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NASA NTRS2018

Chapter 8: Materials for Exploration Systems

Materials science and processing research in space can be thought of as a field of study that began with the sounding rocket experiments in the 1950s. Material science studies of the lunar surface materials returned during the Apollo missions enabled the study of lunar resource utilization. The study of materials science and processing in space continued with over 30 years of microgravity materials processing research which continues today in the International Space Station. These studies are the technical foundation that could enable lower cost human exploration through the use of in-situ propellant production, the production of energy from space resources, and the eventual establishment of a substantial portion of humanity living self sufficiently off Earth.

Curreri, Peter A.↗

DOE OSTI2023

TRISO fuel performance analysis: Uncertainty quantification toward optimization

Tri-structural isotropic (TRISO) fuel particles are a fuel form being considered for potential use in next-generation nuclear reactors (i.e., high-temperature gas-cooled reactors). Though the TRISO fuel manufacturing process has continually advanced in recent years, particle comparisons still reveal statistical variations and uncertainties in terms of geometric configurations and material properties. Given that the physical processes ongoing in TRISO fuel particles during reactor operation are highly correlated with each other, a small degree of uncertainty in one model may lead to significant uncertainty in another. This makes appropriate uncertainty quantification of TRISO fuel particles essential. However, one may wonder about the extent to which the current version of TRISO particles has been optimized, and whether any room remains for further improvements. This paper quantifies TRISO fuel performance model uncertainties that stem from geometric and material data. For this analysis, the BISON code was used, and the Advanced Gas Reactor (AGR)-2 experiment served as a reference case. A total of 10 5 calculations was performed for the uncertainty and optimization analysis, altering the geometric and material data within their uncertainty range. Lastly, the optimization potential of TRISO particles is evaluated from a fuel performance perspective.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS1980

Influence of module requirements on flat plate module design evolution

Photovoltaic module design features and performance characteristics have undergone significant evolutionary changes between pre-1975 First Generation configurations and current Third Generation design technology. A major contributor to this evolution was an iterative process of continuing design guideline and specification development for major module procurements. Module manufacturers have actively responded to these evolving requirements through progressively improving designs. This iterative/feedback process is described. Interim design guidelines and preliminary design options reflecting the LSA 1982 Module Technical Readiness Specification (November 1979) are described with respect to previous design and performance requirements.

Arnett, J. C.↗

NASA NTRS1981

Continuous replenishment of molten semiconductor in a Czochralski-process, single-crystal-growing furnace

A replenishment crucible is mounted adjacent the usual drawing crucible, from which a monocrystalline boule is drawn according to the Czochralski method. A siphon tube for molten semiconductor transfer extends from the replenishment crucible to the drawing crucible. Each crucible is enclosed within its own hermetic shell and is provided with its own heater. The siphon tube is initially filled with molten semiconductor by raising the inert atmospheric pressure in the shell surrounding the replenishment crucible above that surrounding the drawing crucible. Thereafter, adjustment of the level of molten semiconductor in the drawing crucible may be achieved by adjusting the level in either crucible, since the siphon tube will establish the same level in both crucibles. For continuous processing, solid semiconductor may be added to and melted in the replenishment crucible during the process of drawing crystals from the drawing crucible. A constant liquid level of melted semiconductor is maintained in the system by an optical monitoring device and any of several electromechanical controls of the rate of replenishment or crucible height.

Fiegl, George↗

NASA NTRS1989

Manufacturing development of pultruded composite panels

The weight savings potential, of graphite-epoxy composites for secondary and medium primary aircraft structures, was demonstrated. One of the greatest challenges facing the aircraft industry is to reduce the acquisition costs for composite structures to a level below that of metal structures. The pultrusion process, wherein reinforcing fibers, after being passed through a resin bath are drawn through a die to form and cure the desired cross-section, is an automated low cost manufacturing process for composite structures. The Lockheed Aeronautical Systems Company (LASC) Composites Development Center designed, characterizated materials for, fabricated and tested a stiffened cover concept compatible with the continuous pultrusion process. The procedures used and the results obtained are presented.

