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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 343 records · Page 19

VPS GRCop-84 Liner Development Efforts

For the past several years, NASA's Marshall Space Flight Center (MSFC) has been working with Plasma Processes, Inc. (PPI) to fabricate combustion chamber liners using the Vacuum Plasma Spray (VPS) process. Multiple liners of a variety of shapes and sizes have been created. Each liner has been fabricated with GRCop-84 (a copper alloy with chromium and niobium) and a functional gradient coating (FGC) on the hot wall. While the VPS process offers versatility and a reduced fabrication schedule, the material system created with VPS allows the liners to operate at higher temperatures, with maximum blanch resistance and improved cycle life. A subscal unit (5K lbf thrust class) is being cycle tested in a LOX/Hydrogen thrust chamber assembly at MSFC. To date, over 75 hot-fire tests have been accumulated on this article. Tests include conditions normally detrimental to conventional materials, yet the VPS GRCop-84 liner has yet to show any signs of degradation. A larger chamber (15K lbf thrust class) has also been fabricated and is being prepared for hot-fire testing at MSFC near the end of 2003. Linear liners have been successfully created to further demonstrate the versatility of the process. Finally, scale up issues for the VPS process are being tackled with efforts to fabricate a full size, engine class liner. Specifically, a liner for the SSME's Main Combustion Chamber (MCC) has recently been attempted. The SSME size was chosen for convenience, since its design was readily available and its size was sufficient to tackle specific issues. Efforts to fabricate these large liners have already provided valuable lessons for using this process for engine programs. The material quality for these large units is being evaluated with destructive analysis and these results will be available by the end of 2003.

Elam, Sandra K.↗

Cryogenic System for Interferometric Measurement of Dimensional Changes at 40 K: Design and Performance

This report describes the facility, experimental methods, characterizations, and uncertainty analysis of the Cryo Distortion Measurement Facility (CDMF) at the Goddard Space Flight Center (GSFC). This facility is designed to measure thermal distortions of structural elements as the temperature is lowered from 320K to below 40 K over multiple cycles, and is capable of unattended running and data logging. The first measurement is to be the change in length and any bending of composite tubes with Invar end-fittings. The CDMF includes a chamber that is efficiently cooled with two cryo-coolers (one single-stage and one two-stage) rather than with liquid cryogens. Five optical ports incorporate sapphire radiation shields - transparent to the interferometer - on each of two shrouds and a fused silica vacuum-port window. The change in length of composite tubes is monitored continuously with displacement-measuring interferometers; and the rotations, bending, and twisting are measured intermittently with theodolites and a surface-figure interferometer. Nickel-coated invar mirrors and attachment mechanisms were developed and qualified by test in the CDMF. The uncertainty in measurement of length change of 0.4 m tubes is currently estimated at 0.9 micrometers.

Blake, Peter↗

Development of a Cryogenic Thermal Distortion Measurement Facility for Testing the James Webb Space Telescope Instrument Support Integration Module 2-D Test Assemblies

The James Webb Space Telescope Instrument Support Integration Module (ISIM) is being designed and developed at the Goddard Space Flight Center. The ISM Thermal Distortion Testing (ITDT) program was started with the primary objective to validate the ISM mechanical design process. The ITDT effort seeks to establish confidence and demonstrate the ability to predict thermal distortion in composite structures at cryogenic temperatures using solid element models. This-program's goal is to better ensure that ISIM meets all the mechanical and structural requirements by using test results to verify or improve structural modeling techniques. The first step to accomplish the ITDT objectives was to design, and then construct solid element models of a series 2-D test assemblies that represent critical building blocks of the ISIM structure. Second, the actual test assemblies consisting of composite tubes and invar end fittings were fabricated and tested for thermal distortion. This paper presents the development of the GSFC Cryo Distortion Measurement Facility (CDMF) to meet the requirements of the ISIM 2-D test. assemblies, and other future ISIM testing needs. The CDMF provides efficient cooling with both a single, and two-stage cryo-cooler. Temperature uniformity of the test assemblies during thermal transients and at steady state is accomplished by using sapphire windows for all of the optical ports on the radiation shields and by using .thermal straps to cool the test assemblies. Numerical thermal models of the test assemblies were used to predict the temperature uniformity of the parts during cooldown and at steady state. Results of these models are compared to actual temperature data from the tests. Temperature sensors with a 0.25K precision were used to insure that test assembly gradients did not exceed 2K lateral, and 4K axially. The thermal distortions of two assemblies were measured during six thermal cycles from 320K to 35K using laser interferometers. The standard deviation for all of the distortion measurements is less than 0.5 microns, which falls within the ISIM requirement of 3 microns.

