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NASA NTRS2000

Turbine Airfoil With CMC Leading-Edge Concept Tested Under Simulated Gas Turbine Conditions

Silicon-based ceramics have been proposed as component materials for gas turbine engine hot-sections. When the Navy s Harrier fighter experienced engine (Pegasus F402) failure because of leading-edge durability problems on the second-stage high-pressure turbine vane, the Office of Naval Research came to the NASA Glenn Research Center at Lewis Field for test support in evaluating a concept for eliminating the vane-edge degradation. The High Pressure Burner Rig (HPBR) was selected for testing since it could provide temperature, pressure, velocity, and combustion gas compositions that closely simulate the engine environment. The study focused on equipping the stationary metal airfoil (Pegasus F402) with a ceramic matrix composite (CMC) leading-edge insert and evaluating the feasibility and benefits of such a configuration. The test exposed the component, with and without the CMC insert, to the harsh engine environment in an unloaded condition, with cooling to provide temperature relief to the metal blade underneath. The insert was made using an AlliedSignal Composites, Inc., enhanced HiNicalon (Nippon Carbon Co. LTD., Yokohama, Japan) fiber-reinforced silicon carbide composite (SiC/SiC CMC) material fabricated via chemical vapor infiltration. This insert was 45-mils thick and occupied a recessed area in the leading edge and shroud of the vane. It was designed to be free floating with an end cap design. The HPBR tests provided a comparative evaluation of the temperature response and leading-edge durability and included cycling the airfoils between simulated idle, lift, and cruise flight conditions. In addition, the airfoils were aircooled, uniquely instrumented, and exposed to the exact set of internal and external conditions, which included gas temperatures in excess of 1370 C (2500 F). In addition to documenting the temperature response of the metal vane for comparison with the CMC, a demonstration of improved leading-edge durability was a primary goal. First, the metal vane was tested for a total of 150 cycles. Both the leading edge and trailing edge of the blade exhibited fatigue cracking and burn-through similar to the failures experienced in service by the F402 engine. Next, an airfoil, fitted with the ceramic leading edge insert, was exposed for 200 cycles. The temperature response of those HPBR cycles indicated a reduced internal metal temperature, by as much as 600 F at the midspan location for the same surface temperature (2100 F). After testing, the composite insert appeared intact, with no signs of failure on either the vane s leading or trailing edge. Only a slight oxide scale, as would be expected, was noted on the insert. Overall, the CMC insert performed similarly to a thick thermal barrier coating. With a small air gap between the metal and the SiC/SiC leading edge, heat transfer from the CMC to the metal alloy was low, effectively lowering the temperatures. The insert's performance has proven that an uncooled CMC can be engineered and designed to withstand the thermal up-shock experienced during the severe lift conditions in the Pegasus engine. The design of the leading-edge insert, which minimized thermal stresses in the SiC/SiC CMC, showed that the CMC/metal assembly can be engineered to be a functioning component.

Robinson, R. Craig↗

DOE OSTI2024

Ducted Fuel Injection And Cooled Spray Technologies For Particulate Control In Heavy-duty Diesel Engines (Final Report)

