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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS1998

Advanced Subsonic Combustion Rig

Researchers from the NASA Lewis Research Center have obtained the first combustion/emissions data under extreme future engine operating conditions. In Lewis' new world-class 60-atm combustor research facility--the Advanced Subsonic Combustion Rig (ASCR)--a flametube was used to conduct combustion experiments in environments as extreme as 900 psia and 3400 F. The greatest challenge for combustion researchers is the uncertainty of the effects of pressure on the formation of nitrogen oxides (NOx). Consequently, U.S. engine manufacturers are using these data to guide their future combustor designs. The flametube's metal housing has an inside diameter of 12 in. and a length of 10.5 in. The flametube can be used with a variety of different flow paths. Each flow path is lined with a high-temperature, castable refractory material (alumina) to minimize heat loss. Upstream of the flametube is the injector section, which has an inside diameter of 13 in. and a length of 0.5-in. It was designed to provide for quick changeovers. This flametube is being used to provide all U.S. engine manufacturers early assessments of advanced combustion concepts at full power conditions prior to engine production. To date, seven concepts from engine manufacturers have been evaluated and improved. This collaborated development can potentially give U.S. engine manufacturers the competitive advantage of being first in the market with advanced low-emission technologies.

Lee, Chi-Ming↗
NASA NTRS2021

ISAAC

This document describes the ISAAC (Integrated Structural Assembly of Advanced Composites) robotic system. ISAAC is a highly accurate, automated robotic platform used to support research on the design, analysis, manufacturing and evaluation of advanced composite materials and structures. ISAAC can build composite parts using automated fiber placement (AFP) and stitching through the thickness of dry fabric. The system is frequently upgraded to include new capabilities. ISAAC is located at the NASA Langley Research Center

carbon-epoxy↗
NASA NTRSDate not supplied

Stiffener Jumping for Unitized Stitched Composite Preform Manufacturing

A single-sided stitching head is used to assemble unitized three-dimensional preforms using the NASA Langley Research Center (LaRC) Integrated Structural Assembly of Advanced Composites (ISAAC) robotic manufacturing system. Typically, assembly of a preform includes a “skin” that is stiffened by stiffener elements stitched to the skin. The single-sided stitching head has two needles that pass through the preform from the same side to form the stitch, typically from the smooth outer surface so the needles penetrate through the preform towards the stiffener side. The single-sided head cannot stitch across stiffening elements (e.g., stringer, frame, integral cap, etc.) because the needles would penetrate into the stiffener web, which would not allow the stitch form because the thread movement would be impeded. As a result, stitching seams cannot cross stiffening elements, and therefore are very short and must remain in the skin/flange connections within the space between the stiffening element webs. Each short segment requires a stop and cut process that takes a significant amount of time. A stiffener jumping stitching method was developed that eliminates the need to cut and restart seams when encountering a stiffener, thus providing a long, continuous seam with a significant reduction in stitching time by eliminating cutting operations and associated excess thread end trimming. This stiffener jumping process places what could be considered a very long stitch that bridges the stiffener to connect the end of one segment of the seam with the beginning of the next segment of the seam to provide a longer continuous seam. As a result, all intermediate thread cuts that would be done at the end of each individual segment of the seam are eliminated, with only a single cut at the end of the seam. The process and programming requirements for carrying out the stiffener jumping stitching approach are presented in this paper. Using the presented stiffener jumping approach to produce the long continuous seams, the stitching time for a representative commercial transport unitized stiffened wing cover panel can possibly be reduced by at least 25 percent.

stitched↗
NASA NTRS2018

Automated Fiber Placement Defect Identity Cards: Cause, Anticipation, Existence, Significance, and Progression

