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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 451 records · Page 25
All sourcesNASA NTRSDOE OSTI
NASA NTRS2012

Dichroic Filter for Separating W-Band and Ka-Band

The proposed Aerosol/Cloud/Ecosystems (ACEs) mission development would advance cloud profiling radar from that used in CloudSat by adding a 35-GHz (Ka-band) channel to the 94-GHz (W-band) channel used in CloudSat. In order to illuminate a single antenna, and use CloudSat-like quasi-optical transmission lines, a spatial diplexer is needed to add the Ka-band channel. A dichroic filter separates Ka-band from W-band by employing advances in electrical discharge machining (EDM) and mode-matching analysis techniques developed and validated for designing dichroics for the Deep Space Network (DSN), to develop a preliminary design that both met the requirements of frequency separation and mechanical strength. First, a mechanical prototype was built using an approximately 102-micron-diameter EDM process, and tolerances of the hole dimensions, wall thickness, radius, and dichroic filter thickness measured. The prototype validated the manufacturing needed to design a dichroic filter for a higher-frequency usage than previously used in the DSN. The initial design was based on a Ka-band design, but thicker walls are required for mechanical rigidity than one obtains by simply scaling the Ka-band dichroic filter. The resulting trade of hole dimensions for mechanical rigidity (wall thickness) required electrical redesign of the hole dimensions. Updates to existing codes in the linear solver decreased the analysis time using mode-matching, enabling the electrical design to be realized quickly. This work is applicable to missions and instruments that seek to extend W-band cloud profiling measurements to other frequencies. By demonstrating a dichroic filter that passes W-band, but reflects a lower frequency, this opens up the development of instruments that both compare to and enhance CloudSat.

Epp, Larry W.↗
NASA NTRS2019

Additive Manufacturing of Multi-Material Systems for Aerospace Applications

Additive manufacturing methods for producing single materials are rapidly improving. The resulting material properties and microstructures are becoming more comparable to those of conventionally fabricated materials. However, the need for multi-functional and complex structures and components requires additional innovations in manufacturing such as multi-material and hybrid additive manufacturing approaches. Additive manufacturing machines with multiple print capabilities and combinations of AM, machining, and conventional processing methods will further open up design spaces and possibilities. In this presentation, several examples of the needs and methods for multi-material fabrication will be discussed with a focus on aerospace applications. Direct printing of silver coils in conjunction with fused deposition modeling, machined parts, and, binder jetting is being developed for innovative stator designs. Binder jetting of silicon-based materials with powder bed additions is being developed for heat exchanger applications. Additive manufacturing of bi-material systems is being pursued to fabricate lightweight, integrated, multifunctional structures.

multi-materials↗
NASA NTRS2026

Manufacturing and Scale-Up of Natural Fiber Composite eVTOL Propeller Skin and C-Channel

This report presents the manufacturing and scale-up of natural fiber composites for aerospace applications, conducted within NASA’s Convergent Aeronautics Solutions portfolio to advance aircraft capabilities and efficiency. The effort focused on the development and demonstration of two proof-of-concept articles, an Electric Vertical Take-off and Landing (eVTOL) propeller skin and a C-channel, produced through an iterative design and process optimization approach. Best practices and guidance on addressing key challenges with bio-based composite materials and manufacturing is provided. Ideally suited for non-load-bearing structural components, these emerging materials offer potential for weight reduction, vibration damping, noise mitigation, interference-free communication, and cost savings, without compromising the performance of safety-critical primary structures.

Natural fibers↗
NASA NTRS2019

Challenges and Opportunities For Ensuring Entry System Technology Readiness For Ice Giants Probe Missions

The Ice Giants represent a distinct class of planets within our solar system, and appear to be similar to most exoplanets that have been detected thus far. Exploring Ice Giants in our Solar System would allow us to better understand their formation and evolution processes, and thus help establish scientific links to exoplanets. In situ exploration using probes similar to Galileo, along with an orbiter or a relay spacecraft, will require entry followed by deployment of the descent probe containing science instruments into Uranus or Neptune atmosphere. The challenge is not in the deployment of the probe, but in the atmospheric entry prior to deployment. The entry system has to have a capable, robust and efficient ablative thermal protection system (TPS) designed to protect the descent probe from the thermal and mechanical entry loads. Although entries into Ice Giants may not be as demanding as the Galileo entry at Jupiter, the entry environments will be more severe than environments for Mars, Sample Return missions, and Venus, and will therefore require robust TPS. While Galileo Probe’s success, nearly 25 years ago, should give us confidence, the recession data from the Galileo entry informs us that the entry environment was under predicted and the design thickness was barely adequate. The lesson learned from Galileo probe for future Ice Giant missions will require us to be cautious and demand a more robust design. The TPS technology used on Galileo entry system no longer exists due to atrophy of manufacturing processes. Instead of attempting to revive Galileo-legacy TPS technology, NASA invested in a new and innovative TPS called HEEET (Heat-shield for Extreme Entry Environment Technology). HEEET has been matured, and is now ready to support future missions not only to the Ice Giants but also for Venus, high-speed sample return, and Saturn probe missions. This lead talk, intended for the technology section of the workshop, will cover entry, descent, and deployment (EDD), with an emphasis on entry. A brief history of the TPS challenges for extreme entry missions will be given along with a quick overview of the concept of operations for EDD. The development and maturation of HEEET system capability will be described. Data gathered in ground-test facilities in the US will be highlighted to show that the technology is mature and ready for Ice Giant missions. All thermal protection systems carry some risk as a result of ground test limitations and Ice Giant missions present some unique challenges. These challenges are not only technical, but also due to limitations in the currently established manufacturing and integration. In addition, the concerns that arise due to potential for atrophy for future Ice Giant mission a decade or more from now will be analyzed. Plausible avenues for mitigation will be presented. There are two companion planned presentations by Dr. Prabhu and Dr. Hwang will dive deeper in the challenges and opportunities. This intended talk will set the stage for their presentations.

