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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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NASA NTRSDate not supplied

Laser Beam Welding for in-Space Joining Demonstrated Under Vacuum on the Ground and By Parabolic Flight Experiments

High energy density electron beam welding enabled the first and, to date, only American weld performed in space during the M551 experiment on Skylab in 1973. Though welding is critical to 90% of durable goods manufacturing in America, there is not yet regular and reliable application of welding processes to the In-space Servicing, Assembly, and Manufacturing (ISAM) sector. Fundamental studies are needed to develop basic capabilities and to enhance fundamental process knowledge, which will support follow-on efforts to mature in-space welding for use in commercial, defense, and other aerospace applications. The current work seeks to build on past flights and improve understanding and quantification of materials joining in space conditions using laser beam welding (LBW). LBW offers several advantages over the electron beam welding of Skylab, amongst others: reduced electromagnetic interference, less exposure of operators to ionizing radiation, and flexible delivery through optical fibers supporting unique workpieces and joints. Since there is no orbital laboratory to mature laser beam welding for space, the current effort addresses maturation of laser beam welding through parabolic flights augmented with data collection to enable numerical modeling efforts that capture the physical effects of the space environment. This team has retrofitted an LBW experimental apparatus that can simulate the vacuum and, during a parabolic flight, the reduced gravity & microgravity conditions of in-space welding. A team of Capstone students modified the setup, originally developed by NASA Langley Research Center for electron beam free-form fabrication, to replace its electron gun with a 1 kW, 1070 nm Yb fiber laser. The apparatus was further instrumented with temperature sensing and high-speed welding cameras to monitor and record changes in the thermal state of the workpiece, the melt pool, the laser penetration level, and the development and orientation of spatter & plumes. The system will operate autonomously, demonstrating its utility to uncrewed missions. During upcoming parabolic flight campaigns expected summer 2024, this LBW equipment will weld common aerospace alloys of aluminum, stainless steel, and titanium under conditions representative of the space environment. This data will guide future computational modeling efforts of laser welding in space and help to qualify in-space welding as a viable ISAM technique.

laser beam welding↗
NASA NTRS2006

G2 Flywheel Module Design

Design of a flywheel module, designated the G2 module, is described. The G2 flywheel is a 60,000 RPM, 525 W-hr, 1 kW system designed for a laboratory environment; it will be used for component testing and system demonstrations, with the goal of applying flywheels to aerospace energy storage and integrated power and attitude control (IPACS) applications. G2 has a modular design, which allows for new motors, magnetic bearings, touchdown bearings, and rotors to be installed without a complete redesign of the system. This design process involves several engineering disciplines, and requirements are developed for the speed, energy storage, power level, and operating environment. The G2 rotor system consists of a multilayer carbon fiber rim with a titanium hub on which the other components mount, and rotordynamics analysis is conducted to ensure rigid and flexible rotor modes are controllable or outside of the operating speed range. Magnetic bearings are sized using 1-D magnetic circuit analysis and refined using 3-D finite element analysis. The G2 magnetic bearing system was designed by Texas A&M and has redundancy which allows derated operation after the loss of some components, and an existing liquid cooled two pole permanent magnet motor/generator is used. The touchdown bearing system is designed with a squeeze film damper system allowing spin down from full operating speed in case of a magnetic bearing failure. The G2 flywheel will enable module level demonstrations of component technology, and will be a key building block in system level attitude control and IPACS demonstrations.

Jensen, Ralph H.↗
NASA NTRS2019

New Test Rig to Measure Alternating Current Losses of Both Low and High Critical Temperature Superconductors