Cooled Spray (CS) and Ducted Fuel Injection (DFI) are in-cylinder technologies for diesel engines that can reduce particulate matter and soot emissions and data has been published showing that these technologies can reduce soot emissions by 75-100% for some engines at some operating conditions. However, little is known about scaling the devices for engine size. Additionally, the performance of either technology over the engine duty cycle has not been explored. This project addresses both of these points through single-cylinder engine investigations. The objectives of this project are to provide details about dimensional scaling of these devices and to demonstrate 75% PM reduction over a range of operating conditions on a single-cylinder engine. Two engines were used for this project: a 125mm bore optically accessible engine at Sandia National Laboratories and a 168mm bore metal engine at Southwest Research Institute. The optical engine was used to study the performance of DFI and CS inserts for a large injector orifice diameter injector that is characteristic of a locomotive engine and to perform scaling studies for DFI. The metal engine was used to perform scaling and alignment studies for CS and to evaluate the technology for both EGR and non-EGR engines over the engine operating map. Modifications were required for both engines to accept the prototype inserts being tested. The optical engine required a new fuel injector, cylinder head and piston so that tests could be run at the pressures and engine speeds required. Additionally, a novel rotating stage was designed for the optical engine to simplify alignment of the modules. The metal engine required a modified cylinder head to accept CS inserts and a modified piston to provide additional space around the fuel injector for the CS inserts. Tests on the optical engine showed that DFI reduces PM emissions for both small injector orifices (0.170mm diameter) and large injector orifices (0.290mm). For high load testing, the DFI modules were not as effective as at low load testing, but it was acknowledged that minimal geometric optimization was performed and more improvements may be possible. Comparing DFI to CS and conventional diesel combustion (CDC), DFI performed better than CS or CDC. The CS geometries used in these studies may not be ideal for that engine and additional modifications likely would improve performance. Tests on the metal engine showed PM reductions as high has 80% at some operating conditions with duty-cycle PM reductions of ~50% for EGR and non-EGR configurations. The CS testing on the metal engine showed that chamfering of the fuel passage inlet either through hydro-erosion or mechanical grinding provided significant improvements in the PM reduction capabilities of the insert. Additionally, alignment sensitivities were explored and the data show that the tolerance to misalignment is approximately 0.05 to 0.1mm for the inserts that were studied here. Air-fuel ratio was shown to be important in the effectiveness of the CS inserts. In several tests, it was shown that the CS inserts are more effective at reducing the PM for high-AFR operating conditions compared to low AFR conditions. In summary, multiple designs were evaluated on both engines. It was found that for the conditions and configurations studied here, a fuel passage diameter of ~2.5mm performed best overall. Significant duty-cycle PM reductions are possible using these technologies and sensitivities to AFR, alignment fuel passage diameter and inlet fuel passage shaping were explored and are reported here. More PM reduction may be possible with improved geometric design and attention to alignment practices.

02 PETROLEUM↗

NASA NTRS2007

Improving Robotic Operator Performance Using Augmented Reality

The Special Purpose Dexterous Manipulator (SPDM) is a two-armed robot that functions as an extension to the end effector of the Space Station Robotics Manipulator System (SSRMS), currently in use on the International Space Station (ISS). Crew training for the SPDM is accomplished using a robotic hardware simulator, which performs most of SPDM functions under normal static Earth gravitational forces. Both the simulator and SPDM are controlled from a standard robotic workstation using a laptop for the user interface and three monitors for camera views. Most operations anticipated for the SPDM involve the manipulation, insertion, and removal of any of several types of Orbital Replaceable Unit (ORU), modules which control various ISS functions. Alignment tolerances for insertion of the ORU into its receptacle are 0.25 inch and 0.5 degree from nominal values. The pre-insertion alignment task must be performed within these tolerances by using available video camera views of the intrinsic features of the ORU and receptacle, without special registration markings. Since optimum camera views may not be available, and dynamic orbital lighting conditions may limit periods of viewing, a successful ORU insertion operation may require an extended period of time. This study explored the feasibility of using augmented reality (AR) to assist SPDM operations. Geometric graphical symbols were overlaid on one of the workstation monitors to afford cues to assist the operator in attaining adequate pre-insertion ORU alignment. Twelve skilled subjects performed eight ORU insertion tasks using the simulator with and without the AR symbols in a repeated measures experimental design. Results indicated that using the AR symbols reduced pre-insertion alignment error for all subjects and reduced the time to complete pre-insertion alignment for most subjects.

Maida, James C.↗

DOE OSTI2024

Linear Free Energy Relationships Associated with Hydride Transfer From [(6,6'-R 2 -bpy)Re(CO) 3 H]: A Cautionary Tale in Identifying Hydrogen Bonding Effects in the Secondary Coordination Sphere

