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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
DOE OSTI2024

Selective Deposition and Fusion of AISI 316L: An Additive Manufacturing Process for Space Environments via Direct Ink Writing and Laser Processing

Unlocking the potential of additive manufacturing (AM) for space exploration hinges on overcoming key challenges, notably the ability to manufacture or repair parts on-site during exploration missions with consideration of quality, feedstock utilization, and challenges involved in microgravity environments. While there are multiple efforts to investigate the use of existing metal AM processes such as powder bed fusion (PBF), directed energy deposition (DED), and filament-based material extrusion, each process comes with a different set of challenges in space environments. Here, in this work, we introduce a new AM method that integrates the benefits of direct ink writing (DIW) to selectively deposit metallic pastes with laser-based processing to locally debind and subsequently melt and fuse metal powder, layer by layer, enabling the manufacturing of AISI 316L samples with densities exceeding 99.0%. The impact of process parameters on single-track dimensions, surface morphology, and porosity was characterized. The efficacy of laser debinding was assessed via secondary-ion mass spectrometry, permitting the carbon content to be estimated at 0.0152%, which is safely below the acceptable limit (0.03 wt%) for AISI 316L.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Warpage-Resistant, Under-Extrusion-Free, High-Surface-Quality Additive Manufacturing Process for Polyethylene-Based Composite Radiation Shielding Material

Polyethylene (PE) is one of the best shielding materials for primary space radiation due to its high hydrogen content. For effective secondary neutron shielding, boron-rich fillers are incorporated to enhance performance. The semicrystalline nature and high thermal expansion coefficient of PE impede its adoption for in situ additive manufacture in space via the fused deposition modeling (FDM) 3D printing. Here, we developed an optimized PE blend to mitigate the effects of under-extrusion and warpage. Guided by studies on extrusion and warpage, we developed an optimal set of printing parameters for the proposed PE blend. The optimum PE blend─both in its pure form and when doped with fillers─has been tested on different FDM printers. The printed structures exhibit high and uniform density, smooth surfaces, no warpage, and competitive mechanical properties. The FDM-printed plates demonstrate efficient shielding from thermal neutrons, predicted via modeling and confirmed experimentally using extended Q-range small-angle neutron scattering.

additive manufacturing↗
NASA NTRS2000

Space Resources Development: The Link Between Human Exploration and the Long-Term Commercialization of Space

In a letter to the NASA Administrator, Dan Goldin, in January of 1999, the Office of Management and Budget (OMB) stated the following . OMB recommends that NASA consider commercialization in a broader context than the more focused efforts to date on space station and space shuttle commercialization. We suggest that NASA examine architectures that take advantage of a potentially robust future commercial infrastructure that could dramatically lower the cost of future human exploration." In response to this letter, the NASA Human Exploration and Development of Space (HEDS) Enterprise launched the BEDS Technology & Commercialization Initiative (HTCI) to link technology and system development for human exploration with the commercial development of space to emphasize the "D" (Development) in BEDS. The development of technologies and capabilities to utilize space resources is the first of six primary focus areas in this program. It is clear that Space Resources Development (SRD) is key for both long-term human exploration of our solar system and to the long-term commercialization of space since: a) it provides the technologies, products, and raw materials to support efficient space transportation and in-space construction and manufacturing, and b) it provides the capabilities and infrastructure to allow outpost growth, self-sufficiency, and commercial space service and utility industry activities.

Sanders, Gerald B.↗
NASA NTRSDate not supplied

In-Space Laser Forming Simulated Under Thermal Vacuum (TVAC) Conditions

NASA Marshall Space Flight Center is investigating laser forming under thermal vacuum conditions representative of the space environment through a partnership with the DARPA NOM4D program. The thermal gradient mechanism (TGM) is used to bend a metal sheet towards the laser optics. Laser equipment and process parameters are being optimized for thermal vacuum conditions. Such conditions are representative of the extreme cold and hot temperatures and high vacuum that exist on orbit or on the lunar surface. in situ photogrammetry and thermography assess the bend/counterbend and elucidate the TGM in thermal vacuum. Structured light scanning and metallography after bending reveal the macroscopic and microscopic structure after TGM.