This paper presents the design, development, operation, and test capabilities of a proposed superconducting coil testbed to measure alternating current (AC) losses at the NASA Glenn Research Center. Superconducting AC losses are important in the design of electric stators and rotors, power transmission lines, transformers, fault current limiters, magnets, and superconducting energy storage (not batteries). The new liquid-hydrogen-based rig will allow superconducting testing across a wide range of test parameters, including injected current up to 400 A, frequency (0 to 400 Hz), magnetic field (0 to 0.6 T), phase angle between induced voltage and injected current (–180° to 180°), coil coolant temperature (18 to 28 K), and AC power loss (5 to 30 W). While the target application of interest is 20 K superconducting MgB2 (the only superconductor that can presently be made with low losses) stator coils for future electric machines, the rig can accommodate test articles (TAs) with straight wire, tape, cables, coils of any shape, any allowable combination of superconducting wire and fluid (e.g., yttrium barium copper oxide (YBCO) coils and liquid nitrogen), and AC or direct current (DC) testing. The new spin rig builds upon the existing Air Force spin rig through a more flexible mode of fluid control, a wider gap space (up to 10.2 cm) for TAs, and the ability to accommodate TAs over a wider range of operating temperatures (18 to 95 K) using liquid hydrogen, gaseous helium, or liquid nitrogen as the working fluid, thus supporting direct cooled machines below 77 K.

liquid hydrogen↗
NASA NTRS2021

Small UAV Flight Planning in Urban Environments

This work proposes a fast algorithm for generating obstacle-free and wind-efficient flight paths at a constant above-ground-level altitude in urban environments because a fast flight path planning algorithm is an essential function or service needed for enabling small unmanned aerial vehicle (sUAV) to operate in urban environments within Class G airspace. The proposed method first converts the 3D path planning problem to a 2D problem by constructing an obstacle map at a given above-ground-level altitude. A quad-tree decomposition is then used to build a search space in terms of obstacle occupancy and wind difference. The wind cost of traveling through each cell is defined based on energy consumption under various wind conditions. A repulsive potential is also adopted to make sure that the flight plans stay away from obstacles. The Theta* search algorithm, a variant of A* algorithm, is applied to mitigate the path angle change constraints introduced by grid-based graphs. With the Theta* and postsmoothing techniques, an obstacle-free, wind efficient, and constant above-ground-level flight plan can be quickly generated for sUAV operations in urban environments while meeting the lateral path angle constraints. The results showed that the path planning algorithm is efficient and can be finished within several seconds. With a proper choice of wind coefficient, the proposed path planning algorithm outperforms the multiple-shooting trajectory optimization method even in an obstacle-free environment. With the flexibility of incorporating other geo-related costs and computation efficiency, the proposed algorithm shows the potential for real-time flight path planning in complex urban environments.

Path planning↗
NASA NTRS2005

Experiments With Small Animals Rarely Go This Well

In the mid-1950s, a young U.S. Air Force engineer named Clark Beck began work with what is now one of NASA s most prolific spinoffs, the radiant barrier technology. Beck s work involved creating materials that could withstand the immense heat created by passage through the Earth s atmosphere. He was working on structures and resources that could withstand the fluctuations in temperature created by a skip reentry, where a craft would skip along the surface of the atmosphere, gradually making inroads sufficient for reentry, a process that took the craft from extreme heat to frigid cold every few seconds. The material also needed to withstand millions of pounds of pressure per inch of bending without twisting, the simulated force of reentry. Without reflective material, the craft would get what Beck refers to as "red hot wings," and without the required flexibility, the craft would break apart. One result of Beck s work was the discovery of the useful properties of radiant barrier material. The Space Agency used Beck s design work for the materials that went into building the space capsules, heat resistant instrument panels, and, in conjunction with the Air Force, an early spacecraft prototype, the DynaSoar, that looks remarkably similar to the present-day Space Shuttle. NASA used the thin, shiny, silver material to protect the first space explorers from the harsh environment of space, which could range from -460 F to 541 F. If the engineers had used conventional insulation for the space suits, the fabric would have been 7-feet thick, a little awkward for even the most nimble of astronauts to maneuver. Radiant barrier technology was clearly the solution. It reflected the astronaut s body heat back into the suit to keep him warm, while at the same time reflecting radiant energy from the Sun outward to keep him cool. The radiant barrier material reflected more than 95 percent of the radiant energy away from the wearer, while tiny holes in the fabric allowed moisture to escape and longer heat waves to get through. This amazing fabric had an added benefit that made it ideal for its space-bound application: It weighed only 17 pounds per 1,000 square feet. NASA has used this material ever since the Gemini and Apollo missions, on virtually all of its spacecraft, and even on unmanned missions as thermal protection for instruments.

