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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
NASA NTRS2007

Critical Issues for Cu(InGa)Se2 Solar Cells on Flexible Polymer Web

Elemental in-line evaporation on glass substrates has been a viable process for the large-area manufacture of CuInSe2-based photovoltaics, with module efficiencies as high as 12.7% [1]. However, lightweight, flexible CuInSe2-based modules are attractive in a number of applications, such as space power sources. In addition, flexible substrates have an inherent advantage in manufacturability in that they can be deposited in a roll-to-roll configuration allowing continuous, high yield, and ultimately lower cost production. As a result, high-temperature polymers have been used as substrates in depositing CuInSe2 films [2]. Recently, efficiency of 14.1% has been reported for a Cu(InGa)Se2-based solar cell on a polyimide substrate [3]. Both metal foil and polymer webs have been used as substrates for Cu(InGa)Se2-based photovoltaics in a roll-to-roll configuration with reasonable success [4,5]. Both of these substrates do not allow, readily, the incorporation of Na into the Cu(InGa)Se2 film which is necessary for high efficiency devices [3]. In addition, polymer substrates, can not be used at temperatures that are optimum for Cu(InGa)Se2 deposition. However, unlike metal foils, they are electrically insulating, simplifying monolithically-integrated module fabrication and are not a source of impurities diffusing into the growing film. The Institute of Energy Conversion (IEC) has modified its in-line evaporation system [6] from deposition onto glass substrates to roll-to-roll deposition onto polyimide (PI) film in order to investigate key issues in the deposition of large-area Cu(InGa)Se2 films on flexible polymer substrates. This transition presented unexpected challenges that had to be resolved. In this paper, two major problems, spitting from the Cu source and the cracking of Mo back contact film, will be discussed and the solution to each will be presented.

Eser, Erten↗
NASA NTRS1976

Experiments to evaluate high-temperature rolling as a low-cost process for silicon solar cells

Mechanical rolling (a process used in industry for producing large quantities of metallic sheet and strip) has been suggested for the rapid low-cost manufacture of silicon sheet to be used for photovoltaic power generation equipment, such as solar arrays. The advantages of rolling include: high rates of production, wide sheets as products, good control of dimension, and (in the case of solar grade silicon) minimal development of impurities. Experiments have been performed using high-temperature, high-speed compression of polycrystalline silicon cylinders. Metallography and X-ray diffraction techniques have been used to examine the samples both before and after compression, and a model process has been designed to evaluate the technical practicality and economic feasibility of the method.

Noel, G. T.↗
NASA NTRSDate not supplied

Tribological Prospects and Progress for NiTi Bearings for Aerospace Applications

Rolling element and sliding bearings made from dimensionally stable, nickel-rich NiTi alloys have been successfully manufactured, tested and applied in several different aerospace applications. In this presentation, the development history and material properties of NiTi alloys is reviewed and its behavior in sliding and rolling contacts is examined. Key material characteristics such as superelasticity and fracture toughness and their effects on bearing applications are considered. With proper application engineering, it is shown that NiTi bearings can resolve longstanding and persistent bearing problems related to heavy loads and operation in corrosive and debris contaminated environments.

Bearings↗
NASA NTRS1994

Numerical Simulation Of Cutting Of Gear Teeth

Shapes of gear teeth produced by gear cutters of specified shape simulated computationally, according to approach based on principles of differential geometry. Results of computer simulation displayed as computer graphics and/or used in analyses of design, manufacturing, and performance of gears. Applicable to both standard and non-standard gear-tooth forms. Accelerates and facilitates analysis of alternative designs of gears and cutters. Simulation extended to study generation of surfaces other than gears. Applied to cams, bearings, and surfaces of arbitrary rolling elements as well as to gears. Possible to develop analogous procedures for simulating manufacture of skin surfaces like automobile fenders, airfoils, and ship hulls.

Oswald, Fred B.↗
NASA NTRS1981

History of ball bearings

The familiar precision rolling-element bearings of the twentieth century are products of exacting technology and sophisticated science. Their very effectiveness and basic simplicity of form may discourage further interest in their history and development. Yet the full story covers a large portion of recorded history and surprising evidence of an early recognition of the advantages of rolling motion over sliding action and progress toward the development of rolling-element bearings. The development of rolling-element bearings is followed from the earliest civilizations to the end of the eighteenth century. The influence of general technological developments, particularly those concerned with the movement of large building blocks, road transportation, instruments, water-raising equipment, and windmills are discussed, together with the emergence of studies of the nature of rolling friction and the impact of economic factors. By 1800 the essential features of ball and rolling-element bearings had emerged and it only remained for precision manufacture and mass production to confirm the value of these fascinating machine elements.

