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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 433 records · Page 24
All sourcesNASA NTRSDOE OSTI
NASA NTRS2001

PMR Extended Shelf Life Technology Given 2000 R and D 100 Award

An approach developed at the NASA Glenn Research Center for extending the shelf life of PMR polyimide solutions and prepregs received an R&D 100 Award this year. PMR polyimides, in particular PMR-15, have become attractive materials for a variety of aerospace applications because of their outstanding high-temperature stability and performance. PMR-15 can be used in components with exposures to temperatures as high as 290 C, which leads to substantial reductions in weight, as much as 30 percent over metal components. PMR-15 composites are used widely in aerospace applications ranging from ducts and external components in aircraft engines to an engine access door for the Space Shuttle Main Engine. A major barrier to more widespread use of these materials is high component costs. Recent efforts at Glenn have addressed the various factors that contribute to these costs in an attempt to more fully utilize these lightweight, high-temperature materials.

Meador, Michael A.↗
NASA NTRS1990

An integrated approach to system design, reliability, and diagnosis

The requirement for ultradependability of computer systems in future avionics and space applications necessitates a top-down, integrated systems engineering approach for design, implementation, testing, and operation. The functional analyses of hardware and software systems must be combined by models that are flexible enough to represent their interactions and behavior. The information contained in these models must be accessible throughout all phases of the system life cycle in order to maintain consistency and accuracy in design and operational decisions. One approach being taken by researchers at Ames Research Center is the creation of an object-oriented environment that integrates information about system components required in the reliability evaluation with behavioral information useful for diagnostic algorithms. Procedures have been developed at Ames that perform reliability evaluations during design and failure diagnoses during system operation. These procedures utilize information from a central source, structured as object-oriented fault trees. Fault trees were selected because they are a flexible model widely used in aerospace applications and because they give a concise, structured representation of system behavior. The utility of this integrated environment for aerospace applications in light of our experiences during its development and use is described. The techniques for reliability evaluation and failure diagnosis are discussed, and current extensions of the environment and areas requiring further development are summarized.

Patterson-Hine, F. A.↗
NASA NTRS1993

The development of hydrogen sensor technology at NASA Lewis Research Center

The detection of hydrogen leaks in aerospace applications, especially those involving hydrogen fuel propulsion systems, is of extreme importance for reasons of reliability, safety, and economy. Motivated by leaks occurring in liquid hydrogen lines supplying the main engine of the Space Shuttle, NASA Lewis has initiated a program to develop point-contact hydrogen sensors which address the needs of aerospace applications. Several different approaches are being explored. They include the fabrication of PdAg Schottky diode structures, the characterization of PdCr as a hydrogen sensitive alloy, and the use of SiC as a semiconductor for hydrogen sensors. This paper discusses the motivation behind and present status of each of the major components of the NASA LeRC hydrogen sensor program.

Hunter, Gary W.↗
NASA NTRS2025

Improving Adhesive Bondline Time of Flight Predictions During Autoclave Cure Utilizing Machine Learning

Composite materials are increasingly being used in aerospace applications due to their superior strength-to-weight ratio compared to commonly used metals. A current limitation to widespread adoption is the certification of adhesively bonded joints. One approach to improving adhesive bonding in composites is accurately measuring the thickness of adhesive bondlines in composite laminates. Precise bondline thickness control is essential for aerospace applications where adhesive layer thickness directly affects joint fracture properties and structural performance. This study focused on implementing machine learning techniques to determine the ultrasonic time of flight (directly correlated to thickness) in adhesive bondlines throughout autoclave cure cycles. A high-temperature (use up to 180°C) ultrasonic scanning system was deployed in an autoclave to provide time of flight data through composite panels. Three experiments were conducted on the curing of 305 mm × 305 mm unidirectional composite panels. In the first experiment, a piecewise function was fit for the temperature correction factor to account for changing autoclave temperatures. Due to deficiencies in the first calibration experiment, a second experiment was run, and the results were used to train a machine learning model. The revised experiment, in combination with the machine learning model, significantly increased the accuracy of the bondline time of flight predictions (~14% error reduced to <1%). Data was processed using the Regression Learner Application in MATLAB®, with a Support Vector Machine selected for the model. The result was a machine learning algorithm capable of reliably quantifying ultrasonic time of flight through adhesive bondlines. The third experiment provided independent test data for the machine learning model, demonstrating that the model produces accurate predictions from data beyond its training set.