thermal vacuum↗
NASA NTRS1975

Skylab materials processing facility experiment developer's report

The development of the Skylab M512 Materials Processing Facility is traced from the design of a portable, self-contained electron beam welding system for terrestrial applications to the highly complex experiment system ultimately developed for three Skylab missions. The M512 experiment facility was designed to support six in-space experiments intended to explore the advantages of manufacturing materials in the near-zero-gravity environment of Earth orbit. Detailed descriptions of the M512 facility and related experiment hardware are provided, with discussions of hardware verification and man-machine interfaces included. An analysis of the operation of the facility and experiments during the three Skylab missions is presented, including discussions of the hardware performance, anomalies, and data returned to earth.

Parks, P. G.↗
NASA NTRS1991

Manufacturing processes

The following issues are covered: process development frequently lags behind material development, high fabrication costs, flex joints (bellows) - a continuing program, SRM fabrication-induced defects, and in-space assembly will require simplified design.

Bennet, Jay↗
NASA NTRS1993

Design of a water electrolysis flight experiment

Supply of oxygen (O2) and hydrogen (H2) by electolyzing water in space will play an important role in meeting the National Aeronautics and Space Administration's (NASA's) needs and goals for future space missios. Both O2 and H2 are envisioned to be used in a variety of processes including crew life support, spacecraft propulsion, extravehicular activity, electrical power generation/storage as well as in scientific experiment and manufacturing processes. The Electrolysis Performance Improvement Concept Study (EPICS) flight experiment described herein is sponsored by NASA Headquarters as a part of the In-Space Technology Experiment Program (IN-STEP). The objective of the EPICS is to further contribute to the improvement of the SEF technology, specifially by demonstrating and validating the SFE electromechanical process in microgravity as well as investigating perrformance improvements projected possible in a microgravity environment. This paper defines the experiment objective and presents the results of the preliminary design of the EPICS. The experiment will include testing three subscale self-contained SFE units: one containing baseline components, and two units having variations in key component materials. Tests will be conducted at varying current and thermal condition.

Lee, M. Gene↗
NASA NTRS1992

A path to in-space welding and to other in-space metal processing technologies using Space Shuttle small payloads

As we venture into space, it becomes necessary to assemble, expand, and repair space-based structures for our housing, research, and manufacturing. The zero gravity-vacuum of space challenges us to employ construction options which are commonplace on Earth. Rockwell International (RI) has begun to undertake the challenge of space-based construction via numerous options, of which one is welding. As of today, RI divisions have developed appropriate resources and technologies to bring space-based welding within our grasp. Further work, specifically in the area of developing space experiments to test RI technology, is required. RI Space Welding Project's achievements to date, from research and development (R&E) efforts in the areas of microgravity, vacuum, intra- / extra- vehicular activity and spinoff technologies, are reviewed. Special emphasis is given to results for G-169's (Get Away Special) microgravity flights aboard a NASA KC-135. Based on these achievements, a path to actual development of a space welding system is proposed with options to explore spinoff in-space metal processing technologies. This path is constructed by following a series of milestone experiments, of which several are to utilize NASA's Shuttle Small Payload Programs. Conceptual designs of the proposed shuttle payload experiments are discussed with application of lessons learned from G-169's design, development, integration, testing, safety approval process, and KC-135 flights.

Tamir, David↗
NASA NTRS1979

Extraterrestrial processing and manufacturing of large space systems. Volume 3: Executive summary

Facilities and equipment are defined for refining processes to commercial grade of lunar material that is delivered to a 'space manufacturing facility' in beneficiated, primary processed quality. The manufacturing facilities and the equipment for producing elements of large space systems from these materials and providing programmatic assessments of the concepts are also defined. In-space production processes of solar cells (by vapor deposition) and arrays, structures and joints, conduits, waveguides, RF equipment radiators, wire cables, converters, and others are described.