Source record↗
NASA NTRS2002

Solid Freeform Fabrication: An Enabling Technology for Future Space Missions

The emerging class of direct manufacturing processes known as Solid Freeform Fabrication (SFF) employs a focused energy beam and metal feedstock to build structural parts directly from computer aided design (CAD) data. Some variations on existing SFF techniques have potential for application in space for a variety of different missions. This paper will focus on three different applications ranging from near to far term to demonstrate the widespread potential of this technology for space-based applications. One application is the on-orbit construction of large space structures, on the order of tens of meters to a kilometer in size. Such structures are too large to launch intact even in a deployable design; their extreme size necessitates assembly or erection of such structures in space. A low-earth orbiting satellite with a SFF system employing a high-energy beam for high deposition rates could be employed to construct large space structures using feedstock launched from Earth. A second potential application is a small, multifunctional system that could be used by astronauts on long-duration human exploration missions to manufacture spare parts. Supportability of human exploration missions is essential, and a SFF system would provide flexibility in the ability to repair or fabricate any part that may be damaged or broken during the mission. The system envisioned would also have machining and welding capabilities to increase its utility on a mission where mass and volume are extremely limited. A third example of an SFF application in space is a miniaturized automated system for structural health monitoring and repair. If damage is detected using a low power beam scan, the beam power can be increased to perform repairs within the spacecraft or satellite structure without the requirement of human interaction or commands. Due to low gravity environment for all of these applications, wire feedstock is preferred to powder from a containment, handling, and safety standpoint. The energy beams may be either electron beam or laser, and the developments required for either energy source to achieve success in these applications will be discussed.

Taminger, Karen M. B.↗
NASA NTRS2015

Conformal Ablative Thermal Protection System for Small and Large Scale Missions: Approaching TRL 6 for Planetary and Human Exploration Missions and TRL 9 for Small Probe Missions

In 2011, NASAs Aeronautics Research Mission Directorate (ARMD) funded an effort to develop an ablative thermal protection system (TPS) material that would have improved properties when compared to Phenolic Impregnated Carbon Ablator (PICA) and AVCOAT. Their goal was a conformal material, processed with a flexible reinforcement that would result in similar or better thermal characteristics and higher strain-to-failure characteristics that would allow for easier integration on flight aeroshells than then-current rigid ablative TPS materials. In 2012, NASAs Space Technology Mission Directorate (STMD) began funding the maturation of the best formulation of the game changing conformal ablator, C-PICA. Progress has been reported at IPPW over the past three years, describing C-PICA with a density and recession rates similar to PICA, but with a higher strain-to-failure which allows for direct bonding and no gap fillers, and even more important, with thermal characteristics resulting in half the temperature rise of PICA. Overall, C-PICA should be able to replace PICA with a thinner, lighter weight, less complicated design. These characteristics should be particularly attractive for use as backshell TPS on high energy planetary entry vehicles. At the end of this year, the material should be ready for missions to consider including in their design, in fact, NASAs Science Mission Directorate (SMD) is considering incentivizing the use of C-PICA in the next Discovery Proposal call. This year both scale up of the material to large (1-m) sized pieces and the design and build of small probe heatshields for flight tests will be completed. NASA, with an industry partner, will build a 1-m long manufacturing demonstration unit (MDU) with a shape based on a mid LD lifting body. In addition, in an effort to fly as you test and test as you fly, NASA, with a second industry partner, will build a small probe to test in the Interactive Heating Facility (IHF) arc jet and, using nearly the same design, build the aeroshell and TPS, with instrumentation, for a small probe flight test article, due to fly in 2017. At the end of the year, the C-PICA will be at TRL 5+, and with the flight data in 2017, it will be at TRL 9 for missions needs with C-PICA at a small scale (12 diameter). The scale-up and small probe efforts will be de-scribed in this presentation.