Here, six rhenium hydride complexes, [(6,6'-R 2 -bpy)Re(CO) 3 H] (bpy = 2,2'-bipyridine, R = OEt, OMe, NHMe, Me, F, Br), were synthesized. These complexes insert CO 2 to form rhenium formate complexes of the type [(6,6'-R 2 -bpy)Re(CO) 3 {OC(O)H}]. All the rhenium formate species were characterized using X-ray crystallography, which revealed that the bpy ligand is not coplanar with the metal coordination plane containing the two nitrogen donors of the bpy ligand but tilted. A solid-state structure of [(6,6'-Me 2 -bpy)Re(CO) 3 H] determined using MicroED also featured a tilted bpy ligand. The kinetics of CO 2 insertion into complexes of the type [(6,6'-R 2 -bpy)Re(CO) 3 H] were measured experimentally and the thermodynamic hydricities of [(6,6'-R 2 -bpy)Re(CO) 3 H] species were determined using theoretical calculations. A Brønsted plot constructed using the experimentally determined rate constants for CO 2 insertion and the calculated thermodynamic hydricities for [(6,6'-R 2 -bpy)Re(CO) 3 H] revealed a linear free energy relationship (LFER) between thermodynamic and kinetic hydricity. This LFER is different to the previously determined relationship for CO 2 insertion into complexes of the type [(4,4'-R 2 -bpy)Re(CO) 3 H]. At a given thermodynamic hydricity, CO 2 insertion is faster for complexes containing a 6,6'-substituted bpy ligand. This is likely in part due to the tilting observed for systems with 6,6'-substituted bpy ligands. Notably, the 6,6'-(NHMe) 2 -bpy ligand could in principle stabilize the transition state for CO 2 insertion via hydrogen bonding. This work shows that if only the rate of CO 2 insertion into [(6,6'-(NHMe) 2 -bpy)Re(CO) 3 H] is compared to [(4,4'-R 2 -bpy)Re(CO) 3 H] systems, the increase in rate could be easily attributed to hydrogen bonding, but in fact all 6,6'-substituted systems lead to faster than expected rates.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1998

Evaluation of dual-tip micromanometers during 21-day implantation in goats

Investigative research efforts using a cardiovascular model required the determination of central circulatory haemodynamic and arterial system parameters for the evaluation of cardiovascular performance. These calculations required continuous beat-to-beat measurement of pressure within the four chambers of the heart and great vessels. Sensitivity and offset drift, longevity, and sources of error for eight 3F dual-tipped micromanometers were determined during 21 days of implantation in goats. Subjects were instrumented with pairs of chronically implanted fluid-filled access catheters in the left and right ventricles, through which dual-tipped (test) micromanometers were chronically inserted and single-tip (standard) micromanometers were acutely inserted. Acutely inserted sensors were calibrated daily and measured pressures were compared in vivo to the chronically inserted sensors. Comparison of the pre- and post-gain calibration of the chronically inserted sensors showed a mean sensitivity drift of 1.0 +/- 0.4% (99% confidence, n = 9 sensors) and mean offset drift of 5.0 +/- 1.5 mmHg (99% confidence, n = 9 sensors). Potential sources of error for these drifts were identified, and included measurement system inaccuracies, temperature drift, hydrostatic column gradients, and dynamic pressure changes. Based upon these findings, we determined that these micromanometers may be chronically inserted in high-pressure chambers for up to 17 days with an acceptable error, but should be limited to acute (hours) insertions in low-pressure applications.

Non-NASA Center↗

NASA NTRS2012

The DECLIC Research Facility - a Fertile Platform for NASA/CNES Scientific Collaboration

The DECLIC (Device for the Study of Critical Liquids and Crystalization) Facility was launched to the International Space Station (ISS) on Shuttle flight 17-A (August 2009) and has been in service for a little over three years. Activity from the three originally planned investigations, the HTI (High Temperature Insert) investigation, the ALI (Alice Like Insert) investigation and the DSI (Directional Solidication Insert) investigation has led to fruitful collaborations among a team of scientists, sponsored by NASA and CNES, to extend the utility of the inserts and the breadth of science beyond its initial scope. These follow-on investigations plan to use inserts that have been returned to earth for refurbishment, two of which (i.e., HTI-R and DSI-R) simply entail changing the test sample and the third (i.e., ALI-R) entails a slight hardware modication to allow for precise changes in sample volume. The first investigation, the Supercritical Water Mixture (SCWM) experiment, uses the refurbished HTI-R, which will accommodate a dilute aqueous mixture of Na2SO4 -0.5% w. This investigation will extend earlier observations of pure water at near-critical conditions. The second experiment uses a modified insert, the DSI-R, with a different concentration of succinonitrile-camphor than the original flight sample. This will allow, among other objectives, a detailed study of dendritic sidebranch formation in extended three-dimensional arrays, with the goal of elucidating whether noise amplication and/or a deterministic limit cycle is the main cause of sidebranch formation. The final experiment, the ALI-R, uses a sample cell with variable density to allow for additional observations of thermo-physical properties on SF6 at near critical conditions. The presentation will provide a discussion of the DECLIC facility's hardware, its modied inserts, and an overview of the extended science that will be achieved through these collaborative activities.