Automated Fiber Placement (AFP), a major composite manufacturing process, can result in many defects during the layup process that often require manual corrective action to produce a part with acceptable quality. These defects are the main limitation of the technology and can be hard to categorize or define in many situations. This paper provides a thorough definition and classification of all AFP defects. This effort constitutes a comprehensive and extensive library relevant to AFP defects. The defects selected and defined in this work are based on understanding and experience from the manufacture and research of advanced composite structure. Proper classification of these defects required an in-depth literature review and consideration of various viewpoints ranging from designers, manufacturers, analysts, and inspection professionals. Collectively, these sources were utilized to develop the most accurate view of each of the individual defect types. The results are presented as identity cards for each defect type, intended to provide researchers and the manufacturing industry a clear understanding of the (1) cause, (2) anticipation, (3) existence, (4) significance, and (5) progression of the defined AFP defects. The link between AFP defects and process planning, layup strategies, and machining was also investigated. Categorization of all important automated fiber placement defects is presented.

Harik, Ramy↗
NASA NTRS2015

No-Oven, No-Autoclave Composite Processing

Very large composite structures, such as those used in NASA's Space Launch System, push the boundaries imposed by current autoclaves. New technology is needed to maintain composite performance and free manufacturing engineers from the restraints of curing equipment size limitations. Recent efforts on a Phase II project by Cornerstone Research Group, Inc. (CRG), have advanced the technology and manufacturing readiness levels of a unique two-part epoxy resin system. Designed for room-temperature infusion of a dry carbon preform, the system includes a no-heat-added cure that delivers 350 F composite performance in a matter of hours. This no-oven, no-autoclave (NONA) composite processing eliminates part-size constraints imposed by infrastructure and lowers costs by increasing throughput and reducing capital-specific, process-flow bottlenecks. As a result of the Phase II activity, NONA materials and processes were used to make high-temperature composite tooling suitable for further production of carbon-epoxy laminates and honeycomb/ sandwich-structure composites with an aluminum core. The technology platform involves tooling design, resin infusion processing, composite part design, and resin chemistry. The various technology elements are combined to achieve a fully cured part. The individual elements are not unusual, but they are combined in such a way that enables proper management of the heat generated by the epoxy resin during cure. The result is a self-cured carbon/ epoxy composite part that is mechanically and chemically stable at temperatures up to 350 F. As a result of the successful SBIR effort, CRG has launched NONA Composites as a spinoff subsidiary. The company sells resin to end users, fabricates finished goods for customers, and sells composite tooling made with NONA materials and processes to composite manufacturers.

Rauscher, Michael D.↗
NASA NTRS1994

The use of interactive computer vision and robot hand controllers for enhancing manufacturing safety

Current available robotic systems provide limited support for CAD-based model-driven visualization, sensing algorithm development and integration, and automated graphical planning systems. This paper describes ongoing work which provides the functionality necessary to apply advanced robotics to automated manufacturing and assembly operations. An interface has been built which incorporates 6-DOF tactile manipulation, displays for three dimensional graphical models, and automated tracking functions which depend on automated machine vision. A set of tools for single and multiple focal plane sensor image processing and understanding has been demonstrated which utilizes object recognition models. The resulting tool will enable sensing and planning from computationally simple graphical objects. A synergistic interplay between human and operator vision is created from programmable feedback received from the controller. This approach can be used as the basis for implementing enhanced safety in automated robotics manufacturing, assembly, repair and inspection tasks in both ground and space applications. Thus, an interactive capability has been developed to match the modeled environment to the real task environment for safe and predictable task execution.

Marzwell, Neville I.↗
NASA NTRS1991

Cost-efficient manufacturing of composite structures

The Advanced Composites Technology (ACT) program is seeking research breakthroughs that will allow structures made of graphite epoxy materials to replace metals in the wings and fuselages of future aircrafts. NASA's goals are to reduce acquisition cost by 20 to 25 percent, structural weight for a resized aircraft by 40 to 50 percent, and the number of parts by half compared to current production aluminum aircraft. The innovative structural concepts, materials, and fabrication techniques emerging from the ACT program are described, and the relationship between aerospace developments and industrial, commercial, and sporting goods applications are discussed.