Meade, L. E.↗

NASA NTRS1981

Development of advanced Czochralski growth process to produce low cost 150 kg silicon ingots from a single crucible for technology readiness

The process development continued, with a total of nine crystal growth runs. One of these was a 150 kg run of 5 crystals of approximately 30 kg each. Several machine and process problems were corrected and the 150 kg run was as successful as previous long runs on CG2000 RC's. The accelerated recharge and growth will be attempted when the development program resumes at full capacity in FY '82. The automation controls (Automatic Grower Light Computer System) were integrated to the seed dip temperature, shoulder, and diameter sensors on the CG2000 RC development grower. Test growths included four crystals, which were grown by the computer/sensor system from seed dip through tail off. This system will be integrated on the Mod CG2000 grower during the next quarter. The analytical task included the completion and preliminary testing of the gas chromatograph portion of the Furnace Atmosphere Analysis System. The system can detect CO concentrations and will be expanded to oxygen and water analysis in FY '82.

Source record↗

NASA NTRSDate not supplied

Quality Assurance of ISS LIS lightning Data

Optical lighting detection from space has been ongoing since 1995 from the Optical Transient detector (1995-2000), then later by the Lightning Imaging Sensors (LIS) on the Tropical Rainfall Measuring Mission (TRMM) satellite (1997-2015) and the International Space Station (ISS) (ISS 2017-present). A rapid readout (2 ms) 128x128 pixel CCD (Charge-coupled Device) array detects optical transients from lightning (events) and transmits the observations to ground. Ground processing determines whether individual events are likely due to lightning or noise. Likely lightning events are then grouped into groups, flashes, and areas and their location on the earth are determined. The lightning data are saved in orbit files; each file containing the time, location, and intensity of the lightning events, groups, flashes, and areas detected during one orbit. Even after this processing anomalies may exist in some of the orbits. A manual quality assurance (QA) procedure is performed monthly to assess the data and omit orbits with obvious anomalies from the dataset. These files are not included in the final dataset that has undergone QA. The manual QA was developed during the OTD mission to identify artifacts that made it through ground processing algorithms. The manual QA process was continued for the TRMM and ISS LIS missions. Many anomalies have been identified and software updates now address many of them. However, some anomalies still occur in the processed datasets. The manual QA process examines the data for obvious issues in the lightning files that passed through the processing algorithms. These files are considered anomalous and are not included in the final QA dataset. Some issues that may cause an orbit to be considered anomalous include: obvious noise (excess events that make it through the processing), suspect geolocation, and excessive missing data packets. As an example, one way noise manifests is as “streaks” in lightning climatology plots. These streaks are especially apparent in low lightning rate regions (eg., over oceans). Since there is no method at present to extract these anomalies during processing, orbit files with significant anomalies are identified and removed from the final QA ISS LIS dataset. The final QA dataset can be obtained files from the Global Hydrometeorological Resource Center (GHRC). This presentation will provide examples of the various anomalies and examine how often the various anomalies occur and how much data is lost due to the omission of the anomalous orbits. Comparisons with OTD and TRMM LIS will also be examined.

ISS↗

NASA NTRS1979

Advanced manufacturing development of a composite empennage component for L-1011 aircraft

Work on process verification and tooling development continued. The cover process development was completed with the decision to proceed with low resin content prepreg material (34 + or - 3% by weight) in the fabrication of production readiness verification test (PRVT) specimens and the full-scale covers. The structural integrity of the cover/joint design was verified with the successful test of the cover attachment to fuselage ancillary test specimen (H25). Failure occurred, as predicted, in the skin panel away from the fuselage joint at 141 percent of the design ultimate load. With the successful completion of the H25 test, the PRVT cover specimens, which are identical to the H25 ancillary test specimen, were cleared for production. Eight of the twenty cover specimens were fabricated and are in preparation for test. All twenty of the PRVT spar specimens were fabricated and also were prepared for test. The environmental chambers used in the durability test of ten cover and ten spar PRVT specimens were completed and installed in the load reaction frames.