Dowson, D.↗
NASA NTRS1992

Development of thermoplastic composite aircraft structures

Efforts focused on the use of thermoplastic composite materials in the development of structural details associated with an advanced fighter fuselage section with applicability to transport design. In support of these designs, mechanics developments were conducted in two areas. First, a dissipative strain energy approach to material characterization and failure prediction, developed at the Naval Research Laboratory, was evaluated as a design/analysis tool. Second, a finite element formulation for thick composites was developed and incorporated into a lug analysis method which incorporates pin bending effects. Manufacturing concepts were developed for an upper fuel cell cover. A detailed trade study produced two promising concepts: fiber placement and single-step diaphragm forming. Based on the innovative design/manufacturing concepts for the fuselage section primary structure, elements were designed, fabricated, and structurally tested. These elements focused on key issues such as thick composite lugs and low cost forming of fastenerless, stiffener/moldine concepts. Manufacturing techniques included autoclave consolidation, single diaphragm consolidation (SDCC) and roll-forming.

Renieri, Michael P.↗
NASA NTRS2004

NASA Glenn's Advanced Subsonic Combustion Rig Supported the Ultra-Efficient Engine Technology Project's Emissions Reduction Test

The Advanced Subsonic Combustor Rig (ASCR) is NASA Glenn Research Center's unique high-pressure, high-temperature combustor facility supporting the emissions reduction element of the Ultra-Efficient Engine Technology (UEET) Project. The facility can simulate combustor inlet test conditions up to a pressure of 900 psig and a temperature of 1200 F (non-vitiated). ASCR completed three sector tests in fiscal year 2003 for General Electric, Pratt & Whitney, and Rolls-Royce North America. This will provide NASA and U.S. engine manufacturers the information necessary to develop future low-emission combustors and will help them to better understand durability and operability at these high pressures and temperatures.

Beltran, Luis R.↗
NASA NTRS1992

A basis for solid modeling of gear teeth with application in design and manufacture

A new approach to modeling gear tooth surfaces is discussed. A computer graphics solid modeling procedure is used to simulate the tooth fabrication process. This procedure is based on the principles of differential geometry that pertain to envelopes of curves and surfaces. The procedure is illustrated with the modeling of spur, helical, bevel, spiral bevel, and hypoid gear teeth. Applications in design and manufacturing are discussed. Extensions to nonstandard tooth forms, to cams, and to rolling element bearings are proposed.

Huston, Ronald L.↗
NASA NTRS1994

A Basis for Solid Modeling of Gear Teeth with Application in Design and Manufacture

This paper discusses a new approach to modeling gear tooth surfaces. A computer graphics solid modeling procedure is used to simulate the tooth fabrication processes. This procedure is based on the principles of differential geometry that pertain to envelopes of curves and surfaces. The procedure is illustrated with the modeling of spur, helical, bevel, spiral bevel and hypoid gear teeth. Applications in design and manufacturing arc discussed. Extensions to nonstandard tooth forms, to cams, and to rolling element hearings are proposed.

Huston, Ronald L.↗
NASA NTRS2004

Erosion Coatings Developed to Increase the Life and Durability of Composites

Both the NASA Glenn Research Center and the Allison Advanced Development Company (AADC) have worked to develop and demonstrate erosion-resistant coatings that would increase the life and durability of composite materials used in commercial aircraft engines. These composite materials reduce component weight by 20 to 30 percent and result in less fuel burn and emissions and more fuel savings. Previously, however, their use was limited because of poor erosion resistance, which causes concerns about safety and leads to high maintenance costs. The coatings were tested by the University of Cincinnati, and the composites were manufactured by Texas Composites and coated by Engelhard and NASA Glenn. Rolls-Royce Corporation uses composite materials, which are stronger and less dense than steel or titanium, to make bypass vanes for their AE3007 engines. These engines are widely used in regional jet aircraft (Embraer) and unmanned air vehicles such as the Northrop Grumman Global Hawk. Coatings developed by NASA/Rolls-Royce can reduce erosion from abrasive materials and from impurities in the air that pass over these vanes, allowing Rolls-Royce to take advantage of the benefits of composite materials over titanium without the added costs of increased maintenance and/or engine failure. The Higher Operating Temperature Propulsion Components (HOTPC) Project developed cost-effective, durable coatings as part of NASA's goal to increase aviation system capacity growth. These erosion coatings will reduce the number of special inspections or instances of discontinued service due to erosion, allowing aircraft capacity to be maintained without inconveniencing the traveling public. A specific example of extending component life showed that these coatings increased the life of graphite fiber and polymer composite bypass vanes up to 8 times over that of the uncoated vanes. This increased durability allows components to operate to full design life without the fear of wear or failure. Recently, Rolls-Royce completed over 2000 hr of engine testing with the coated fan exit bypass vanes. There was no loss of coating after nearly 5000 typical engine cycles. Midway through the engine tests, the coated vanes were removed from the engine during a scheduled maintenance and inspection period. The vanes were shipped back to Glenn, where they underwent further stress testing in the Structural Dynamics Lab, mimicking more extreme conditions than those typical of the AE3007 engine cycle. These vanes were then replaced in the AE3007 and subjected to another 1000 hr of engine tests. Once again, there was no loss of coating and only a minimal appearance of cracking.