Machine Learning↗
NASA NTRS2024

Extreme Temperature Additively Manufactured GRX-810 Alloy Development and Hot-fire Testing for Liquid Rocket Engines

Additive manufacturing (AM) has revolutionized component design for liquid rocket engines by offering rapid manufacturing capabilities. This has led to significant opportunities for development and flight programs in the propulsion industry, resulting in cost and schedule savings, as well as performance improvements through new designs and alloy development. A noteworthy example is the GRX-810 oxide dispersion strengthened (ODS) alloy, which was specifically developed for extreme temperatures. This Ni-Co-Cr based alloy was created using integrated computational materials engineering (ICME) techniques to focus on a new class of materials with exceptional temperature and oxidation-resistant properties. The GRX-810 alloy utilizes AM processes to incorporate nano-scale yttria particles throughout its microstructure, resulting in remarkable enhancements. Compared to traditional Nickel-based superalloys, the GRX-810 alloy offers a two-fold increase in tensile strength, 1,000-fold better creep properties, and two-fold improvement in oxidation resistance. NASA successfully demonstrated the development and manufacturing of components using the GRX-810 alloy through laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Extensive efforts were made to model, evaluate metallurgical properties, develop heat treatment processes, characterize the microstructure, and determine mechanical properties. The GRX-810 alloy was specifically designed for aerospace applications, including liquid rocket engine injectors, preburners, turbines, and hot-section components, capable of withstanding temperatures up to 1,100 °C. The objective of this alloy development is to bridge the temperature gap between traditional Nickel-based superalloys and refractory alloys. This paper provides a comprehensive comparison of the GRX-810 alloy with other aerospace alloys, discussing its microstructure, mechanical properties, processing advancements, component development, and hot-fire testing results. The ultimate goal of this development was to elevate the Technology Readiness Level (TRL) of the GRX-810 alloy, enabling its integration into NASA and commercial aerospace applications.

GRX-810↗
NASA NTRS2024

Extreme Temperature Additively Manufactured GRX-810 Alloy Development and Hot-fire Testing for Liquid Rocket Engines

Additive manufacturing (AM) has revolutionized component design for liquid rocket engines by offering rapid manufacturing capabilities. This has led to significant opportunities for development and flight programs in the propulsion industry, resulting in cost and schedule savings, as well as performance improvements through new designs and alloy development. A noteworthy example is the GRX-810 oxide dispersion strengthened (ODS) alloy, which was specifically developed for extreme temperatures. This Ni-Co-Cr based alloy was created using integrated computational materials engineering (ICME) techniques to focus on a new class of materials with exceptional temperature and oxidation-resistant properties. The GRX-810 alloy utilizes AM processes to incorporate nano-scale yttria particles throughout its microstructure, resulting in remarkable enhancements. Compared to traditional Nickel-based superalloys, the GRX-810 alloy offers a two-fold increase in tensile strength, 1,000-fold better creep properties, and two-fold improvement in oxidation resistance. NASA successfully demonstrated the development and manufacturing of components using the GRX-810 alloy through laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Extensive efforts were made to model, evaluate metallurgical properties, develop heat treatment processes, characterize the microstructure, and determine mechanical properties. The GRX-810 alloy was specifically designed for aerospace applications, including liquid rocket engine injectors, preburners, turbines, and hot-section components, capable of withstanding temperatures up to 1,100 °C. The objective of this alloy development is to bridge the temperature gap between traditional Nickel-based superalloys and refractory alloys. This paper provides a comprehensive comparison of the GRX-810 alloy with other aerospace alloys, discussing its microstructure, mechanical properties, processing advancements, component development, and hot-fire testing results. The ultimate goal of this development was to elevate the Technology Readiness Level (TRL) of the GRX-810 alloy, enabling its integration into NASA and commercial aerospace applications.