Source record↗

NASA NTRS2018

Layered Pressure Vessels (LPV) Validating an Aging, Non-compliant Product

General information regarding efforts by NASA to validate continued use of fifty to sixty-five year old passive pressure containing vessels, to assess and reduce risks associated with LPV. With the goal of developing a standard Agency process for continued usage, maintenance, and inspection of LPV.

Greulich, Owen R.↗

DOE OSTI2021

Biomass Feedstock National User Facility--Improving Bale Deconstruction and Material Flow

The project aims to reduce feedstock variability using a quality-by-design approach beginning when the biomass is introduced to the process and will continue through the size reduction process, which will yield the results of fine generation reduction, contaminant removal, control of the physical and chemical critical material attributes in the process, and management of the flowability.

09 BIOMASS FUELS↗

DOE OSTI2023

Photovoltaic Deployment Scenarios toward Global Decarbonization: Role of Disruptive Technologies

To totally decarbonize global electrical systems using photovoltaics (PVs) in the 2050–2060 decade, the world would need to install 63.4 TW of PV. This article models and explores how a PV manufacturing ramp‐up trajectory toward this goal can be achieved while assuming that investors continue to make financially rational decisions avoiding stranded production assets and therefore protecting their return on investment. The model effectively exploits experience curve benefits in both the scaling of the manufacturing process and continued progress in product design technologies. The scale‐up challenge is amplified because trajectories that achieve this goal require an unprecedented ramp‐up of production capacity over just two decades, followed by relatively modest demand to maintain the installed base and support continued population growth. It is demonstrated that sustainable ramp‐up of manufacturing is indeed possible and shown that the deployment of the requisite manufacturing capacity can be accelerated and accomplished at lower total capital cost by the introduction of disruptive technologies that have lower capital intensity, embedded energy, or higher efficiency.

14 SOLAR ENERGY↗

NASA NTRS1990

A comparison of forming technologies for ceramic gas-turbine engine components

For over ten years, injection molding and slip casting have been actively developed as forming techniques for ceramic gas turbine components. Co-development of these two processes has continued within the U.S. DOE-sponsored Advanced Turbine Technology Application Project (ATTAP). Progress within ATTAP with respect to these two techniques is summarized. A critique and comparison of the two processes are given. Critical aspects of both processes with respect to size, dimensional control, material properties, quality, cost, and potential for manufacturing scale-up are discussed.

Hengst, R. R.↗

NASA NTRS2005

Projected Regional Climate in 2025 Due to Urban Growth

By 2025, 60 to 80 percent of the world s population will live in urban environments. Additionally, the following facts published by the United Nations further illustrates how cities will evolve in the future. Urban areas in the developing world are growing very rapidly. The urban growth rate will continue to be particularly rapid in the urban areas of less developed regions, averaging 2.4 per cent per year during 2000-2030, consistent with a doubling time of 29 years. The urbanization process will continue worldwide. The concentration of population in cities is expected to continue so that, by 2030, 84 percent of the inhabitants of more developed countries will be urban dwellers. Urbanization impacts the whole hierarchy of human settlements. In 2000,24.8 per cent of the world population lived in urban settlements with fewer than 500,000 inhabitants and by 2015 that proportion will likely rise to 27.1 per cent.