Sutter, James K.↗
NASA NTRS2012

Rolling Bearing Steels - A Technical and Historical Perspective

Starting about 1920 it becomes easier to track the growth of bearing materials technology. Until 1955, with few exceptions, comparatively little progress was made in this area. AISI 52100 and some carburizing grades (AISI 4320, AISI 9310) were adequate for most applications. The catalyst to quantum advances in high-performance rolling-element bearing steels was the advent of the aircraft gas turbine engine. With improved bearing manufacturing and steel processing together with advanced lubrication technology, the potential improvements in bearing life can be as much as 80 times that attainable in the late 1950s or as much as 400 times that attainable in 1940. This paper summarizes the chemical, metallurgical and physical aspects of bearing steels and their effect on rolling bearing life and reliability. The single most important variable that has significantly increased bearing life and reliability is vacuum processing of bearing steel. Differences between through hardened, case carburized and corrosion resistant steels are discussed. The interrelation of alloy elements and carbides and their effect on bearing life are presented. An equation relating bearing life, steel hardness and temperature is given. Life factors for various steels are suggested and discussed. A relation between compressive residual stress and bearing life is presented. The effects of retained austenite and grain size are discussed.

Zaretsky, Erwin V.↗
NASA NTRS1994

Electrical characterization of a Space Station Freedom alpha utility transfer assembly

Electrical power, command signals and data are transferred across the Space Station Freedom solar alpha rotary joint by roll rings, which are incorporated within the Utility Transfer Assembly (UTA) designed and manufactured by Honeywell Space Systems Operations. A developmental Model of the UTA was tested at the NASA Lewis Research Center using the Power Management and Distribution DC test bed. The objectives of these tests were to obtain data for calibrating system models and to support final design of qualification and flight units. This testing marked the first time the UTA was operated at high power levels and exposed to electrical conditions similar to that which it will encounter on the actual Space Station. Satisfactory UTA system performance was demonstrated within the scope of this testing.

Yenni, Edward J.↗
NASA NTRS1992

ACT/ICAPS: Thermoplastic composite activities

McDonnell Aircraft Company (MCAIR) is teamed with Douglas Aircraft Company (DAC) under NASA's Advanced Composite Technology (ACT) initiative in a program entitled Innovative Composite Aircraft Primary Structures (ICAPS). Efforts at MCAIR have focused on the use of thermoplastic composite materials in the development of structural details associated with an advanced fighter fuselage section with applicability to transport design. Based on innovative design/manufacturing concepts for the fuselage section primary structure, elements were designed, fabricated, and structurally tested. These elements focused on key issues such as thick composite lugs and low cost forming of fastenerless, stiffener/moldline concepts. Manufacturing techniques included autoclave consideration, single diaphragm co-consolidation (SDCC), and roll-forming.

Renieri, M. P.↗
NASA NTRS1972

Development of dispersion strengthened nickel-chromium alloy (Ni-Cr-ThO2) sheet for space shuttle vehicles, part 2

Two dispersion strengthened nickel base alloy systems were developed for use at temperatures up to 1204 C(2200 F); TD nickel chromium (TDNiCr) and TD nickel chromium aluminum (TDNiCrA1). They are considered candidate materials for use on the thermal protection systems of the space shuttle and for long term use in aircraft gas turbine engine applications. Improved manufacturing processes were developed for the fabrication of TDNiCr sheet and foil to specifications. Sheet rolling process studies and extrusion studies were made on two aluminum containing alloys: Ni-16%Cr-3.5%A1-2%ThO2 and Ni-16%Cr-5.0%A12%ThO2. Over 1600 kg.(3500 lb.) of plate, sheet, foil, bar and extrusion products were supplied to NASA Centers for technology studies.

Klingler, L. J.↗
NASA NTRS2002

Surface Enhancement Improves Crack Resistance

The low plasticity burnishing (LPB) process produces a deep layer of surface compression in a quick and affordable manner to produce metal surfaces free of scratches, nicks, and gouges. The process, designed for easy inclusion in the manufacturing environment, can be performed with conventional Computer Numerical Control machine tools. This allows parts to be processed during manufacturing, rather than as a post process in a separate facility. A smooth, free-rolling spherical ball suspended in a fluid allows for single-point contact. The ball comes into mechanical contact only with the surface to be burnished, and can be moved in any direction. LPB can be applied to all types of carbon and alloy steel, stainless steel, cast iron, aluminum, titanium, and nickel- based super alloys. In addition to improving a surface's resistance to fatigue and damage, treatment stops the growth of shallow cracks. The LPB process is used on the leading edges of turbine blades to improve resistance to foreign object damage and crack growth. This means significant savings for aircraft owners, since maintenance requirements to inspect for fatigue damage, replace parts, and remove corrosion damage increase the cost of operation.