Freeman, W. Tom↗
NASA NTRS2012

Materials Advance Chemical Propulsion Technology

In the future, the Planetary Science Division of NASA's Science Mission Directorate hopes to use better-performing and lower-cost propulsion systems to send rovers, probes, and observers to places like Mars, Jupiter, and Saturn. For such purposes, a new propulsion technology called the Advanced Materials Bipropellant Rocket (AMBR) was developed under NASA's In-Space Propulsion Technology (ISPT) project, located at Glenn Research Center. As an advanced chemical propulsion system, AMBR uses nitrogen tetroxide oxidizer and hydrazine fuel to propel a spacecraft. Based on current research and development efforts, the technology shows great promise for increasing engine operation and engine lifespan, as well as lowering manufacturing costs. In developing AMBR, ISPT has several goals: to decrease the time it takes for a spacecraft to travel to its destination, reduce the cost of making the propulsion system, and lessen the weight of the propulsion system. If goals like these are met, it could result in greater capabilities for in-space science investigations. For example, if the amount (and weight) of propellant required on a spacecraft is reduced, more scientific instruments (and weight) could be added to the spacecraft. To achieve AMBR s maximum potential performance, the engine needed to be capable of operating at extremely high temperatures and pressure. To this end, ISPT required engine chambers made of iridium-coated rhenium (strong, high-temperature metallic elements) that allowed operation at temperatures close to 4,000 F. In addition, ISPT needed an advanced manufacturing technique for better coating methods to increase the strength of the engine chamber without increasing the costs of fabricating the chamber.

Source record↗
NASA NTRS2008

Friction Stir Welding: Standards and Specifications in Today's U.S. Manufacturing and Fabrication

New welding and technology advancements are reflected in the friction stir welding (FSW) specifications used in the manufacturing sector. A lack of publicly available specifications as one of the reasons that the FSW process has not propagate through the manufacturing sectors. FSW specifications are an integral supporting document to the legal agreement written between two entities for deliverable items. Understanding the process and supporting specifications is essential for a successful FSW manufacturing operation. This viewgraph presentation provides an overview of current FSW standards in the industry and discusses elements common to weld specifications.

Ding, Robert Jeffrey↗
NASA NTRSDate not supplied

Advanced Materials and Feedstock Development for On-orbit Manufacturing

This presentation is for the On-orbit Servicing, Assembly, and Manufacturing (OSAM) Technology Transfer Workshop. The content discusses materials research done to date, and research that is ongoing, applicable to OSAM applications. The talk includes content from the In-Space Manufacturing and Moon to Mars Planetary Autonomous Construction Technology projects.

On-orbit Servicing Assembly and Manufacturing↗
NASA NTRS2026

Computational Materials for Qualification and Certification (CM4QC) Strategy Document: Maturation of Computational Materials Methods for Aviation-Focused Qualification and Certification of Metal Additive Manufacturing (as an Example of Process-Intensive Materials)

Although considerable scientific and technological advances have been made in recent years in additive manufacturing (AM) processes, these advances have not translated into significant market penetration of AM parts within the aviation industry. It is broadly acknowledged that using traditional qualification and certification (Q&C) approaches for AM components is one of the most significant barriers to broader adoption of AM, resulting in high costs, long product development and certification timelines, and complex design iterations during the product development cycle. A new approach is urgently needed. This document lays out a vision for a new Q&C paradigm with increased use of computational materials (CM) methods aimed at decreasing the time and cost of Q&C of process-intensive material (PIM) approaches in the aviation industry, with AM as the immediate use case. This vision was developed with substantial input from industry, regulatory agencies, government research organizations, and academia.

