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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 NTRS2022

An Overview of the Current State of the Art on Small Spacecraft Avionics Systems

Small spacecraft command and data handling and flight software systems, technologies, and capabilities are continuously evolving, enabling new opportunities for developing and deploying next-generation small spacecraft avionics. When small spacecraft were first introduced, their primary purpose was to observe and send information back to Earth. As awareness and utility expands, there is a need to improve the overall capability of collecting data in a specific mission environment. Small spacecraft currently perform a wide variety of science in low-Earth orbit and are emerging as candidates for more formidable beyond low-Earth orbit missions. This paper will expand on the technological evolution of avionics systems, their requirements to meet the need for modern, complex small spacecraft missions, and the updated avionics architecture composition. The authors will also inform the readers on the current state-of-the-art in SmallSat avionics and connect decentralized avionics architecture to non-aerospace applications and its underlying role in the movement to “digitally managed everything”.

B. Yost↗
NASA NTRS1975

Vidicon spectral imaging - Color enhancement and digital maps

A silicon imaging photometer system (SIPS) was used to obtain visible and near-infrared spectral imaging data in four narrow bandpasses (0.38, 0.56, 0.85, and 1.05 microns) for a 400-by-400-km lunar region which includes the Serenitatis-Tranquillitatis border. Three ratio frames were used to make color composites of radio images, and spectral maps based on interactive 'cluster' analysis were produced from four video channels. A low albedo titanium-poor unit occurs near the southern edge of the Serenitatis and south of the basin; this unit appears to postdate the high-titanium dark Tranquillitatis and 'blue-ring' material and may be associated with an Al/Si anomaly noticed in Apollo orbital X-ray data.

Johnson, T. V.↗
NASA NTRS2008

New Insights into the Composition and Texture of Lunar Regolith Using Ultrafast Automated Electron-Beam Analysis

Sieved grain mounts of Apollo 16 drive tube samples have been examined using QEMSCAN - an innovative electron beam technology. By combining multiple energy-dispersive X-ray detectors, fully automated control, and off-line image processing, to produce digital mineral maps of particles exposed on polished surfaces, the result is an unprecedented quantity of mineralogical and petrographic data, on a particle-by-particle basis. Experimental analysis of four size fractions (500-250 microns, 150-90 microns, 75-45 microns and < 20 microns), prepared from two samples (64002,374 and 64002,262), has produced a robust and uniform dataset which allows for the quantification of mineralogy; texture; particle shape, size and density; and the digital classification of distinct particle types in each measured sample. These preliminary data show that there is a decrease in plagioclase modal content and an opposing increase in glass modal content, with decreasing particle size. These findings, together with data on trace phases (metals, sulphides, phosphates, and oxides), provide not only new insights into the make-up of lunar regolith at the Apollo 16 landing site, but also key physical parameters which can be used to design lunar simulants, and compute Figures of Merit for each material produced.

Rickman, Doug↗
NASA NTRS2002

Uses of Computed Tomography in the NASA Materials Science Program

Computed Tomography (CT) has proved to be of inestimable use in providing a rapid evaluation of a variety of samples from Mechanics of Granular Materials (MGM) to electronic materials (Ge-Si alloys) to space grown materials such as meteorites. The system at Kennedy Space Center (KSC), because of its convenient geographical location, is ideal for examining samples immediately after returning to Earth. It also has the advantage of the choice of fluxes, and in particular the use of a radioactive cobalt source, which is basically monochromatic. This permits a reasonable measurement of density to be made from which chemical composition can be determined. Due to the current dearth of long duration space grown materials, the CT instrument has been used to characterize materials in preparation for flight, to determine thermal expansion values, and to examine long duration space grown materials, i.e. meteorites. The work will first describe the establishment of the protocol for obtaining the optimum density readings for any material. This will include both the effects of the hardware or instrumental parameters that can be controlled, and the techniques used to process the CT data. Examples will be given of the compositional variation along single crystals of germanium-silicon alloys. Density variation with temperature has been measured in preparation for future materials science experiments; this involved the fabrication and installation of a single zone furnace incorporating a heat pipe to ensure of high temperature uniformity. At the time of writing the thermal expansion of lead has been measured from room temperature to 900 C. Three methods are available. Digital radiography enable length changes to be determined. Prior to melting the sample is small than the container and the diameter change can be measured. Most critical, however, is the density change in solid, through the melting region, and in the liquid state. These data are needed for engineering purposes to aid in the design of containment cartridges, and for enabling fluid flow calculations. A second sample, with the lead alloyed with antimony is ready for scanning. This corresponds to the planned composition of Dr. Poirier's flight experiment. Finally, three-dimensional results will be shown of the structure of a two-phase metallic meteorite of metal and sulfide, in which the iron-nickel phase has coarsened during slow cooling over hundreds of millions of years.

