithium alloys. This approach to fabrication offers the potential for significant improvements in both structural efficiency and overall manufacturing costs. Superplasticity is the ability of specially processed material to sustain very large forming strains without failure at elevated temperatures under controlled deformation conditions. It was demonstrated that superplastic forming technology can be used to fabricate complex structural components in a single operation and increase structural efficiency by as much as 60 percent compared to conventional configurations in skin-stiffened structures. Details involved in the application of this technology to commercial grade superplastic aluminum lithium material are presented. Included are identification of optimum forming parameters, development of forming procedures, and assessment of final part quality in terms of cavitation volume and thickness variation.
This paper describes ongoing research and development of CMOS active pixel image sensors for low cost commercial applications. A number of sensor designs have been fabricated and tested in both p-well and n-well technologies. Major elements in the development of the sensor include on-chip analog signal processing circuits for the reduction of fixed pattern noise, on-chip timing and control circuits and on-chip analog-to-digital conversion (ADC). Recent results and continuing efforts in these areas will be presented.
Lunar Surface temperatures can span from equatorial highs near 400K and polar lows of 50K. The extreme cold combined with the 354-hour duration of the lunar night is particularly challenging for small robotic lander missions. NASA’s Commercial Lunar Payload Services (CLPS) missions involve robotic landers intended to provide low-cost access to the lunar surface. Current CLPS Missions are solar powered and are only intended to survive a single lunar day. The ability to survive the night and continue operations over many lunar cycles would provide a dramatic increase in science productivity. The Power Hibernation approach relies on battery cells that can tolerate the extreme cold night and recover once temperatures return to normal. System recovery from hibernation depends on power electronics that can “cold start” at lunar dawn and operate on solar array output alone. Once battery and avionics systems are restored the spacecraft resumes daytime operations. The challenge is to achieve this capability with minimum impact to the spacecraft design and payload capacity. This talk will describe recent and ongoing investigations in battery and electronics technologies that will enable power hibernation and recovery.
Lunar Surface temperatures can span from equatorial highs near 400K and polar lows of 50K. The extreme cold combined with the 354-hour duration of the lunar night is particularly challenging for small robotic lander missions. NASA’s Commercial Lunar Payload Services (CLPS) missions involve robotic landers intended to provide low-cost access to the lunar surface. Current CLPS Missions are solar powered and are only intended to survive a single lunar day. The ability to survive the night and continue operations over many lunar cycles would provide a dramatic increase in science productivity. The Power Hibernation approach relies on battery cells that can tolerate the extreme cold night and recover once temperatures return to normal. System recovery from hibernation depends on power electronics that can “cold start” at lunar dawn and operate on solar array output alone. Once battery and avionics systems are restored the spacecraft resumes daytime operations. The challenge is to achieve this capability with minimum impact to the spacecraft design and payload capacity. This talk will describe recent and ongoing investigations in battery and electronics technologies that will enable power hibernation and recovery.
Viable processes were developed for secondary working of oxide dispersion strengthened (ODS) alloys to near-net shapes (NNS) for aircraft turbine vanes. These processes were shown capable of producing required microstructure and properties for vane applications. Material cost savings of 40 to 50% are projected for the NNS process over the current procedures which involve machining from rectangular bar. Additional machining cost savings are projected. Of three secondary working processes evaluated, directional forging and plate bending were determined to be viable NNS processes for ODS vanes. Directional forging was deemed most applicable to high pressure turbine (HPT) vanes with their large thickness variations while plate bending was determined to be most cost effective for low pressure turbine (LPT) vanes because of their limited thickness variations. Since the F101 LPT vane was selected for study in this program, development of plate bending was carried through to establishment of a preliminary process. Preparation of ODS alloy plate for bending was found to be a straight forward process using currently available bar stock, providing that the capability for reheating between roll passes is available. Advanced ODS-NiCrAl and ODS-FeCrAl alloys were utilized on this program. Workability of all alloys was adequate for directional forging and plate bending, but only the ODS-FeCrAl had adequate workability for shaped preform extrustion.
A description is presented of work concerned with determining the effects of long-term flight service on advanced composite helicopter airframe components. The helicopter chosen for the program is the Long Ranger Model 206L. The components to be evaluated include the baggage door, litter door, vertical fin, and forward fairing. Only the vertical fin is classified as primary structure. Loss of any of the other components will not compromise safety of the aircraft. Attention is given to the program objectives, the design of the forward fairing, the fabrication procedures, the exterior surface, the cocure procedure, material tests, and initial cost-tracking. The considered program demonstrates the ability to produce an acceptable fairing by the 'one-shot' cocured process and, based on learning curve experience, production costs will be low. The low-temperature 200 F cure does not affect the structural properties to an unacceptable degree. A method for obtaining a smooth, exterior painted surface for Kevlar/epoxy fabric has been developed.
A study of life-cycle cost is conducted to determine acceptable options for composite propellant tanks at low cost and weight and for use at moderate pressures. The review examines all cost issues relevant to the production, mass, applications, and reliability of the tanks for pressure-fed rockets. Specific attention is given to the manufacturing and life-cycle issues relevant to the use of composite materials in this application since composites are effective materials for liquid propellant tanks. Specific costs and parametric considerations are given for several tank candidates with 62,303-lb capacities. The mass sensitivity of the fourth stage for the concept vehicle is shown to be high, and the use of a 325-psi fourth-stage tank is shown to yield the minimum cost/lb for the stage. Wound S-glass/epoxy composites can be employed as cost-effective replacements for steel in the design of liquid-propellant tanks.
The use of robots in different fields is common and effective in developed countries. In case of incident management or emergency rescue after a disaster, robots are often used to lessen the human effort where it is either impossible or life-threatening for rescuers. Though developed countries can afford robotic-effort for pro-disaster management, the scenario is totally opposite for developing and under-developed countries to engage such a machine-help due to high cost of the machines and high maintenance cost as well. In this research paper, the authors proposed a low-cost "Rescue-Robot" for pro-disaster management which can overcome the budget-constraints as well as fully capable of rescue purposes for incident management. Here, all the research works were performed in Bangladesh - a developing country in South Asia. A disaster struck structure was chosen and a thorough survey was performed to understand the real-life environment for the prototype. The prototype was developed considering the results of this survey and it was manufactured using all locally available components and facilities.
Design of low-cost microwave adaptor suitable for television reception from high-power communications satellites
The present work describes briefly the design, construction, and operation of a low cost air mass 2 solar simulator, and then presents the performance characteristics of a modified version in terms of total irradiance, uniformity of irradiance, spectral distribution, and beam subtense angle. The simulator consists of an array of 143 tungsten halogen lamps and a corresponding array of 143 Fresnel lenses parallel and in front of the lenses, so that a 1.2 m by 1.2 m area is irradiated with uniform collimated irradiance. The performance of this 143-lamp version is compared with that of the 12-lamp prototype. It was found that the larger design required a lower lamp voltage for an equivalent average total irradiance in the test plane. However, distribution of total irradiance was not as good for the large simulator.