Edward H Glaessgen↗
NASA NTRSDate not supplied

Multifaceted Considerations for Fission Surface Power Radiation Shielding Design

The purpose of the Fission Surface Power (FSP) nuclear system is to provide energy on the Moon and Mars for supporting their exploration and colonization. The FSP design and deployment can leverage the past research and development work in areas, such as reactor design, but such crucial components as radiation shielding and instrumentation still need material and manufacturing studies, modeling, and testing. The shielding components are needed for the protection of humans, electronics, and sensitive components. They are essential system components, but they are often the heaviest components of the system for which each kilogram matters. Different material combinations and layouts are possible. The studies presented were focused on the evaluation of several options. The initial analysis included their performance assessment, initial temperature distribution evaluation and manufacturability considerations. Several feasible shield design options were identified and discussed in this paper, as well.

Fission Surface Power↗
NASA NTRSDate not supplied

Manufacture, Characterization, and Fusion Welding of Thermoplastic Composites for Space Applications

The goals of NASA’s Thermoplastic Development for Exploration Applications (TDEA) Project include an assessment of thermoplastic composite joints for space structures by developing and maturing design capabilities, analysis tools and techniques, and manufacturing processes for thermoplastic composites. Through this effort the TDEA project will expand NASA’s in-house thermoplastic composite manufacturing capabilities, develop an understanding of advanced thermoplastic joining techniques relevant to space environments, evaluate the feasibility of reconfigurable composite structures, and advance structural analysis capabilities. This presentation will provide an overview of the materials and manufacturing effort within the TDEA project. Three semi-crystalline and one amorphous thermoplastic composite materials were selected for initial screening and provided an opportunity to gain manufacturing experience across a range of processing temperatures, rheological behavior, and composite properties. Equivalency to the National Center for Advanced Materials Performance (NCAMP) test report for Toray’s TC1225 material was established to provide confidence in in-house manufacturing and material properties were generated through baseline mechanical tests for each material. Material characterization data was generated for a subset of materials to (1) provide data for analysis and model development and (2) generate thermal, rheological and conductivity data across relevant temperatures. A key objective of the TDEA project is evaluation of thermoplastic composite joining processes suitable for in-space operations. This presentation will outline the project’s progress in fusion bonding of candidate materials to assess the quality, reproducibility and strength of the bond, as well as identify limitations to in-space manufacturing. The feasibility of joint disassembly and reassembly will be discussed.

thermoplastic composite↗
NASA NTRS1978

The Automated Array Assembly Task of the Low-cost Silicon Solar Array Project, Phase 2

An advanced process sequence for manufacturing high efficiency solar cells and modules in a cost-effective manner is discussed. Emphasis is on process simplicity and minimizing consumed materials. The process sequence incorporates texture etching, plasma processes for damage removal and patterning, ion implantation, low pressure silicon nitride deposition, and plated metal. A reliable module design is presented. Specific process step developments are given. A detailed cost analysis was performed to indicate future areas of fruitful cost reduction effort. Recommendations for advanced investigations are included.

Coleman, M. G.↗
NASA NTRS1984

Study of utilization of advanced composites in fuselage structures of large transports

The effort required by the transport aircraft manufacturers to support the introduction of advanced composite materials into the fuselage structure of future commercial and military transport aircraft is investigated. Technology issues, potential benefits to military life cycle costs and commercial operating costs, and development plans are examined. The most urgent technology issues defined are impact dynamics, acoustic transmission, pressure containment and damage tolerance, post-buckling, cutouts, and joints and splices. A technology demonstration program is defined and a rough cost and schedule identified. The fabrication and test of a full-scale fuselage barrel section is presented. Commercial and military benefits are identified. Fuselage structure weight savings from use of advanced composites are 16.4 percent for the commercial and 21.8 percent for the military. For the all-composite airplanes the savings are 26 percent and 29 percent, respectively. Commercial/operating costs are reduced by 5 percent for the all-composite airplane and military life cycle costs by 10 percent.