Hicks, Michael C.↗

NASA NTRS2005

Experimental Investigation of Oscillatory Flow Pressure and Pressure Drop Through Complex Geometries

A series of experiments have been performed to investigate the oscillatory flow pressure and pressure drop through complex geometries. These experiments were conducted at the CSU-SLRE facility which is a horizontally opposed, two-piston, single-acting engine with a split crankshaft driving mechanism. Flow through a rectangular duct, with no insert (obstruction), was studied first. Then four different inserts were examined: Abrupt, Manifold, Diverging Short and Diverging Long. The inserts were mounted in the center of the rectangular duct to represent different type of geometries that could be encountered in Stirling machines. The pressure and pressure drop of the oscillating flow was studied for: 1) different inserts, 2) different phase angle between the two pistons of the engine (zero, 90 lead, 180, and 90 lag), and 3) for different piston frequencies (5, 10, 15, and 20 Hz). It was found that the pressure drop of the oscillatory flow increases with increasing Reynolds number. The pressure drop was shown to be mainly due to the gas inertia for the case of oscillatory flow through a rectangular duct with no insert. On the other hand, for the cases with different inserts into the rectangular duct, the pressure drop has three sources: inertia, friction, and local losses. The friction pressure drop is only a small fraction of the total pressure drop. It was also shown that the dimensionless pressure drop decreases with increasing kinetic Reynolds number.

Ibrahim, Mounir B.↗

NASA NTRS2006

Repairing Fractured Bones by Use of Bioabsorbable Composites

A proposed method of surgical repair of fractured bones would incorporate recent and future advances in the art of composite materials. The composite materials used in this method would be biocompatible and at least partly bioabsorbable: that is, during the healing process following surgery, they would be wholly or at least partly absorbed into the bones and other tissues in which they were implanted. Relative to the traditional method, the proposed method would involve less surgery, pose less of a risk of infection, provide for better transfer of loads across fracture sites, and thereby promote better healing while reducing the need for immobilization by casts and other external devices. One requirement that both the traditional and proposed methods must satisfy is to fix the multiple segments of a broken bone in the correct relative positions. Mechanical fixing techniques used in the traditional method include the use of plates spanning the fracture site and secured to the bone by screws, serving of wire along the bone across the fracture site, insertion of metallic intramedullary rods through the hollow portion of the fractured bone, and/or inserting transverse rods through the bone, muscle, and skin to stabilize the fractured members. After the bone heals, a second surgical operation is needed to remove the mechanical fixture(s). In the proposed method, there would be no need for a second surgical operation. The proposed method is based partly on the observation that in the fabrication of a structural member, it is generally more efficient and reliable to use multiple small fasteners to transfer load across a joint than to use a single or smaller number of larger fasteners, provided that the stress fields of neighboring small fasteners do not overlap or interact. Also, multiple smaller fasteners are more reliable than are larger and fewer fasteners. However, there is a trade-off between structural efficiency and the cost of insertion time and materials. The proposed method is further based partly on the conjecture that through-the-thickness reinforcements could be excellent for fixing bone segments for surgical repair. The through-the-thickness reinforcements would superficially resemble nails in both form and function. Denoted small-diameter rods (SDRs) to distinguish them from other narrow rods, these reinforcements would be shot or otherwise inserted through adjacent segments of fractured bone to fix them in their correct relative positions (see figure). Shot insertion would be effected by use an applicator that would amount to a miniaturized and highly refined version of the pneumatic guns often used in carpentry to drive nails and brads. The applicator, envisioned to be about the size of a ball-point-pen, would be driven by pressurized carbon dioxide. To further promote stabilization of the segments, layers of bone glue could be applied to the fracture surfaces prior to insertion of the SDRs. The bone glue could be therapeutically loaded with chemicals to promote growth of bone and fight infection