Engel, H. Peter↗
DOE OSTI2025

Myna: Connecting powder bed fusion build data to simulation tools for digital twin applications

Additive manufacturing (AM), as a digital process, can generate a detailed digital thread linking a part’s design and manufacturing to its operational performance. As AM systems advance, an increasing amount of process data is stored in manufacturing databases. In principle, this data can be utilized by simulation-based digital twin approaches, such as real-time process control and asynchronous post-processing guidance. However, few tools currently exist for systematically integrating digital thread data with computational tools. Here, in this study, we propose a software package, called Myna, for connecting data from powder bed fusion processes to simulation tools. The utility of such a platform is demonstrated using build data from the Oak Ridge National Laboratory Manufacturing Demonstration Facility “Peregrine v2023-10” public dataset to automatically configure and run 54 semi-analytical 3DThesis melt pool simulations, 78 numerical Additive FOAM melt pool simulations, and 3 ExaCA microstructure simulations. The simulated, spatially registered microstructures are then compared directly with electron backscatter diffraction characterization of the corresponding as-built part locations. The resulting simulated microstructure showed variation as a function of process parameters, particularly stripe width; however, the experimental data had little variation between the microstructure texture and grain size resulting from different processing conditions. Analysis of the discrepancies suggest that it is possible a two-phase ferritic-austenitic solidification model is needed to accurately predict grain size and texture for certain stainless steel 316L feedstock compositions under powder bed fusion conditions, providing direction for future research. As illustrated here, due to the number and complexity of the simulations involved in AM process-structure–property predictions, automated methods to connect process data and simulations will remain necessary tools for testing hypotheses and implementing digital twin applications.

Knapp, Gerald L. [Oak Ridge National Laboratory (O↗
DOE OSTI2024

Impact of Backing Plate and Thermal Boundary Conditions for High-Speed Friction Stir Welding of 25-mm Thick Aluminum Alloy 7175-T79

Here this study demonstrates high-speed (150 mm/min) single pass friction stir butt joining of 25 mm thick aluminum alloy 7175-T79. To understand the impact of quenching and cooling rate on process responses, joint strength, and grain size distributions across the weld thickness, we performed a series of friction stir welding (FSW) trials in air and with a trailing water spray using steel and composite backing plates (BP). Welds made in air and trailing water spray exhibit significantly different hardness distributions across the nugget, heat affected zone (HAZ), and HAZ minimum hardness as evidenced by detailed microhardness mapping. The effect of trailing water spray (TWS) on joint efficiency overshadows the influence of BP composition due to the vastly different contribution to quenching. TWS also resulted in a multifaceted effect on FSW such as lowering processing temperature, increasing X and Z forces while lowering Y force, and narrow heat affecting zone. Finally, digital image correlation (DIC)-based fracture mode analysis and grain size measurements correlate with the hardness distribution.

42 ENGINEERING↗
NASA NTRS1994

(abstract) Transmission Electron Microscopy of Al(sub x)Ga(sub 1-x)N/SiC Multilayer Structures

The potential of wide-band-gap III-V nitrides as solar-blind ultraviolet sensors and light emitters has prompted an increasing amount of work recently, including the fabrication of the first UV sensors from as-deposited single crystal GaN. We have used high resolution transmission electron microscopy (TEM) to study the microstructure of two novel developments of wide-band-gap III-V nitrides: the growth of ultra-short period GaN/AlN super lattices (digital alloys); and the incorporation of SiC layers into Al(sub x)Ga(sub 1-x)N structures. By varying the relative periods in a GaN/AlN superlattice, it should be possible to tailor the band gap of the composite to lie between the elemental values of 365 nm for GaN and 200 nm for AlN. The group IV semiconductor, SiC, has a close lattice match (< 3%) to Al(sub x)Ga(sub 1-x)N for growth on the basal plane. Demonstration of epitaxial growth for Al(sub x)Ga(sub 1-x)N/SiC multilayers could enable an extension of direct band-gap material towards the visible.

microscopy GaN AlN semiconductor SiC↗
DOE OSTI2025

A Standardized Analysis Process Using Digital Image Correlation to Calculate In Situ Cladding Strain from Modified Burst Tests for Fuel Performance Code Validation