Shepherd, J. Marshall↗

DOE OSTI2025

Rational Regulation of Layer‐by‐Layer Processed Active Layer via Trimer‐Induced Pre‐Swelling Strategy for Efficient and Robust Thick‐Film Organic Solar Cells

Thick-film (>300 nm) organic solar cells (OSCs) have garnered intensifying attention due to their compatibility with commercial roll-to-roll printing technology for the large-scale continuous fabrication process. However, due to the uncontrollable donor/acceptor (D/A) arrangement in thick-film condition, the restricted exciton splitting and severe carrier traps significantly impede the photovoltaic performance and operability. For this work, combined with layer-by-layer deposition technology, a twisted 3D star-shaped trimer (BTT-Out) is synthesized to develop a trimer-induced pre-swelling (TIP) strategy, where the BTT-Out is incorporated into the buried D18 donor layer to enable the fabrication of thick-film OSCs. The integrated approach characterizations reveal that the exceptional configuration and spontaneous self-organization behavior of BTT-Out trimer could pre-swell the D18 network to facilitate the acceptor's infiltration and accelerate the formation of D/A interfaces. This enhancement triggers the elevated polarons formation with amplified hole-transfer kinetics, which is essential for the augmented exciton splitting efficiency. Furthermore, the regulated swelling process can initiate the favorable self-assembly of L8-BO acceptors, which would ameliorate carrier transport channels and mitigate carrier traps. As a result, the TIP-modified thin-film OSC devices achieve the champion performance of 20.3% (thin-film) and 18.8% (thick-film) with upgraded stability, among one of the highest performances reported of thick-film OSCs.

36 MATERIALS SCIENCE↗

NASA NTRS2012

Processing and Damage Tolerance of Continuous Carbon Fiber Composites Containing Puncture Self-Healing Thermoplastic Matrix

Research at NASA Langley Research Center (NASA LaRC) has identified several commercially available thermoplastic polymers that self-heal after ballistic impact and through-penetration. One of these resins, polybutadiene graft copolymer (PB(sub g)), was processed with unsized IM7 carbon fibers to fabricate reinforced composite material for further evaluation. Temperature dependent characteristics, such as the degradation point, glass transition (T(sub g)), and viscosity of the PBg polymer were characterized by thermogravimetric analysis (TGA), differential scanning calorimetry (DSC), and dynamic parallel plate rheology. The PBg resin was processed into approximately equal to 22.0 cm wide unidirectional prepreg tape in the NASA LaRC Advanced Composites Processing Research Laboratory. Data from polymer thermal characterization guided the determination of a processing cycle used to fabricate quasi-isotropic 32-ply laminate panels in various dimensions up to 30.5cm x 30.5cm in a vacuum press. The consolidation quality of these panels was analyzed by optical microscopy and acid digestion. The process cycle was further optimized based on these results and quasi-isotropic, [45/0/-45/90]4S, 15.24cm x 15.24cm laminate panels were fabricated for mechanical property characterization. The compression strength after impact (CAI) of the IM7/pBG composites was measured both before and after an elevated temperature and pressure healing cycle. The results of the processing development effort of this composite material as well as the results of the mechanical property characterization are presented in this paper.

Grimsley, Brian W.↗

DOE OSTI2024

Vortex fluidic regulated phospholipid equilibria involving liposomes down to sub-micelle size assemblies

Conventional channel-based microfluidic platforms have gained prominence in controlling the bottom-up formation of phospholipid based nanostructures including liposomes. However, there are challenges in the production of liposomes from rapidly scalable processes. These have been overcome using a vortex fluidic device (VFD), which is a thin film microfluidic platform rather than channel-based, affording ~110 nm diameter liposomes. The high yielding and high throughput continuous flow process has a 45° tilted rapidly rotating glass tube with an inner hydrophobic surface. Processing is also possible in the confined mode of operation which is effective for labelling pre-VFD-prepared liposomes with fluorophore tags for subsequent mechanistic studies on the fate of liposomes under shear stress in the VFD. In situ small-angle neutron scattering (SANS) established the co-existence of liposomes ~110 nm with small rafts, micelles, distorted micelles, or sub-micelle size assemblies of phospholipid, for increasing rotation speeds. The equilibria between these smaller entities and ~110 nm liposomes for a specific rotational speed of the tube is consistent with the spatial arrangement and dimensionality of topological fluid flow regimes in the VFD. The prevalence for the formation of ~110 nm diameter liposomes establishes that this is typically the most stable structure from the bottom-up self-assembly of the phospholipid and is in accord with dimensions of exosomes.