Conformal Ablative↗
NASA NTRSDate not supplied

Preliminary Findings of the Experimental Development Unit Cold Flow Test for a Generation Zero Nuclear Propulsion Engine

Nuclear thermal propulsion (NTP) technology will greatly benefit human travel to Mars by significantly shortening transit times, improving crew safety, and providing more mission flexibility than traditional chemical rockets. As part of DRACO follow-on work to develop, build, and fly a generation zero NTP engine, a full scale flight-like experimental design unit (EDU) reactor was constructed to collect sufficient on-ground performance data to characterize flow induced vibrations (FIV) of critical reactor structures/components, inform development of the engine and reactor control algorithm, and collect pressure drop and flow distribution data across the reactor. The fluid conditions for the test program were designed to achieve system responses equivalent to that of an operational engine through all phases of engine operation including reactor startup, mainstage operation, reactor shutdown, and reactor cooldown. Over 100 tests were executed, flowing either GN2 or GHe through the EDU at varying flow rates and pressures. This experiment provided early validation of flow behavior and vibration risks before nuclear testing, boosted critical subsystem TRLs, informed design iterations, and reduced future test costs. The steady-state flow parameters for the experiment were modeled in Ansys Thermal Desktop, allowing rapid tuning and experiment-informed updates to a flight-like test matrix. The EDU dynamic environment was characterized with accelerometers, strain gauges, and high-frequency pressure transducers all sampled at 20 kHz. While many narrow-band oscillations were identified, no significant FIV occurred; the reactor structural responses tend to be enveloped by typical launch vehicle ascent vibration environments (defined up to 2 kHz), although significant energy is also present at higher frequencies.

Flow Induced Vibration↗
NASA NTRS2019

NASA’s Space Launch System: Enabling a New Generation of Lunar Exploration

Following two decades of operational experience in low-Earth orbit (LEO), NASA has turned its focus once again to deep space exploration. The Agency is building the Space Launch System (SLS) to take astronauts and cargo to the Moon and send robotic spacecraft deep into the solar system. Offering unmatched performance, departure energy and payload capacity, SLS is designed to evolve into progressively more powerful configurations, enabling a new generation of human exploration of the Moon in preparation for future missions to Mars. The first build of the Block 1 vehicle is nearly complete for Exploration Mission-1 (EM-1), the first integrated flight of SLS and the Orion crew vehicle. EM-1 will send an uncrewed Orion to a distant retrograde lunar orbit in order to test and verify new systems, and along the way will deploy 13 6U-class CubeSats in deep space along the upper stage disposal trajectory after separation from Orion. The Agency’s current plans call for the first three missions on the SLS manifest to utilize the Block 1 vehicle in crew and cargo configurations. A more powerful evolved vehicle, Block 1B, will provide additional mass and volume performance using a new Exploration Upper Stage (EUS). Block 1B will lift 34 to 40 metric tons (t) to trans-lunar injection (TLI), depending on crew or cargo configuration. The Block 1B crew configuration will offer as much payload volume as industry-standard 5 m-diameter fairings to co-manifested payloads in a Universal Stage Adapter (USA). The Block 1B cargo variant will accommodate 8.4 meter-diameter fairings in 62.7-foot (19.1 meter) or 90-foot (27.4 meter) lengths. Adding smallsat secondary payloads to ride along with primary and co-manifested payloads on future flights may be possible, depending on mass margins. Leveraging a flight-proven, well-understood propulsion system, SLS’s flexible architecture, unmatched performance and expansive payload accommodations will open exciting new mission possibilities in deep space. Launches of habitat modules for NASA’s new Gateway lunar outpost, the next generation of robotic spacecraft to the far reaches of the solar system, large-aperture deep space telescopes, probes to interstellar space and the return of astronauts to the Moon are all possible with SLS.