Historical data collection on nuclear fuel cladding materials has focused on generating a statistically significant amount of data to assess the material and its failure behavior. Furthermore, data generated to support material model and failure criteria development were previously posttest evaluations, so a large number of tests was required to gain new understanding. A way to expedite this process is to develop techniques capable of generating large, high-fidelity data sets from a single test with lower uncertainty or quantified uncertainty. One such example of this approach is Oak Ridge National Laboratory’s use of modified burst tests (MBTs) to analyze the mechanical behavior and failure conditions of cladding during a simulated reactivity-initiated accident (RIA). Each test incorporates digital image correlation (DIC) analysis techniques that are used to assess the accumulated strain in situ, as well as eventual cladding failure. This work has been fruitful in defining strain-to-failure conditions for materials like silicon carbide (SiC) fiber–reinforced/SiC matrix composite tubes (SiC/SiC), iron-chromium-aluminum (FeCrAl) alloy tubes, and chromium-coated Zircaloy-4 tubes. However, there are numerous DIC software available, including open-source and proprietary software. The different DIC software use various algorithms to process images and calculate displacement values. Using these different software and algorithms can lead to varying results, and perhaps larger-than-expected uncertainties. In the present study, previously published MBT data encompassing a variety of test conditions were reanalyzed with two different DIC software to assess the variance in the calculated strain results. The data consisted of SiC/SiC, FeCrAl, and chromium-coated Zircaloy-4 tubes. Plots of the calculated strains during the transient revealed good agreement between the two DIC software. The average root-mean-square errors between the two software was 0.20% strain, which is slightly larger than a previously reported error value for these tests. In conclusion, this variance in results is low enough that this analysis method can be used for code validation.

Reactivity-initiated accident↗
NASA NTRS2018

Digital Image Correlation Data Processing and Analysis Techniques to Enhance Test Data Assessment and Improve Structural Simulations

The NASA Shell Buckling Knockdown Factor Project (SBKF) was established in 2007 by the NASA Engineering and Safety Center (NESC) with the primary goal to develop new analysis-based buckling design factors (a.k.a. knockdown factors) and high-fidelity buckling simulations for selected launch-vehicle-like cylindrical shell structures. A series of tests are being conducted on large-scale metallic and composite cylindrical shells in order to provide validation data for these new factors and simulations. However, the validation of these new factors and simulations is quite demanding and requires test data that is commensurate with their fidelity. Traditional instrumentation, such as linear variable displacement transducers (LVDTs) and electrical-resistance strain gages serve a critical role in providing accurate displacement and strain measurements in these tests, but only allow for data to be recorded at a select number of point locations and are not sufficient to provide all the necessary validation data. Advanced measurement technologies can be used effectively to complement traditional instrumentation and gather additional data required to validate these structural simulations. In particular, three-dimensional digital image correlation (DIC) was implemented during SBKF cylinder testing to characterize the full-field displacement and strain behavior. Commercially available VIC-3DTM software and user-written data processing scripts were used to generate valuable data and insight into the complex buckling response of the cylinders that otherwise would be impossible to gather using traditional instrumentation. In addition, the measured data from DIC was used to verify measured test data obtained from other instrumentation, enhance test and analysis correlation, and help identify the root cause of anomalous test results that may have gone unexplained if only traditional instrumentation was used. Selected test results that demonstrate the use of DIC on the SBKF cylinders are presented and a portion of the data processing methods are described.

Gardner, Nathaniel W.↗
NASA NTRS2003

Uses of Computed Tomography for Characterizing Materials Grown Terrestrially and in Microgravity