Jackson, A. C.↗
NASA NTRS2001

National Rocket Propulsion Materials Plan: A NASA, Department of Defense, and Industry Partnership

NASA, Department of Defense, and rocket propulsion industry representatives are working together to create a national rocket propulsion materials development roadmap. This "living document" will facilitate collaboration among the partners, leveraging of resources, and will be a highly effective tool for technology development planning. The structuring of the roadmap, and development plan, which will combine the significant efforts of the Integrated High Payoff Rocket Propulsion Technology (IHPRPT) Program, and NASA's Integrated Space Transportation Plan (ISTP), is being lead by the IHPRPT Materials Working Group (IMWG). The IHPRPT Program is a joint DoD, NASA, and industry effort to dramatically improve the nation's rocket propulsion capabilities. This phased program is structured with increasingly challenging goals focused on performance, reliability, and cost to effectively double rocket propulsion capabilities by 2010. The IHPRPT program is focused on three propulsion application areas: Boost and Orbit Transfer (both liquid rocket engines and solid rocket motors), Tactical, and Spacecraft. Critical to the success of this initiative is the development and application of advanced materials, processes, and manufacturing technologies. NASA's ISTP is a comprehensive strategy focusing on the aggressive safety, reliability, and affordability goals for future space transportation systems established by the agency. Key elements of this plan are the 2 nd and 3 d Generation Reusable Launch Vehicles (RLV). The affordability and safety goals of these generational systems are, respectively, 10X cheaper and 100X safer by 2010, and 100X cheaper and 10,000X safer by 2025. Accomplishment of these goals requires dramatic and sustained breakthroughs, particularly in the development and the application of advanced material systems. The presentation will provide an overview of the IHPRPT materials initiatives, NASA's 2nd and 3 rd Generation RLV propulsion materials projects, and the approach for the development of the national rocket propulsion materials roadmap.

Clinton, Raymond G., Jr.↗
NASA NTRSDate not supplied

In-Space Inspection Needs: Opportunities for advanced NDE tools such as x-ray CT for additively manufactured parts, in-situ resource utilization, geological applications, and more

It is now 50 years since the first human presence on the surface of the Moon and as we strive to return with women and men in the next few years, we embrace new technical challenges, goals, and innovative solutions to address 21st century objectives. These new ambitions carry fresh challenges and risks, with the field of NDE playing an increasingly more relevant role towards meeting these essential goals. In recent years, more advanced NDE tools have triggered a rapid expansion of applications for the space industry. In particular, x-ray Computed Tomography (CT) has proven to be a trusted and powerful asset for spaceflight hardware inspection, as well as applied geotechnical analysis for natural materials (e.g., rocks, soils) for NASA and across industry. However, such methods have yet to be extended to “deep space” applications such as those that are now part of the US National Space Policy Directive (SPD-1) and the accelerated push to return humans to the Moon (i.e., Artemis). For this reason, advancing these powerful Earth-based laboratory methods via new technologies, integrated computational solutions, and creative engineering approaches is directly aligned with national space policies, as well as with multiple NASA Strategic Plan priorities. The use of x-ray CT at scales as fine as a few microns or smaller can identify spacecraft part failure modes relevant to quality assurance for flight hardware and AM parts such as those recently developed for ISS. This technology could also identify valuable metallic phases within geological materials (i.e., rocks or drill cores), enabling resource-relevant triage of samples for In-Situ Resource Utilization (ISRU) and high science value sample return to Earth laboratories. There is also significant application for 3D imaging tools for medical use such as inspecting protective gear as well as bone density degradation studies which are critical in establishing a sustained presence in space. Timing for development of these tools for space use is advantageous as we prepare for new opportunities in the next few years and recognize recent commercial technology advancements which make it feasible. Moreover, as NASA strives to take full advantage of developments in AM technologies, including In-Space Manufacturing (ISM), it is widely recognized that NDE tools such as CT will play an essential role in acceptance of these parts for widespread use. New in-space 3D inspection tools with complimentary technology such as AI-based automated feature recognition (accelerated by machine learning), rapid compositional analysis, and advanced sample manipulation, would be a game-changing step toward a new class of crew-based laboratory sensors once human outposts on the Moon are established.

In-Space Non-Destructive Evaluation↗