Source record↗
NASA NTRS2026

Influences of Introduced Yttrium Oxide Particles on Superalloy 718

Additive manufacturing has proven useful for introducing oxide particles into superalloys, to provide oxide dispersion strengthening (ODS) at high temperatures. This study screened how such an approach can influence microstructure and failure modes for superalloy 718. The objective of this study was to compare tensile and creep failure modes for additively manufactured superalloy 718 having introduced oxide particles. Fine yttrium-oxide (yttria) particles were introduced into 718 powder using two different powder mixing methods. Additive manufacturing by laser powder bed fusion was then used to prepare specimen blanks for each case, oriented parallel and transverse to the building direction. These were subsequently given consistent stress relief, hot isostatic pressurization, and final heat treatments, then subjected to tensile and creep tests at varied temperatures. Additively manufactured 718 without ODS (“no-ODS”) had nearly equiaxed grains at 50 μm in width. Roll-mixed ODS material had a bimodal grain size distribution, with fine grains at 9 μm and coarse grains at 66 μm in average width. The fine grains were elongated about 5x in the building direction. Acoustic-mixed ODS materials had grains at 10 μm in width that were elongated about 10x in the build direction. Compared to no-ODS, roll-mixed and acoustic mixed ODS materials did not show improved tensile strengths at room temperature, 760 °C, and 1093 °C. The tensile failure strains parallel to the building direction of roll-mixed ODS material were lowest in these tests. Flattened clumps of yttria had formed transverse to the building direction in roll-mixed material, which were easily cracked. Creep rupture response at 760 °C in the building direction was highest for acoustic-mixed material test. Creep tests at 1093 °C showed varied results, with low rupture lives associated with enhanced cavitation at grain boundaries and surface oxidation. Transverse to the building direction, all three materials had low failure strains in tests at 760 °C. The elongated grain boundaries failed readily in all transverse specimens tested at 760 °C and 1093 °C.

oxide dispersion strengthening↗
NASA NTRSDate not supplied

Automated Ply-by-Ply Lamination and In-Situ Consolidation of Thermoplastic Composite High-Contour Stiffeners for High-Rate Aircraft Manufacturing

To meet the future demand of the commercial aircraft market, composite aircraft manufacturing rates must significantly increase. NASA’s Hi-Rate Composites Aircraft Manufacturing (HiCAM) program addresses this need to advance aircraft composite manufacturing technologies. Thermoplastic composites offer a promising solution to these manufacturing demands and present an opportunity for Northrop Grumman to bring the benefits of its Automated Stiffener Forming (ASF) technology to thermoplastic processing. Within HiCAM, Northrop Grumman is evolving the ASF technology for ply-by-ply, in-situ processing of thermoplastic composite materials. The modular process accommodates flexibility in the laminate stacking, while allowing for ply drops, ply additions, and yaw, pitch, and roll in the laminate geometry. To adapt the ASF process for thermoplastics, heating technologies and roller compaction processes were investigated by manufacturing flat test coupons. These panels were evaluated by photo-microscopy, non-destructive inspection, and short beam shear tests and results were compared against baseline autoclave coupons. The results of the laminates fabricated via ASF are presented.

out of autoclave↗
NASA NTRS1999

Metals for Cryotank Structures. Present and Future: MSFC Perspective

The Cryogenic Tank Technology Program (CTTP) program has been a cooperative effort between NASA LARC, NASA MSFC, NASA Headquarters, and industry (Lockheed Martin Aeronautics, Lockheed Martin Manned Space Systems, Wyman Gordon, and Ladish). The scope of the CTTP is to develop state-of-the-art, flight-size, flight-quality, low cost hardware, and use this hardware to design, fabricate and test an all aluminum-lithium, all near net shape-component 14' diameter cryogenic tank with a unique low profile bulkhead design. The logical conclusion to the CTTP is to validate these various technologies to a Technology Readiness Level (TRL) of 6 through the proposed structural test program. The CTTP supports the advancement of key enabling technologies required for aluminum lithium cryogenic tanks. The technologies are focused towards innovative and low cost manufacturing processes such as near net shape technologies: one piece spun formed domes, extruded barrel panels, and one piece roll forged ring frames. Other innovative technologies include the friction stir weld process and weight-efficient low profile bulkhead designs. All of these technologies are of primary importance for NASA's mission plan for reusable and expendable launch vehicles. This program fills the niche for an all 2195 aluminum lithium alloy cryogenic tank which is not being covered by existing NASA technology work.

Vaughn, Timothy P.↗