GRX-810↗
NASA NTRS1988

Machine intelligence and autonomy for aerospace systems

The present volume discusses progress toward intelligent robot systems in aerospace applications, NASA Space Program automation and robotics efforts, the supervisory control of telerobotics in space, machine intelligence and crew/vehicle interfaces, expert-system terms and building tools, and knowledge-acquisition for autonomous systems. Also discussed are methods for validation of knowledge-based systems, a design methodology for knowledge-based management systems, knowledge-based simulation for aerospace systems, knowledge-based diagnosis, planning and scheduling methods in AI, the treatment of uncertainty in AI, vision-sensing techniques in aerospace applications, image-understanding techniques, tactile sensing for robots, distributed sensor integration, and the control of articulated and deformable space structures.

Heer, Ewald↗
NASA NTRS1971

Applications of aerospace technology in industry, a technology transfer profile: Fire safety

The fire safety field is considered as being composed of three parts: an industry, a technology base, and a user base. An overview of the field is presented, including a perspective on the magnitude of the national fire safety problem. Selected NASA contributions to the technology of fire safety are considered. Communication mechanisms, particularly conferences and publications, used by NASA to alert the community to new developments in the fire safety field, are reviewed. Several examples of nonaerospace applications of NASA-generated fire safety technology are also presented. Issues associated with attempts to transfer this technology from the space program to other sectors of the American economy are outlined.

Kottenstette, J. P.↗
NASA NTRS2015

NASA and ESA Collaboration on Hexavalent Chrome Alternatives - Pretreatments with Primers Screening Final Test Report

Hexavalent chromium (hex chrome or Cr(VI)) is a widely used element within applied coating systems because of its self-healing and corrosion-resistant properties. The replacement of hex chrome in the processing of aluminum for aviation and aerospace applications remains a goal of great significance. Aluminum is the major manufacturing material of structures and components in the space flight arena. The National Aeronautics and Space Administration (NASA) and the European Space Agency (ESA) are engaged in a collaborative effort to test and evaluate alternatives to hexavalent chromium containing corrosion coating systems. NASA and ESA share common risks related to material obsolescence associated with hexavalent chromium used in corrosion-resistant coatings. In the United States, Occupational Safety and Health Administration (OSHA) studies have concluded that hexavalent chromium is carcinogenic and poses significant risk to human health. On May 5, 2011, amendments to the Defense Federal Acquisition Regulation Supplement (DFARS) were issued in the Federal Register. Subpart 223.73 prohibits contracts from requiring hexavalent chromium in deliverables unless certain exceptions apply. Subpart 252.223-7008 provides the contract clause prohibiting contractors and subcontractors from using or delivering hexavalent chromium in a concentration greater than 0.1 percent by weight for all new contracts associated with supplies, maintenance and repair services, and construction materials. ESA faces its own increasingly stringent regulations within European directives such as Registration, Evaluation, Authorization and Restriction of Chemical (REACH) substances and the Restriction of Hazardous Substances Directive (RoHS) which have set a mid-2017 sunset date for hexavalent chromium. NASA and ESA continue to search for an alternative to hexavalent chromium in coatings applications that meet their performance requirements in corrosion protection, cost, operability, and health and safety, while typically specifying that performance must be equal to or greater than existing systems. The overall objective of the collaborative effort between NASA TEERM and ESA is to test and evaluate coating systems (pretreatments, pretreatments with primer, and pretreatments with primer and topcoat) as replacements for hexavalent chrome coatings in aerospace applications. This objective will be accomplished by testing promising coatings identified from previous NASA, ESA, Department of Defense (DOD), and other project experience. Additionally, several new materials will be analyzed according to ESA-identified specifications.