Farley, Gary L.↗

NASA NTRSDate not supplied

Uranus Flagship-class Orbiter and Probe Using Aerocapture

Exploration of the Ice Giants, especially Uranus, via orbiter and atmospheric probes, is required to answer pressing science questions that have been raised in the latest National Academies of Sciences Planetary Decadal Survey. Since the Ice Giants are the farthest planets from Earth, traditional fully-propulsive orbit insertion missions have transit times to the planetary bodies bordering 13-15 years and require a large amount of propellant (wet mass percentages of around 60-70%) for the orbit insertion maneuver, leaving less mass for the scientific payload and a planetary probe. Aerocapture uses aerodynamic forces generated by flight within a planetary atmosphere to decelerate and achieve orbit insertion. Aerocapture has been considered for several past missions but it has not been demonstrated. However, recent developments in thermal protection systems (TPS), guidance and control (G&C), and interplanetary navigation capabilities show the potential for using rigid, heritage entry vehicle configurations already flown at other planetary bodies for Ice Giants aerocapture. Aerocapture can robustly deliver spacecraft to Ice Giant orbits, while substantially increasing on-orbit payload mass (more than 40%) that can be used for a robust atmospheric entry probe. Additionally, the aerocapture maneuver would reduce the interplanetary transit time by 2-5 years (15-30%) relative to fully-propulsive orbit insertion. Recent work has shown that a flagship-class mission can be conducted in a shorter time than fully-propulsive missions if using aerocapture. This paper will consider the merits of including aerocapture as the orbit-insertion mechanism for a Uranus mission. Specifically, the implications of aerocapture orbit insertion for in-situ atmospheric probes will be discussed. The Uranus Orbiter and Probe concept mission study [3] is considered as the potential payload. Results from a recent NASA Space Technology Mission Directorate (STMD)-funded activity that is designing an aerocapture mission for a Uranus orbiter will be presented.

Soumyo Dutta↗

NASA NTRSDate not supplied

Uranus Flagship-class Orbiter and Probe Using Aerocapture

Soumyo Dutta↗

NASA NTRS2024

Aerocapture: An Enabling Technology for Flagship-Class Uranus Orbiter and Probe Mission

Introduction: The current decadal survey published by the National Academies of Sciences has informed National Aeronautics and Space Administration (NASA) to prioritize the study of the Ice Giants, especially Uranus. To gather the required data that addresses the science questions raised in this survey, a mission to Uranus with an orbiter and atmospheric probe must be designed. The Uranus Orbiter and Probe (UOP) study, which the survey identified as the flagship mission of this decade, proposes a 2031 launch to take advantage of a Jupiter fly-by and utilizes a fully propulsive orbit insertion design with an Earth-to-Uranus transit times ranging from 13 to 15 years. This fully propulsive orbit insertion at Uranus will be very fuel expensive (wet mass percentages of around 60-70\%) thereby leaving less mass for the scientific payload and additional planetary probes. In addition, scientists are more interested in visiting Uranus before 2049, when the Spring Equinox will occur, as it allows studying Uranus seasons not seen during Voyager 2's flyby in 1987. A NASA Flagship-Class mission would require at least 10 years of lead time prior to launch thereby making the 2031 launch to take advantage of the Jupiter fly-by extremely challenging. The consequence of missing the Jupiter fly-by and launching in the late 2030s is the challenge of a fully-propulsive mission like UOP to have a feasible alternative interplanetary trajectory that reaches Uranus before 2050. As an alternative, to address the shortcomings of the fully propulsive mission, one can design a mission to Uranus using aerocapture. What is aerocapture: Aerocapture is an atmospheric maneuver that uses aerodynamic forces generated by flight within a planetary atmosphere to decelerate and achieve orbit insertion. Using aerocapture allows one to provide the change in velocity (Delta V) needed to slow down from the approach hyperbolic trajectory to achieve the desired captured orbit around the target planet using aerodynamic forces of the vehicle (lift and drag). Using aerodynamic forces instead of fully-propulsive maneuvers results in significant savings in the fuel. Furthermore, aerocapture can also allow one to consider interplanetary trajectories with higher approach hyperbolic velocities, thus reducing the mission transit times. Aerocapture as an enabling technology: To use aerocapture as an enabling technology for the Uranus exploration mission, one would require an integrated system-level design, including a Thermal Protection System (TPS), hardware needed for aerodynamic modulation, and autonomous Guidance, Navigation, and Control (GNC) systems. Aerocapture has yet to be demonstrated, despite considering it for several past missions. Recent advancements in TPS and GNC capabilities show the potential for using rigid, heritage entry vehicle configurations already flown at other planetary bodies for Uranus aerocapture. Aerocapture can be a robust technology that can deliver spacecraft to Uranus science orbits while substantially increasing on-orbit payload mass (more than 40\%) that can enable robust atmospheric entry probes. Additionally, the aerocapture maneuver would reduce the interplanetary transit time by 2–5 years (15-30\%) relative to fully-propulsive orbit insertion. Recent work has shown that one can conduct a flagship-class mission in a shorter period than fully-propulsive missions if using aerocapture. What does aerocapture bring in for a Uranus Mission: Using aerocapture for a Uranus orbiter and atmospheric probe mission can provide one with considerable propellant savings. Spacecraft in interplanetary trajectories to Uranus typically need an Delta V in orders of kilometers per second to insert into science orbit. One would require thousands of kilograms of fuel to achieve such a Delta V using a traditional fully propulsive maneuver, leaving less mass for payload during the mission launch. Aerocapture can reduce the propulsion needs by dissipating energy in the sizable atmosphere of Uranus without a significant mass increase due to the need for an aeroshell. One can use the mass savings achieved using the aerocapture to reduce the launch vehicle requirements. In addition, one can also have additional science instruments on the orbiter or create a robust instrumentation suite on an atmospheric probe that can significantly increase the science outcome of the Uranus exploration mission. Furthermore, since aerocapture performance is relatively insensitive to increases in hyperbolic excess velocity, one can design the interplanetary trajectory to arrive at Uranus faster, reducing the interplanetary transit time and operations cost. All these savings, achieved using aerocapture, could help fit a larger class mission, such as the Uranus mission within a smaller capital, e.g., a Flagship-class orbiter mission in a New Frontiers class capital. Summary: This talk will provide an overview of how aerocapture can enable the Uranus exploration mission. Specifically, this talk will discuss the latest advancements made in the Uranus aerocapture study, such as investigating interplanetary trajectories with higher hyperbolic approach velocities and their implications on the aero heating and the TPS design, incorporating FNPAG (an advanced numerical-predictor guidance) and comparison of multiple navigation approaches. In addition, this talk will focus on mechanical design that can house more than one atmospheric probe and the six degrees of freedom simulation of aerocapture at Uranus. Findings from a recent NASA Space Technology Mission Directorate (STMD)-funded activity studying the aerocapture as an enabling technology for a Uranus orbiter will be presented. Using the science payload recommended by the Decadal Survey for Uranus exploration, this work shows many improvements over the baseline fully-propulsive mission. These improvements include a shorter cruise phase, flexibility in launch opportunities late into the 2030s while reaching Uranus before the 2050 equinox for the desired science opportunities, and lower propellant mass needs. This talk will highlight how aerocapture can be utilized for Uranus science orbit insertion using a lower-risk, heritage entry vehicle configuration used extensively as a Mars entry, descent, and landing vehicle. Furthermore, this talk will explore how the demonstration of aerocapture at Earth can benefit the aerocapture-enabled Uranus mission.