Tomography (CT) has proved to be of inestimable use in providing a rapid evaluation of a variety of samples from Mechanics of Granular Materials (MGM) to electronic materials (Ge-Si alloys) to space grown materials such as meteorites. The system at Kennedy Space Center (KSC), because of its convenient geographical location, is ideal for examining samples before launch and immediately after returning to Earth. It also has the advantage of the choice of fluxes, and in particular the use of a radioactive cobalt source, which is basically monochromatic. This permits a reasonable measurement of density to be made from which chemical composition can be determined. Due to the current dearth of long duration space grown materials, the CT instrument has been used: (1) to characterize materials in preparation for flight, (2) to determine thermal expansion values, and (3) to examine long duration space grown materials, i.e. meteorites. This work will first describe the establishment of the protocol for obtaining the optimum density readings for any material. Included will be the effects of the hardware or instrumental parameters that can be controlled, and the techniques used to process the CT data. Examples will be given of the compositional variation along a single crystal of Ge-Si alloy. Density variation with temperature has been measured in preparation for future materials science experiments; this involved the fabrication at MSFC and installation of a single zone furnace at KSC incorporating a heat pipe to ensure high temperature uniformity. At the time of writing the thermal expansion of lead (Pb) has been measured from room temperature to 900 C. Three methods are available. Digital radiography enables length changes to be determined. Prior to melting the sample is smaller than the container and the diameter change can be measured. Most critical, however, is the density change in solid, through the melting region, and in the liquid state. These data are needed for engineering purposes to aid in the design of containment cartridges, and for enabling fluid flow calculations. A second sample, with the Pb alloyed with Sb is ready for scanning. This corresponds to the planned composition of Dr. Poirier s flight experiment. Other materials pertinent to NASA programs such as Al-Cu (Trivedi), CdTe (Banish), HgCdTe (Lehoczky) will be examined below and above the melting point. Finally, three-dimensional results will be shown of the structure of a two-phase metallic meteorite of metal and sulfide, in which the Fe-Ni phase has coarsened during slow cooling over hundreds of millions of years.

Source record↗
NASA NTRS2003

Macromolecular Topography Leaps into the Digital Age

A low-cost, real-time digital topography system is under development which will replace x-ray film and nuclear emulsion plates. The imaging system is based on an inexpensive surveillance camera that offers a 1000x1000 array of 8 im square pixels, anti-blooming circuitry, and very quick read out. Currently, the system directly converts x-rays to an image with no phosphor. The system is small and light and can be easily adapted to work with other crystallographic equipment. Preliminary images have been acquired of cubic insulin at the NSLS x26c beam line. NSLS x26c was configured for unfocused monochromatic radiation. Six reflections were collected with stills spaced from 0.002 to 0.001 degrees apart across the entire oscillation range that the reflections were in diffracting condition. All of the reflections were rotated to the vertical to reduce Lorentz and beam related effects. This particular CCD is designed for short exposure applications (much less than 1 sec) and so has a relatively high dark current leading to noisy raw images. The images are processed to remove background and other system noise with a multi-step approach including the use of wavelets, histogram, and mean window filtering. After processing, animations were constructed with the corresponding reflection profile to show the diffraction of the crystal volume vs. the oscillation angle as well as composite images showing the parts of the crystal with the strongest diffraction for each reflection. The final goal is to correlate features seen in reflection profiles captured with fine phi slicing to those seen in the topography images. With this development macromolecular topography finally comes into the digital age.

Lovelace, J.↗
DOE OSTI2025

Experimental evidence of disordered crystalline premixing in sputter-deposited Ni(V)/Al multilayers

The sputter deposition of alternating layers of Ni(V) and Al forms a reactive multilayer known to undergo self-propagating formation reactions when ignited. The sequential deposition process leads to nanometer-scale premixing of reactants at each included interface, which ultimately affects multilayer exothermicity. This work performs the direct measurement of a disordered face-centered cubic (FCC) solid solution premixed phase at the interfaces of Ni(V)/Al multilayers via scanning transmission electron microscopy. The crystallinity of the observed phase differs from previously reported a priori predictions of an amorphous interlayer. The disordered FCC phase retains its symmetry after annealing for 16 h at 135 ± 5 °C, but the lattice parameter shifts consistently with an Al-rich composition. The existence of a crystalline premix in Ni(V)/Al is attributed to the electronic contribution to the entropy of crystallization. The importance of electronic entropy to the phase formation of energetic materials motivates its inclusion when constructing digital twins for atomistic kinetics and ignition sensitivity.

Crystal structure↗
NASA NTRS1975

Mariner 6 and 7 picture analysis

Analysis of Mariner 6 and 7 far-encounter (FE) pictures is discussed. The purpose of the studies was to devise ways to combine digital data from the full set of FE pictures so as to improve surface resolution, distinguish clouds and haze patches from permanent surface topographic markings, deduce improved values for radius, oblateness, and spin-axis orientation, and produce a composite photographic map of Mars. Attempts to measure and correct camera distortions, locate each image in the frame, and convert image coordinates to martian surface coordinates were highly successful; residual uncertainties in location were considerably less than one pixel. However, analysis of the data to improve the radius, figure, and axial tilt and to produce a composite map was curtailed because of the superior data provided by Mariner 9. The data, programs, and intermediate results are still available (1976), and the project could be resumed with little difficulty.