Miller, Franklin↗

Guidance, Navigation, and Control Performance for the GOES-R Spacecraft

The Geostationary Operational Environmental Satellite-R Series (GOES-R) is the first of the next generation geostationary weather satellites, scheduled for delivery in late 2015 and launch in early 2016. Relative to the current generation of GOES satellites, GOES-R represents a dramatic increase in Earth and solar weather observation capabilities, with 4 times the resolution, 5 times the observation rate, and 3 times the number of spectral bands for Earth observations. GOES-R will also provide unprecedented availability, with less than 120 minutes per year of lost observation time. The Guidance Navigation & Control (GN&C) design requirements to achieve these expanded capabilities are extremely demanding. This paper first presents the pointing control, pointing stability, attitude knowledge, and orbit knowledge requirements necessary to realize the ambitious Image Navigation and Registration (INR) objectives of GOES-R. Because the GOES-R suite of instruments is sensitive to disturbances over a broad spectral range, a high fidelity simulation of the vehicle has been created with modal content over 500 Hz to assess the pointing stability requirements. Simulation results are presented showing acceleration, shock response spectrum (SRS), and line of sight responses for various disturbances from 0 Hz to 512 Hz. These disturbances include gimbal motion, reaction wheel disturbances, thruster firings for station keeping and momentum management, and internal instrument disturbances. Simulation results demonstrate excellent performance relative to the pointing and pointing stability requirements, with line of sight jitter of the isolated instrument platform of approximately 1 micro-rad. Low frequency motion of the isolated instrument platform is internally compensated within the primary instrument. Attitude knowledge and rate are provided directly to the instrument with an accuracy defined by the Integrated Rate Error (IRE) requirements. The allowable IRE ranges from 1 to 18.5 micro-rad, depending upon the time window of interest. The final piece of the INR performance is orbit knowledge. Extremely accurate orbital position is achieved by GPS navigation at Geosynchronous Earth Orbit (GEO). Performance results are shown demonstrating compliance with the 50 to 75 m orbit position accuracy requirements of GOES-R, including during station-keeping and momentum management maneuvers. As shown in this paper, the GN&C performance for the GOES-R series of spacecraft supports the challenging mission objectives of the next generation GEO Earth-observation satellites.

Guidance↗

Guidance, Navigation, and Control Performance for the GOES-R Spacecraft

The Geostationary Operational Environmental Satellite-R Series (GOES-R) is the first of the next generation geostationary weather satellites. The series represents a dramatic increase in Earth observation capabilities, with 4 times the resolution, 5 times the observation rate, and 3 times the number of spectral bands. GOES-R also provides unprecedented availability, with less than 120 minutes per year of lost observation time. This paper presents the Guidance Navigation & Control (GN&C) requirements necessary to realize the ambitious pointing, knowledge, and Image Navigation and Registration (INR) objectives of GOES-R. Because the suite of instruments is sensitive to disturbances over a broad spectral range, a high fidelity simulation of the vehicle has been created with modal content over 500 Hz to assess the pointing stability requirements. Simulation results are presented showing acceleration, shock response spectra (SRS), and line of sight (LOS) responses for various disturbances from 0 Hz to 512 Hz. Simulation results demonstrate excellent performance relative to the pointing and pointing stability requirements, with LOS jitter for the isolated instrument platform of approximately 1 micro-rad. Attitude and attitude rate knowledge are provided directly to the instrument with an accuracy defined by the Integrated Rate Error (IRE) requirements. The data are used internally for motion compensation. The final piece of the INR performance is orbit knowledge, which GOES-R achieves with GPS navigation. Performance results are shown demonstrating compliance with the 50 to 75 m orbit position accuracy requirements. As presented in this paper, the GN&C performance supports the challenging mission objectives of GOES-R.