coating↗
NASA NTRS2009

NASA TEERM Hexavalent Chrome Alternatives Projects

This slide presentation reviews the NASA/DOD projects to select an alternative to hexavalent chrome in the aerospace industry. The Phase I process of the project performed: (1) Evaluation and testing of non-chromated coating systems as replacements for hexavalent chrome coatings in aircraft and aerospace applications. (2) Testing of coating systems to DoD and NASA specifications for corrosion resistance and adhesion. (3) Bare corrosion resistance and atmospheric exposure will be focus areas of Phase II Testing. The description includes a chart that summarizes the 3000 hour salt fog test results. The second phase of the project includes (1) Evaluation and testing of coating systems that do not contain hexavalent chrome as replacements for aerospace applications. (2) Evaluation of coatings at Beach Test Site and Launch Complex 39B (3) Evaluation of non-chrome coatings for electronic housings (bare corrosion resistance and electrical impedance) is a part of this round of testing. This project was performed for the Technology Evaluation for Environmental Risk Mitigation (TEERM)

Rothgeb, Matt↗
NASA NTRS1979

Evaluation of verifiability in HAL/S

The ability of HAL/S to write verifiable programs, a characteristic which is highly desirable in aerospace applications, is lacking since many of the features of HAL/S do not lend themselves to existing verification techniques. The methods of language evaluation are described along with the means in which language features are evaluated for verifiability. These methods are applied in this study to various features of HAL/S to identify specific areas in which the language fails with respect to verifiability. Some conclusions are drawn for the design of programming languages for aerospace applications and ongoing work to identify a verifiable subset of HAL/S is described.

Young, W. D.↗
NASA NTRS1995

Development and evaluation of polybenzoxazole fibrous structures

Woven and braided polybenzoxazole (PBO) structures have been developed for aerospace applications. The properties of PBO fibers are compared to those of other high performance fibers. PBO is unique for combining excellent flammability properties with the highest tensile strength and modulus of all synthetic organic fibers. The PBO structures are specifically developed to be compared to similar Kevlar structures. The physical, mechanical, thermal, and oxidative properties of the PBO woven and braided structures are determined. The resistance to various chemicals and to UV light is evaluated. Recommendations for specific aerospace applications are given with comments for further development and industrial applications.

Orndoff, Evelyne↗
NASA NTRS1995

Effects of thermal and electrical stressing on the breakdown behavior of space wiring

Several failures in the electrical wiring systems of many aircraft and space vehicles have been attributed to arc tracking and damaged insulation. In some instances, these failures proved to be very costly as they have led to the loss of many aircraft and imperilment of space missions. Efforts are currently underway to develop lightweight, reliable, and arc track resistant wiring for aerospace applications. In this work, six wiring constructions were evaluated in terms of their breakdown behavior as a function of temperature. These hybrid constructions employed insulation consisting of Kapton, Teflon, and cross-linked Tefzel. The properties investigated included the 400 Hz AC dielectric strength at ambient and 200 C, and the lifetime at high temperature with an applied bias of 40, 60, and 80% of breakdown voltage level. The results obtained are discussed, and conclusions are made concerning the suitability of the wiring constructions investigated for aerospace applications.

Hammoud, Ahmad↗
DOE OSTI2023

Science-Based Acceleration of the Full Value Stream for Metal Additive Manufacturing: Expedited Powder Development and Additive Manufacturing Deployment in the Areas of Ni-Base Superalloy and Custom Alloy Powders for AM (Final Report)

The overall Science-based Acceleration of the Full Value Stream for Metal Additive Manufacturing (AM): Expedited Powder Development and Additive Manufacturing Deployment (“X-P4AM”) project objective is to drastically reduce the time-to-market barriers for new additive alloys of interest in automotive and aerospace applications, through computational alloy design with rapid screening and down- selection via synthesis of candidate alloys with rapid solidification. The project will also refine the technology in high pressure gas atomization to improve the production of commercial quantities of selected powders with high powder yields and enhanced powder quality. Production of modified nickel-based superalloys and a Ni-containing alloy based on a high entropy composition, enhanced powder production methods, and optimized AM build parameterization provided critical steps in widespread adoption of AM technology for aerospace applications, in this case. The individual backgrounds and capabilities of the Parties are ideally suited to the successful execution of this work. The included work enhanced the Contractors’ AM capabilities, a core competency of the Contractors, and develop a close working relationship with the Participant in the area of nickel-based powder superalloys and custom alloys and their end use.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Science-Based Acceleration of the Full Value Stream for Metal Additive Manufacturing: Expedited Powder Development and Additive Manufacturing Deployment in the Areas of Ni-Base Superalloy and Custom Alloy Powders for AM