Creech, Stephen D.↗
NASA NTRS1993

A widely adaptable habitat construction system utilizing space resources

This study suggests that the cost of providing accommodations for various manned activities in space may be reduced by the extensive use of resources that are commonly found throughout the solar system. Several concepts are proposed for converting these resources into simple products with many uses. Concrete is already being considered as a possible moonbase material. Manufacturing equipment should be as small and simple as possible, which leads to the idea of molding it into miniature modules that can be produced and assembled in large numbers to create any conceivable shape. Automated equipment could build up complex structures by laying down layer after layer in a process resembling stereolithography. These tiny concrete blocks handle compression loads and provide a barrier to harmful radiation. They are joined by a web of tension members that could be made of wire or fiber-reinforced plastic. The finished structure becomes air-tight with the addition of a flexible liner. Wire can be made from the iron modules found in lunar soil. In addition to its structural role, a relatively simple apparatus can bend and weld it into countless products like chairs and shelving that would otherwise need to be supplied from Earth. Wire woven into a loose blanket could be an effective micrometeoroid shield, tiny wire compression beams could be assembled into larger beams which in turn form larger beams to create very large space-frame structures. A technology developed with lunar materials could be applied to the moons of Mars or the asteroids. To illustrate its usefulness several designs for free-flying habitats are presented. They begin with a minimal self-contained living unit called the Cubicle. It may be multiplied into clusters called Condos. These are shown in a rotating tether configuration that provides a substitute for gravity. The miniature block proposal is compared with an alternate design based on larger triangular components and a tetrahedral geometry. The overall concept may be expanded to envision city-sized self-sufficient environments where humans could confortably live their entire lives. One such proposal is the Hive. It is configured around a unique sunlight collection system that could provide all its energy needs and that could be scaled up to compensate for the reduced solar intensity at greater distances from the sun. Its outer perimeter consists of a cylindrical section mated to two conical end walls that taper inwards toward a small aperture at the center of rotation. Light collected by two huge mirrors of unusual design enters the aperture and is redirected to the inside of the cylinder. The conical end walls are shielded from direct sunlight and are designed to radiate heat into space. They are lined with air ducts that passively recirculate the atmosphere while extracting moisture by condensation. Although there is no immediate demand for spacecraft on this scale, their consideration can influence even the earliest stages of the development process.

Wykes, Harry B.↗
NASA NTRS2001

High Power Thruster Based on Inductive Magnetized Plasmoid Acceleration

Regardless of the power source, deep space missions will require both high specific impulse (greater than 500 s) and high thrust power (greater than 100kW). These high Isp thrusters will need to have high electrical efficiency (approx. 90%) and low specific mass (alpha approximately less than 10 kg/kW) as well. Additionally they should have high thrust to allow greater mission flexibility. All these requirements can potentially be achieved with the pulsed formation and acceleration of magnetically self-confined plasmoids commonly referred to as compact toroids (CTs). An electromagnetic plasma thruster based on CT acceleration makes an ideal candidate for a high power, high Isp thruster, since the CT is magnetically isolated from the accelerator so that there is no contact between the propellant and the accelerator. The transfer of momentum to the CT occurs through an electromagnetic interaction with the magnetic field. By maintaining an axial magnetic field gradient across it, the directed velocity of the CT can be increased indefinitely. In previous experiments carried out at the University of Washington, CT's of near milligram mass were accelerated to velocities of 250 km/s in a single pulse. The ejection of the plasmoid by an external axial field also avoids the serious problem of detachment, which would occur in thrusters that employ a magnetic mirror or magnetic nozzle. To employ the CT for propulsion, one must design, construct and test a plasma source that is capable of generating a self-confined plasma inductively, and to do it repeatedly at a sufficiently high rep rate. A repetitively pulsed 100 kW level FRC thruster was built and was operated for short bursts at a 10 kHz rep rate and will be described. Another regime for the FRC thruster however is to produce an FRC in a more conventional manner at high voltage and magnetic field. With the large energy transfer with each pulse, the rep rate for this approach is much lower (approximately 100 Hz). This is the approach that is being evaluated at MSFC in the FAST experiment. The purpose of this experiment is to build an FRC thruster, measure its performance characteristics e.g. specific impulse, thrust, and efficiency. This experiment will also be described as well as various mission scenarios that that are well matched for this type of propulsion.