Aerocapture↗

NASA NTRS1993

Phenotypic characterization of xpr, a global regulator of extracellular virulence factors in Staphylococcus aureus

We recently described a Tn551 insertion in the chromosome of Staphylococcus aureus S6C that resulted in drastically reduced expression of extracellular lipase (M. S. Smeltzer, S. R. Gill, and J. J. Iandolo, J. Bacteriol. 174:4000-4006, 1992). The insertion was localized to a chromosomal site (designated omega 1058) distinct from the lipase structural gene (geh) and the accessory gene regulator (agr), both of which were structurally intact in the lipase-negative (Lip-) mutants. In this report, we describe a phenotypic comparison between strains S6C, a hyperproducer of enterotoxin B; KSI9051, a derivative of S6C carrying the Tn551 insertion at omega 1058; ISP546, an 8325-4 strain that carries a Tn551 insertion in the agr locus; and ISP479C, the parent strain of ISP546 cured of the Tn551 delivery plasmid pI258repA36. Compared with their respective parent strains, ISP546 and KSI9051 produced greatly reduced amounts of lipase, alpha-toxin, delta-toxin, protease, and nuclease. KSI9051 also produced reduced amounts of staphylococcal enterotoxin B. Coagulase production was increased in ISP546 but not in KSI9051. Using a mouse model, we also demonstrated that ISP546 and KSI9051 were far less virulent than ISP479C and S6C. We have designated the genetic element defined by the Tn551 insertion at omega 1058 xpr to denote its role as a regulator of extracellular protein synthesis. We conclude that xpr and agr are similar and possibly interactive regulatory genes that play an important role in pathogenesis of staphylococcal disease.