The overall Science-based Acceleration of the Full Value Stream for Metal Additive Manufacturing (AM): Expedited Powder Development and Additive Manufacturing Deployment (“X-P4AM”) project objective is to drastically reduce the time-to-market barriers for new additive alloys of interest in automotive and aerospace applications, through computational alloy design with rapid screening and down- selection via synthesis of candidate alloys with rapid solidification. The project will also refine the technology in high pressure gas atomization to improve the production of commercial quantities of selected powders with high powder yields and enhanced powder quality. Production of modified nickel-based superalloys and a Ni-containing alloy based on a high entropy composition, enhanced powder production methods, and optimized AM build parameterization provided critical steps in widespread adoption of AM technology for aerospace applications, in this case. The individual backgrounds and capabilities of the Parties are ideally suited to the successful execution of this work. The included work enhanced the Contractors’ AM capabilities, a core competency of the Contractors, and develop a close working relationship with the Participant in the areas of nickel-based powder superalloys and custom alloys and their end use.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Science-Based Acceleration of the Full Value Stream for Metal Additive Manufacturing: Expedited Powder Development and Additive Manufacturing Deployment in the Areas of Ni-Base Superalloy and Custom Alloy Powders for AM

The overall Science-based Acceleration of the Full Value Stream for Metal Additive Manufacturing (AM): Expedited Powder Development and Additive Manufacturing Deployment (“X-P4AM”) project objective is to drastically reduce the time-to-market barriers for new additive alloys of interest in automotive and aerospace applications, through computational alloy design with rapid screening and down- selection via synthesis of candidate alloys with rapid solidification. The project will also refine the technology in high pressure gas atomization to improve the production of commercial quantities of selected powders with high powder yields and enhanced powder quality. Production of modified nickel-based superalloys and a Ni-containing alloy based on a high entropy composition, enhanced powder production methods, and optimized AM build parameterization provided critical steps in widespread adoption of AM technology for aerospace applications, in this case. The individual backgrounds and capabilities of the Parties are ideally suited to the successful execution of this work. The included work enhanced the Contractors’ AM capabilities, a core competency of the Contractors, and develop a close working relationship with the Participant in the areas of nickel-based powder superalloys and custom alloys and their end use.

36 MATERIALS SCIENCE↗
NASA NTRS1986

The pultrusion process for structures on advanced aerospace transportation systems

The pultrusion process, which has the potential for use in the manufacture of structures for aerospace hardware, is described. In this process, reinforcing fibers are pulled continuously through a resin system for wetting and subsequently through a heated die for polymerization. By using this process, fabrication of very long lengths of high strength, lightweight structures with consistently high quality for aerospace applications is possible. The more conventional processes involve hand lay-up, vacuum bagging, autoclaving or oven curing techniques such that lengths of structural elements produced are limited by the lengths of autoclaves or curing ovens. Several types of developmental structural elements are described in which fiberglass, aramid, graphite, and hybrid fiber systems have been used as reinforcements in an epoxy matrix and their flexural properties compared. Reinforcement fibers having tailor-made orientations which achieve tailor-made strength in the pultrusions are described. The potential aerospace applications for the pultruded products are described with advantages cited over conventional hand lay-up methods.

Wilson, Maywood L.↗
NASA NTRS2009

Data Base and Guidelines Document Developed for Lithium-Ion Battery

Lithium-Ion (Li-Ion) batteries are fast becoming the battery chemistry of choice for aerospace applications requiring (rechargeable) power supplies. These batteries offer high-energy density and high-specific energy combined with excellent rate capability and cycle potential. The increased energy content and operational characteristics of this system require defined safety and handling procedures to ensure the safe implementation. Standardized approaches to defining, determining, and addressing safety, handling, and qualification for Li-Ion batteries have been developed and published as an NESC-sponsored Li-Ion Battery Guidelines Document. A data base was established cataloging cells and batteries that have been considered for aerospace applications.

Data Base and Guidelines↗