Slough, John↗
NASA NTRS2005

Space Resource Utilization and Extending Human Presence Across the Solar System

The Presidents Vision for Exploration is not a single mission, but an open ended journey that seeks to answer "How can we live on other worlds?" Using space resources is the only known approach for affordable, sustained, flexible, and self sufficient, human occupation beyond Earth orbit. Earth is a large planet. A simple analysis using the rocket equation shows that if Earth were a bit larger, chemical propulsion as a mechanism to access space would become impractical. Thus, even with the most efficient chemical rocket launch capability, the cost of lifting massive payloads into space will remain very steep (currently about $l00k/lb to the Moon and greater than $500k/lb to Mars). Space resource utilization should begin with an aggressive broad based demonstration program as afforded by the precursor missions implementation of the President's Vision of Exploration. Ion engine upper stages, for example, were studied for over 30 years, but only implemented in design after the Deep Space 1 in space demonstration. These demonstrations should include: extraction of elements from lunar regolith, and Martian soil and atmosphere, demonstration of power break even and growth from lunar or Mars moons derived photovoltaics, oxygen extraction for life support and propellant, and metals and alloys for in space repair and the production of habits and radiation shielding. Space resource utilization yields operational dividends through the subsequent programs including: propellant from lunar oxygen which could cut transportation costs from Earth in half, mega watts per year of power grown from lunar photovoltaics at decreasing cost per kW, decreased cost for human Mars missions by a factor of 10 by using propellant derived from Mars atmosphere for return, and in space manufacturing and food production with space resources yielding safe sustained and eventually self sufficient human presence in space. After the demonstration and implementation, the space resource utilization investment enables commercial and private viability beyond Earth orbit. For example, analysis has shown the lunar oxygen production for propellant becomes commercially viable after the exploration program completes the R&D, and power from lunar derived photovoltaics could, according to past NASA sponsored studies, pay for themselves while supplying most of Earth's electrical energy after about 17 years. Besides the Moon and Mars the resources of the near Earth asteroids enable the building of large space structures and science payloads. Analysis has shown that one of the thousands of these objects (some as easily accessible in space as the Moon and Mars), 2 km dia, the size of a typical open pit mine, would cost the total global financial product of Earth for 30,000 years if we were to launch it from Earth. Beyond Mars, the belt asteroids have been calculated to contain enough materials for habitat and life to support 10 quadrillion people. Thus, the development and use of space resources enables the extension of human life through the solar system allowing humanity to move from a planetary to a solar system society.

Curreri, Peter A.↗
NASA NTRS2009

Thermal Insulation Strips Conserve Energy

Launching the space shuttle involves an interesting paradox: While the temperatures inside the shuttle s main engines climb higher than 6,000 F hot enough to boil iron for fuel, the engines use liquid hydrogen, the second coldest liquid on Earth after liquid helium. Maintained below 20 K (-423 F), the liquid hydrogen is contained in the shuttle s rust-colored external tank. The external tank also contains liquid oxygen (kept below a somewhat less chilly 90 K or -297 F) that combines with the hydrogen to create an explosive mixture that along with the shuttle s two, powdered aluminum-fueled solid rocket boosters allows the shuttle to escape Earth s gravity. The cryogenic temperatures of the main engines liquid fuel can cause ice, frost, or liquefied air to build up on the external tank and other parts of the numerous launch fueling systems, posing a possible debris risk when the ice breaks off during launch and causing difficulties in the transfer and control of these cryogenic liquid propellants. Keeping the fuel at the necessary ultra-cold temperatures while minimizing ice buildup and other safety hazards, as well as reducing the operational maintenance costs, has required NASA to explore innovative ways for providing superior thermal insulation systems. To address the challenge, the Agency turned to an insulating technology so effective that, even though it is mostly air, a thin sheet can prevent a blowtorch from igniting a match. Aerogels were invented in 1931 and demonstrate properties that make them the most extraordinary insulating materials known; a 1-inch-thick piece of aerogel provides the same insulation as layering 15 panes of glass with air pockets in between. Derived from silica, aluminum oxide, or carbon gels using a supercritical drying process - resulting in a composition of almost 99-percent air - aerogels are the world s lightest solid (among 15 other titles they hold in the Guinness World Records), can float indefinitely on water if treated to be hydrophobic, and can withstand extremely hot temperatures (from 1,100 F to 3,000 F depending on the type of aerogel) down to cryogenic levels, making this "frozen smoke" ideal for use in space. Because of its low weight and ability to withstand temperature extremes, an aerogel was even used as the space-based catcher s mitt to trap comet particles and space dust for NASA s Stardust mission, launched in 1999. All of this remarkable technology s characteristics were ideal for NASA s purposes except one: The aerogels were extremely brittle. Through a long-term partnership between Kennedy Space Center and Aspen Aerogels Inc., of Northborough, Massachusetts, researchers developed a flexible, durable form of aerogel that NASA has since used as cryogenic insulation for space shuttle launch systems. Through Aspen Aerogels, the technology has made oil pipeline insulation, extreme weather clothing, and infrared shielding for combat helicopters.

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