NASA Discipline Cell Biology↗

DOE OSTI2025

Structures of vertebrate R2 retrotransposon complexes during target-primed reverse transcription and after second-strand nicking

R2 retrotransposons are site-specific eukaryotic non–long terminal repeat retrotransposons that copy and paste into gene loci encoding ribosomal RNAs. Recently, we demonstrated that avian A-clade R2 proteins achieve efficient and precise insertion of transgenes into their native safe-harbor loci in human cells. The features of A-clade R2 proteins that support gene insertion are not well characterized. Here, we report high-resolution cryo–electron microscopy structures of two vertebrate A-clade R2 proteins at the initiation of target-primed reverse transcription and after cDNA synthesis and second-strand nicking. Using biochemical and cellular assays, we illuminate the basis for high selectivity of template use and unique roles for each of the three zinc-finger domains in nucleic acid recognition. Reverse transcriptase active site architecture is reinforced by an unanticipated insertion motif specific to vertebrate A-clade R2 proteins. Our work provides the first insights into A-clade R2 protein structure during gene insertion and may enable future improvement and adaptation of R2-based systems for precise transgene insertion.

Science & Technology - Other Topics↗

DOE OSTI2025

A Novel Manufacturing Process of Lightweight Automotive Seats (Integration of Additive Manufacturing and Reinforced Polymer Composite)

Lightweight automotive seats offer multiple benefits to original equipment manufacturers in terms of cost savings from various aspects, including less material usage, more integrated processes, and compliance with Corporate Average Fuel Economy Standards. Original equipment manufacturers have been focusing on innovative ways to produce light weight automotive seats. The commercially available automotive seats are currently made of multiple metal components combined through welding and fasteners. The use of additive manufacturing and composite structures is particularly useful for light weighting the automotive components. Additive manufacturing (AM) offers multiple advantages over traditional manufacturing processes such as freedom of design thereby enabling complex structural geometries, mass customization and waste minimization, and control over the fiber alignment through deposition in a predetermined pattern. Combining metal inserts with polymer composites through a novel manufacturing process allows design of lightweight and high-performance materials for automotive components. However, fabricating these metal polymer composite structures through traditional manufacturing processes limits their mechanical properties due to limited design freedom, lack of control over fiber orientation in composite parts, and poor interfacial bonding between the constituent materials. It is essential to develop a novel manufacturing process to enable high throughput production of lightweight automotive seats using metal and polymer composites. As such it is important to design the automotive seat suitable for manufacturing via this process and perform mechanical characterization on various subcomponents of the seat to ensure that the design and performance requirements provided by the auto manufacturer are met. The aim of this project is to develop a novel manufacturing technique to produce lightweight automotive seat by combining AM with conventional manufacturing processes. The car seat back panel will be designed via topology optimization and numerical simulations to minimize the overall weight while ensuring it meets all the performance requirements. The optimization of the seat back structure will be based on computational stress analysis to maximize the stiffness and minimize the weight. Materials currently used by Ford Motor Company will be adopted for a few subcomponents while the in-house composite materials will be used for the rest of the seat back. The composite and metallic materials will be tested to determine their mechanical properties as these are necessary for simulations. A novel manufacturing process will be developed to integrate AM metal inserts with discontinuous reinforced composite through large scale additive manufacturing and compression overmolding processes. The developed manufacturing technique will be used to fabricated various subcomponents suitable for the seat back design and mechanically tested to determine their properties. The manufacturing of the lightweight seat back design through this process involves integrated AM metal inserts with the composite structure for recliner connection. The manufacturing of the entire seat back which is lightweight through the novel manufacturing process will be discussed. The performance of the designed seat back will be investigated through numerical simulations and shown to meet all the requirements provided by the auto manufacturer. The final goal of developing a novel manufacturing process for lightweight automotive seats is met through design optimization of seat back, manufacturing of subcomponents, mechanical characterization, and validation through numerical simulations. The routes to achieve the final goal of the project and the depth in which they were investigated changed throughout the project due to personnel changes and the COVID-19 pandemic. The project resulted in the development of a novel manufacturing process to integrate metal inserts with tailored polymer composite preforms through overmolding. Leveraging this proven manufacturing process, a lightweight seat back was designed through topology optimization and numerical simulations. The designed seat back uses AM metal inserts and compression overmolding of tailored polymer composite preforms obtained via large scale additive manufacturing. The metal polymer composite structures fabricated through this process exhibited enhancement in stiffness and improved ductility upon testing. Overall, the project provided an alternative design and manufacturing technique for automotive seat back that enables weight saving while meeting the safety and performance requirements.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS1975