Miller, R. H.↗
NASA NTRS1981

MSFC evaluation of the space fabrication demonstration system (beam builder)

The beam builder, designed and manufactured as a ground demonstration model, is a precursor to a machine for use in the space environment, transportable by the space shuttle. The beam builder has the capability to automatically fabricate triangular truss beams in low Earth orbit with a highly reliable machine that requires a minimum of in-space maintenance and repair. A performance assessment of the beam builder, which was fabricated from commercial hardware is given.

Adams, E. O.↗
NASA NTRS1988

Pathfinder: Surface exploration, in-space operations and space transfer

Viewgraphs on the Pathfinder program are presented. Information is given on technology needs, a planetary rover, program management, an autonomous lander, mission applications, orbital assembly, cryogenics, space nuclear reactors, space manufacturing, optical communications, spacecraft propulsion, aerobraking, and orbital transfer vehicles.

Mankins, John↗
NASA NTRS1995

Prospects for commercialization of SELV-based in-space operations

A workshop was hosted by the Langley Research Center as a part of an activity to assess the commercialization potential of Small Expendible Launch Vehicle-based in-space operations. Representatives of the space launch insurance industry, industrial consultants, producers of spacecraft, launch vehicle manufacturers, and government researchers constituted the participants. The workshop was broken into four sessions: Customers Small Expendible Launch Systems, Representative Missions, and Synthesis-Government role. This publication contains the presentation material, written synopses of the sessions, and conclusions developed at the workshop.

Katzberg, Stephen J.↗
NASA NTRS1995

SPARTNIK: Engineering catalyst for government and industry

Industrial demands for highly motivated and competent technical personnel to carry forward with the technological goals of the US has posed a significant challenge to graduating engineers. While curricula has improved and diversified over time to meet these industry demands, relevant industry experience is not always available to undergraduates. The microsatellite development program at San Jose State University (SJSU) has allowed an entire undergraduate senior class to utilize a broad range of training and education to refine their engineering skills, bringing them closer to becoming engineering professionals. Close interaction with industry mentors and manufacturers on a real world project provides a significant advantage to educators and students alike. With support from companies and government agencies, the students have designed and manufactured a microsatellite, designed to be launched into a low Earth orbit. This satellite will gather telemetry for characterizing the state of the spacecraft. This will enable the students to have a physical check on their predicted value of spacecraft subsystem performance. Additional experiments will also be undertaken during the two year lifetime, including micro-meteorite impact sensing and capturing digital color images of the Earth. This paper will detail the process whereby students designed, prototype and manufactured a small satellite in a large team environment, along with the experiments that will be performed on board. With the project's limited funds, it needed the support of many industry companies to help with technical issues and hardware acquisition. Among the many supporting companies, NASA's space shuttle small payloads program could be used for an affordable launch vehicle for the student project. The paper address these collaborations between the student project and industry support, as well as explaining the benefits to both. The paper draws conclusion on how these types of student projects can be used by industry as a feasible resource for developing small platforms for space based experiments, as well as increasing the practical experience and engineering knowledge of graduating students. These benefits to industry and universities, can lead to a close working relationship between the two. These types of projects can facilitate the development of low-cost space rated parts to be used by the industry and university projects. It can also help with the understanding and use of acceptable risk non-space rated parts reducing the cost of the spacecraft. This will lead to the development of low cost platforms for space based experiments, providing research companies an inexpensive, long duration platform to conduct their in-space experiments, while better preparing engineering undergraduates for their transition into the work force.