Leighton, R. B.↗
NASA NTRS1984

Development and evaluation of techniques for using combined microwave and optical image data for vegetation studies

Techniques for using combined image data from the Shuttle Imaging Radar (SIR-B) and the LANDSAT Thematic Mapper (TM) or Multispectral Scanner (MSS) for studies of irrigated crops, and boreal and deciduous forests are developed and evaluated. The effects of the structure and composition of crop canopies and soil surfaces on multiangle L-band HH (Horizontal polarization for transmission and reception) backscattering and on optical reflectance (in TM or MSS bands viewed at the nadir) are investigated. The relative accuracy of digital, calibrated SIR-B image data and LANDSAT TM or MSS image data is evaluated. Textural information extraction-techniques are developed for radar and optical image analysis.

Paris, J. F.↗
NASA NTRSDate not supplied

Improving Structural Test and Analysis Correlation Using Digital Image Correlation Boundary Measurements

Simplified idealizations, such as clamped or simply supported, are commonly used as support boundary conditions in modeling and analysis of tested aerospace structures. However, these simplifications are not always appropriate and characterization of the response of non-rigid boundaries is often required to improve test and analysis correlation. While e analysis models are typically modified to better represent the test, this modification is often not practical due to the complexities of the boundary response. A study is conducted to examine the use of digital image correlation (DIC) to measure the boundary support structure response and then to adjust the test data to remove the effects of the boundary response in order to improve test and analysis correlation. A high-aspect ratio composite wing test is the subject of the study. Three sources of boundary flexibility contributing to rigid body rotation of the test wing are identified and quantified using both DIC and conventional test data. The wing displacement test data are adjusted using DIC data for these sources. Wing displacement test data is also adjusted using direct measurement of wing rotation from a DIC system that monitored the top surface, root region of the wing, and using available conventional instrumentation. The adjusted data exhibits improved test and analysis correlation and demonstrated the benefit of using DIC along with conventional instrumentation to collect and interpret test data.

Andrew E Lovejoy↗
NASA NTRS1992

Static and dynamic strain energy release rates in toughened thermosetting composite laminates

In this work, the static and dynamic fracture properties of several thermosetting resin based composite laminates are presented. Two classes of materials are explored. These are homogeneous, thermosetting resins and toughened, multi-phase, thermosetting resin systems. Multi-phase resin materials have shown enhancement over homogenous materials with respect to damage resistance. The development of new dynamic tests are presented for composite laminates based on Width Tapered Double Cantilevered Beam (WTDCB) for Mode 1 fracture and the End Notched Flexure (ENF) specimen. The WTDCB sample was loaded via a low inertia, pneumatic cylinder to produce rapid cross-head displacements. A high rate, piezo-electric load cell and an accelerometer were mounted on the specimen. A digital oscilloscope was used for data acquisition. Typical static and dynamic load versus displacement plots are presented. The ENF specimen was impacted in three point bending with an instrumented impact tower. Fracture initiation and propagation energies under static and dynamic conditions were determined analytically and experimentally. The test results for Mode 1 fracture are relatively insensitive to strain rate effects for the laminates tested in this study. The test results from Mode 2 fracture indicate that the toughened systems provide superior fracture initiation and higher resistance to propagation under dynamic conditions. While the static fracture properties of the homogeneous systems may be relatively high, the apparent Mode 2 dynamic critical strain energy release rate drops significantly. The results indicate that static Mode 2 fracture testing is inadequate for determining the fracture performance of composite structures subjected to conditions such as low velocity impact. A good correlation between the basic Mode 2 dynamic fracture properties and the performance is a combined material/structural Compression After Impact (CAI) test is found. These results underscore the importance of examining rate-dependent behavior for determining the longevity of structures manufactured from composite materials.

Cairns, Douglas S.↗
NASA NTRS1986

The engineering of the Voyager 2 mission to Uranus

The engineers of the Voyager 2 mission to Uranus had to deal with dwindling consumables, navigational challenges unique to the Uranian system, low light-level imaging, increasing communications problems, and failed equipment onboard the spacecraft, each of which could affect the success of the mission. The techniques for coping with each of these factors are discussed in detail. For instance, steadying of the spacecraft, achieved by cancelling the momentum change imparted to it by high-rate operations of the digital tape recorder, enhanced the data quality from several instruments, particularly the cameras. A careful power management scheme made it possible to conduct a successful radio occultation experiment which yielded detailed information on the Uranian atmospheric structure, including temperature and composition. A unique picture of the back-lit ring system was obtained.

Laeser, Richard P.↗