Effect of casing treatment on performance of a multistage compressor

AJ85-GE-13 engine was equipped with a compressor case which allowed changes to the case wall over the rotor tips of six of its stages. The engine was tested with four inlet configurations: undistorted and with 180 deg circumferential, hub radial, and tip radial distortions. Baseline data defining compressor performance and stall regions were taken for these inlet configurations with solid (untreated) compressor case inserts. Circumferentially grooved inserts were installed in the first three and last three stages, and the compressor was mapped under similar conditions. The compressor was mapped a third time with untreated inserts in the first three stages and inserts having slots conforming to blade angles in the last three stages. In most cases, the stall pressure ratio was the same as or lower than the baseline. Pumping capacity with the slotted inserts was reduced. Overall compressor efficiency with the grooved rings installed did not appreciably differ from the baseline, but it was 1 to 2 percentage points lower than the baseline with the slotted rings in place. Average stage characteristics for the undistorted inlet case showed little or no sensitivity to casing treatment.

Wenzel, L. M.↗

NASA NTRS1979

Contingency study for the third international Sun-Earth Explorer (ISEE-3) satellite

The third satellite of the international Sun-Earth Explorer program was inserted into a periodic halo orbit about L sub 1, the collinear libration point between the Sun and the Earth-Moon barycenter. A plan is presented that was developed to enable insertion into the halo orbit in case there was a large underperformance of the Delta second or third stage during the maneuver to insert the spacecraft into the transfer trajectory. After one orbit of the Earth, a maneuver would be performed near perigee to increase the energy of the orbit. A relatively small second maneuver would put the spacecraft in a transfer trajectory to the halo orbit, into which it could be inserted for a total cost within the fuel budget. Overburns (hot transfer trajectory insertions) were also studied.

Dunham, D. W.↗

NASA NTRS1990

Arcjet Nozzle Area Ratio Effects

An experimental investigation was conducted to determine the effect of nozzle area ratio on the operating characteristics and performance of a low power dc arcjet thruster. Conical thoriated tungsten nozzle inserts were tested in a modular laboratory arcjet thruster run on hydrogen/nitrogen mixtures simulating the decomposition products of hydrazine. The converging and diverging sides of the inserts had half angles of 30 and 20 degrees, respectively, similar to a flight type unit currently under development. The length of the diverging side was varied to change the area ratio. The nozzle inserts were run over a wide range of specific power. Current, voltage, mass flow rate, and thrust were monitored to provide accurate comparisons between tests. While small differences in performance were observed between the two nozzle inserts, it was determined that for each nozzle insert, arcjet performance improved with increasing nozzle area ratio to the highest area ratio tested and that the losses become very pronounced for area ratios below 50. These trends are somewhat different than those obtained in previous experimental and analytical studies of low Re number nozzles. It appears that arcjet performance can be enhanced via area ratio optimization.

Curran, Francis M.↗

NASA NTRS1991

Effect of initial delamination on Mode 1 and Mode 2 interlaminar fracture toughness and fatigue fracture threshold

Static and fatigue double-cantilever beam (DCB) and end-notch flexure (ENF) tests were conducted to determine the effect of the simulated initial delamination in interlaminar fracture toughness, G(sub c), and fatigue fracture threshold, G(sub th). Unidirectional, 24-ply specimens of S2/SP250 glass/epoxy were tested using Kapton inserts of four different thickness - 13, 25, 75, and 130 microns, at the midplane at one end, or with tension or shear precracks, to simulate an initial delamination. To determine G(sub c), the fatigue fracture threshold below which no delamination growth would occur in less than 1 x 10(exp 6) cycles, fatigue tests were conducted by cyclically loading specimens until delamination growth was detected. Consistent values of model 1 fracture toughness, G(sub Ic), were measured from DCB specimens with inserts of thickness 75 microns or thinner, or with shear precracks. The fatigue DCB tests gave similar values of G(sub Ith) for the 13, 25, and 75 microns specimens. Results for the shear precracked specimens were significantly lower that for specimens without precracks. Results for both the static and fatigue ENF tests showed that measured G(IIc) and G(IIth) values decreased with decreasing insert thickness, so that no limiting thickness could be determined. Results for specimens with inserts of 75 microns or thicker were significantly higher than the results for precracked specimens or specimens with 13 or 25 microns inserts.

Murri, Gretchen Bostaph↗