Prass, James D.↗
NASA NTRS1998

Status of the Advanced Reusable Technologies Project

The Advanced Reusable Technologies (ART) Project, part of the Advanced Space Transportation Program Office at the NASA's Marshall Space Flight Center in Huntsville, Ala., focuses on future reusable technologies beyond those being pursued by X-33. The prime objective of the project is to dramatically reduce the cost of access to space. In April 1996, an NRA was issued soliciting proposals for tasks focusing on rocket-based combined cycle propulsion system (RBCC). In August of 1996, five contractors were selected for a two year period to design and ground test their RBCC engine concepts. The work on these contracts should be completed by the end of this year. In March of this year, another NRA was issued to solicit inputs for reusable vehicle and propulsion technologies applicable to earth-to-orbit and in-space transportation. The current RBCC effort is the first of three phases leading to a large scale flight demonstrations of the technology for space launch vehicle propulsion. This first phase will provide initial verification of proposed concepts through ground demonstration of combined rocket/air breathing propulsion technologies. Using the most promising concepts identified in the first phase, the second phase will design, manufacture and ground test flight-type engine(s) to demonstrate actual design weights and performance. In the third phase, the first flight of a sub-scale integrated X-vehicle is planned for 2002. This paper describes the current status, plans and progress of the ART Project.

Hueter, Ume↗
NASA NTRS2001

Specimens Prepared for Materials International Space Station Experiment

The Materials International Space Station Experiment (MISSE) is a materials flight experiment sponsored by the Materials and Manufacturing Directorate of the Air Force Research Laboratory at Wright-Patterson Air Force Base and the NASA Space Environmental Effects Program at the NASA Marshall Space Flight Center. MISSE is a cooperative effort among the Air Force, several NASA field centers, and industry. The experiment package will be placed on the exterior of the International Space Station in the summer of 2001. Approximately half of the specimens will be exposed to the space environment for 1 year, and the other half will be exposed for 3 years. The Electro-Physics Branch at the NASA Glenn Research Center has prepared and delivered over 150 specimens to be included in MISSE. Specimens include: 1) Double-coated polyimide Kapton to compare mass loss from in-space atomic oxygen undercutting erosion to ground-laboratory atomic oxygen undercutting erosion for predicting in-space durability; 2) Silicones to study changes in surface hardness and optical properties after combined atomic oxygen--ultraviolet radiation exposure for predicting in-space durability; 3) Forty-one different polymers to accurately measure their atomic oxygen erosion yields; 4) Scattering chambers to study atomic oxygen scattering characteristics that are relevant to the degradation found in spacecraft with exterior openings; 5) Thin polymer film disks and tensile specimens to study the effects of radiation on their optical properties and mechanical properties; 6) Lightweight intercalated graphite epoxy composites to study electromagnetic interference shielding performance; and 7) Polymer-based materials utilizing new atomic oxygen protection concepts to study their durability.

Banks, Bruce A.↗
NASA NTRS2001

Next-Generation Ion Propulsion Being Developed

The NASA Glenn Research Center ion-propulsion program addresses the need for high specific-impulse systems and technology across a broad range of mission applications and power levels. One activity is the development of the next-generation ion-propulsion system as a follow-on to the successful Deep Space 1 system. The system is envisioned to incorporate a lightweight ion engine that can operate over 1 to 10 kW, with a 550-kg propellant throughput capacity. The engine concept under development has a 40-cm beam diameter, twice the effective area of the Deep Space 1 engine. It incorporates mechanical features and operating conditions to maximize the design heritage established by the Deep Space 1 engine, while incorporating new technology where warranted to extend the power and throughput capability. Prototype versions of the engine have been fabricated and are under test at NASA, with an engineering model version in manufacturing. Preliminary performance data for the prototype engine have been documented over 1.1- to 7.3-kW input power. At 7.3 kW, the engine efficiency is 0.68, at 3615-sec specific impulse. Critical component temperatures, including those of the discharge cathode assembly and magnets, have been documented and are within established limits, with significant margins relative to the Deep Space 1 engine. The 1- to 10-kW ion thruster approach described here was found to provide the needed power and performance improvement to enable important NASA missions. The Integrated In-Space Transportation Planning (IISTP) studies compared many potential technologies for various NASA, Government, and commercial missions. These studies indicated that a high-power ion propulsion system is the most important technology for development because of its outstanding performance versus perceived development and recurring costs for interplanetary solar electric propulsion missions. One of the best applications of a highpower electric propulsion system was as an integral part of a solar electric propulsion (SEP) stage to send a payload to outer planet targets. The IISTP studies showed that either trip time or launch vehicle class could be significantly reduced when compared with state-of-the-art systems.

Patterson, Michael J.↗