60 APPLIED LIFE SCIENCES↗

NASA NTRS2000

Autonomy for Constellation

The newer types of space systems, which are planned for the future, are placing challenging demands for newer autonomy concepts and techniques. Motivating these challenges are resource constraints. Even though onboard computing power will surely increase in the coming years, the resource constraints associated with space-based processes will continue to be a major factor that needs to be considered when dealing with, for example, agent-based spacecraft autonomy. To realize "economical intelligence", i.e., constrained computational intelligence that can reside within a process under severe resource constraints (time, power, space, etc.), is a major goal for such space systems as the Nanosat constellations. To begin to address the new challenges, we are developing approaches to constellation autonomy with constraints in mind. Within the Agent Concepts Testbed (ACT) at the Goddard Space Flight Center we are currently developing a Nanosat-related prototype for the first of the two-step program.

Truszkowski, Walt↗

NASA NTRS2000

Solid Freeform Fabrication of Continuous Fiber Reinforced Composites for Propulsion Applications

For propulsion related applications, materials must be able to demonstrate excellent ablation and oxidation resistance at temperature approaching 3500'C, adequate load bearing capabilities, non-catastrophic failure modes, and ability to withstand transient thermal shock. A potential list of propulsion-material property requirements includes, low density, high elastic modulus, low thermal-expansion coefficient, high thermal conductivity, excellent erosion and oxidation/corrosion resistance, and flaw-insensitivity. In many cases, they will also need to be able to be joined, survive thermal cycling and multi-axial stress states, and for reusable applications, the materials must maintain the above attributes after prolonged exposure to extremely harsh chemical environments. The final and possibly most important attribute for these materials are the need to be lower cost and readily available in large quantities. Recently, Advanced Ceramics Research, Inc. (ACR) has developed low cost, flexible- manufacturing processes for Zr & Hf-based carbon fiber reinforced composites, materials with good oxidation and ablation resistance up to 3500 C. This process, called Continuous Composite Co-extrusion (C(sup 3)), incorporates carbon fibers to fabricate 'in-situ' carbide and boride-matrix/carbon fiber composites. This is a variation of ACR's manufacturing process for low-cost structural ceramic materials called Fibrous Monoliths With carbon fiber reinforcements. Fibrous Monolithic materials have a distinct fibrous texture, consist of intertwined cells of a primary phase, separated by cell boundaries of a tailored secondary phase and show very high fracture energies, damage tolerance, and graceful failure. Since they are monolithic powder based composites-, they can be manufactured by conventional powder processing techniques using inexpensive raw materials. This combination of high performance and low cost is a breakthrough that could enable wider application of ceramics in high temperature applications. Typical volume fractions of the two phases are 80 to 95% for the cell phase and 5 to 20% for the interpenetrating cell boundary phase. ACR is currently developing an innovative solid freeform form fabrication (SFF) approach to produce Hf and Zr based ceramic composite components reinforced with continuous carbon fiber tows for critical structural components such as tubes and blisks. The process is simple, robust and will be widely applicable to a number of material systems. This technique was originally developed at the University of Delaware Center for Composite Materials (UD-CCM) for rapid fabrication of polymer matrix composites by a technique called automated tow placement or ATP. The current process is being developed in collaboration with UD-CCM. The paper will detail the freeform fabrication process to create low-cost ceramic fiber reinforced composites for high-temperature applications. The results of mechanical properties and microstructural characterization will be presented, together with examples of complex shapes and parts. It is believed that the process will be able to create complex shaped parts for propulsion applications at an order of magnitude lower cost than current CVI and PIP process.

Vaidyanathan, R.↗