Control↗

GOES-R Spacecraft Verification and Validation Compared with Flight Results

The Geostationary Operational Environmental Satellite, R-Series (GOES-R) represents a dramatic improvement in GEO (Geostationary Earth Orbit) weather observation capabilities over the previous generation. To provide these new capabilities, GOES-R incorporates a number of new technologies flying for the first time. As with any new spacecraft design, extensive ground testing was performed to validate the vehicle performance. In this paper, we present several successes and several lessons-learned from the GOES-R verification and validation (V&V) efforts. Included are the Dynamic Interaction Test (DIT) results for jitter assessment, and comparison to flight results. Also included are the effects of thermally-induced alignment perturbations, along with post-launch mitigations. Finally, we discuss unexpected GOES-17 gyro performance, which caused a Safe Mode entry shortly after launch. V&V mitigations are presented, which will be used for the next two GOES-R vehicles.

GOES-17↗

In-Flight Line-Of-Sight Pointing Performance for the GOES-16 and GOES-17 Spacecraft

The Geostationary Operational Environmental Satellite-R program (GOES-R) has launched two of the next generation geostationary weather satellites, both of which are now fully operational. GOES-16 launched in November 2016, and GOES-17 launched in March 2017. In this paper, we present the pointing and pointing stability results of the two spacecraft, with specific focus on aspects of the design related to mitigating jitter. The flight instrument suite includes 6 seismic accelerometers sampled at approximately 2 kilohertz, allowing in-flight verification of pointing stability and comparison back to simulation predictions. This paper compares the observed flight results with the simulation predictions for acceleration and shock response spectrum (SRS) for various operational scenarios and instrument observation modes. Passive isolation of both the reaction wheels and the payload deck have proved to be effective in reducing jitter responses. Active Vibration Damping (AVD) of flexible-body modes attenuates the low frequency motion of the vehicle appendages, improving the low-frequency pointing performance. Knowledge of the instrument scan mirror motion is fed forward to the reaction wheel control, reducing disturbances on the spacecraft bus. Attitude knowledge and rate data are provided to the primary Earth-observing instrument with an accuracy defined by the Integrated Rate Error (IRE) requirements. The data are used to adjust instrument scanning. As we show in this paper, the in-flight performance of the GN&C (Guidance, Navigation and Control) design provides the necessary capabilities to achieve the demanding GOES-R mission objectives while its robustness enabled the simultaneous operation of the Advanced Baseline Imager (ABI) prime and redundant cryocoolers (CCs) to resolve an in-flight cooling anomaly on GOES-17.

Line-of-Sight↗

The Endurance Rocket Mission

NASA’s Endurance sounding rocket (yard No. 47.001) will launch from Ny Ålesund, Svalbard in May 2022 on a solid fueled Oriole III-A launch vehicle. Its ∼19 minute flight will carry it to an altitude of ∼780 km above Earth’s sunlit polar cap. Its objective is to make the first measurement of the weak “ambipolar” electric field generated by Earth’s ionosphere. This field is thought to play a critical role in the upwelling and escape of ionospheric ions, and thus potentially in the evolution of Earth’s atmosphere. The results will enable us to determine the importance to ion escape of this previously unmeasured fundamental property of our planet, which will aid in a better understanding of what makes Earth habitable. Endurance will carry six science instruments (with 16 sensors) that will measure the total electrical potential drop below the spacecraft, and the physical parameters required to understand the physics of what generates the ambipolar field. The mission will be supported by simultaneous observations of solar and geomagnetic activity.

Glyn Collinson↗

Unveiling Atomistic Mechanisms Governing Additive Manufacturing Processability and Mechanical Behavior of a Refractory Complex Concentrated Alloy

Extending the concept of complex concentrated alloys (CCAs) to the refractory alloys (solidus temperature over 2000 °C) space potentially facilitates the design of lightweight structural alloys with service temperatures that exceed those of Ni and Co‐based alloys. However, the room and elevated temperature tensile properties of the current refractory‐CCAs (R‐CCAs) are inferior to those of the Ni/Co‐based alloys. Furthermore, the manufacturing scalability of R‐CCAs remains challenging, in that cracks are prevalent in all R‐CCAs when processed using near‐net shape manufacturing processes, such as fusion‐based additive manufacturing (F‐BAM). Still, mechanisms governing the poor F‐BAM processability of R‐CCAs remain unexplored. Here, to this end, this work unveils the atomistic mechanisms underlying F‐BAM process‐induced cracking in a NbTiTaMoHfZrC R‐CCA. The implications of light elements’ presence for intrinsic ductility and grain boundary cohesion, and subsequently for F‐BAM processability and mechanical behavior, are revealed. Leveraging the insights, we accomplish what is, to the best of the knowledge, the first instance of crack‐free F‐BAM processing of any R‐CCA. Additionally, the R‐CCA exhibits over 20% tensile ductility and ≈160 MPa tensile yield strength at 1200 °C. In addition to facilitating the design of lightweight R‐CCAs, findings enable scalable manufacturing of these ultra‐high temperature alloys for structural applications.

Refractory alloys↗

Temperature‐Dependent Crystallization in Two‐Step Perovskite Deposition Revealed by In Situ GIWAXS and Machine Learning‐Guided Analysis

The performance and stability of perovskite solar cells are strongly governed by the crystallization behavior of their active layer. In two-step sequential deposition, early-stage film formation plays a decisive role in determining final phase purity and device quality. Guided by a data-driven analysis of nearly 39 000 devices in the FAIR perovskite database, we identified solvent-mediated quenching and thermal processing as key variables affecting power conversion efficiency (PCE), particularly in two-step fabrication. Here, to investigate these effects in real time, we designed and implemented a custom-built, temperature-controlled spin-coating system, enabling precise thermal modulation during precursor deposition. Using this platform, we performed in situ GIWAXS measurements to study the crystallization dynamics of FA 0.5 MA 0.5 PbI 3 films over a temperature range of 30°C–90°C. Our results reveal a non-monotonic relationship between spin-coating temperature and α-phase formation, governed by the interplay between precursor interdiffusion, PbI 2 crystallinity, and δ-phase suppression. The custom thermal control enabled us to isolate and quantify these competing effects during the earliest stages of film formation, providing mechanistic insight into how spin-coating temperature governs both phase purity and kinetic pathways in two-step perovskite systems. Temperature-dependent SEM and photovoltaic device measurements further demonstrate that early-stage crystallization pathways directly translate into differences in morphology, charge-transport continuity, and device performance. These findings inform targeted strategies for optimizing deposition protocols to balance rapid nucleation, phase stability, and device performance.

Saadawy, Ahmed [King Fahd University of Petroleum ↗

Visualizing Crystallization Dynamics and Transformation Pathways of Disordered Rocksalt Oxides During Thermally Activated Sol–Gel Synthesis

Sol–gel synthesis is a wet-chemical processing route for fabricating functional materials with control over composition and microstructure at relatively low temperatures compared to conventional solid-state synthesis. While sol–gel process initiates with intermixed molecular precursors, the early-stage nucleation pathways are insufficiently understood. Here, in this study, the chemical and structural transformation of ion disordered rocksalt (DRX) Li 1.2 Mn 0.4 Ti 0.4 O 2 (LMTO), a promising cathode material for lithium batteries, is studied by multiscale characterizations. In situ heating transmission electron microscopy (TEM) using a liquid cell visualizes and identifies crystallization pathways at the nanoscale. While some regions follow a classical multi-step transition through thermodynamically stable intermediates, others exhibit a kinetic shortcut via a localized amorphous matrix to directly form the DRX structure. Macroscale Fourier transform infrared spectroscopy corroborates the findings and reveals that transition metal ions are more strongly incorporated into the acetate-coordinated network than lithium. Although in situ heating TEM captures diverse local transformation pathways, in situ synchrotron X-ray diffraction indicates that the macroscopic transformation proceeds predominantly through spinel LMTO and lithium titanates toward DRX-LMTO. The findings uncover the spatiotemporal chemical and structural transformations in sol–gel derived DRX-LMTO materials, and call for fine-tuning of such sol–gel chemistries to manipulate the crystallization pathways and achieve target material homogeneity more efficiently.

cathode material↗