Venkatapathy, Ethiraj↗
NASA NTRSDate not supplied

NASA's Composite Overwrap Lessons Learned on 40k Thrust Chamber Assemblies

Filament wound carbon fiber/polymer composite overwraps combined with additively manufactured (AM) copper alloy combustion chambers are a critical part of NASA’s Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project. The composite overwrap is a high strength-to-weight material and allows for significant weight reduction of the high-pressure thrust chamber assembly, reduction of overall cost, and reduced fabrication time while offering structural robustness. Integrated AM/composite overwrap chamber assemblies using 2,000 lbf (2k) and 7,000 lbf (7k) thrust were successfully hot fire tested at NASA Marshall Space Flight Center (MSFC). These assemblies allowed the team to learn lessons related to the design, analysis, and manufacturing of these integrated assemblies. A final goal of the RAMPT project is to design and test a 40,000 lbf (40k) thrust chamber assembly. The40k chamber presented the team several new challenges including an integral inlet port in the main body of the composite overwrap. Through multiple iterations of manufacturing techniques, varied materials, and Non-Destructive Evaluations (NDE), many lessons were learned to obtain a final design solution that would not only allow for the interrupted port inlet but also allow for sufficient material margins for the most critically stressed part of the chamber. This paper will cover the manufacturing techniques exploring fabric designs to help subsidize the coverage in the areas left bare by the inlet port during the filament winding process and custom tooling needed for the final full chamber processing. The original material choice of bismaleimide (BMI) 5250-4 from the 7k chamber performed well for the extreme environment of hot fire testing but proved to be difficult with the increased scale and interrupted port design of the 40kchamber. Discussion in this paper will cover these changes, including evaluation of the design, comparison to the prior 2k and 7k designs, and show the final hardware that will be tested. One primary goal of this work and RAMPT project is to provide this development process and data to industry for infusion into future engine designs.

Filament Wound↗
NASA NTRSDate not supplied

Contracting Quality Early in the Lifecycle Using AS9145 Data Deliverables

Development schedules and a highly dynamic supply chain are a challenge to developers of complex systems produced at low volume. Flaws in designs, parts and materials availability problems, poor manufacturability, and a lack of knowledge about critical items and key process attributes can be realized well before traditional second-party quality assurance activities begin. Supplier audits and product inspections may have little mitigating effect once these foundational problems have been realized. Their impacts can be significant lifecycle disruption, cost overruns, inability to deliver to plan, and even project cancellation. AS9145, Requirements for Advanced Product Quality Planning and Production Part Approval Process, can be used to drive quality engineering practices into early development lifecycles to significantly reduce this late-cycle risk and to reduce the cost of quality overall. Since its initial publication in 2016, it has had very limited adoption by the DoD, no adoption by NASA, and sparse adoption in the aerospace and defense supply chain. A task group within the Aerospace Industries Association's (AIA) Joint Strategic Quality Council (JSQC) identified that both acquirers and suppliers see as AS9145 as a cost-adder and are hesitant to use it as an alternative to late-stage-heavy quality assurance approaches. A lack of prior use creates large capability gaps in request-for-proposal (RFP) teams, proposal teams, suppliers’ quality management systems (QMS), and in experienced personnel executing the early lifecycle approach. To create a more realizable on-ramp for using AS9145 in the space and defense sectors, the AIA JSQC task team created five deliverable requirements descriptions (DRDs) that can be used in a contract to begin to engage both parties in early lifecycle quality engineering and quality assurance activities, that reduce exposure to late-stage cost and schedule collapse due to unidentified risks in design, supply chain, and manufacturability. These DRDs drive the parties to engage in planning and analysis discussions early on to understand what production risks can be known and how they will focus resources based on safety criticality and the key elements of design and construction. The suppliers and acquirers who will produce the data and information required by the DRD will be able to incrementally evolve their QMS and the acquirer will incrementally be able to track and understand the benefits of cost shifting from late to early development phases. A white paper describing this approach and the five recommended DRDs will be published by the AIA in late 2024 or early 2025.

Jeannette Plante↗
NASA NTRS2004

Optimal Synthesis of Compliant Mechanisms using Subdivision and Commercial FEA (DETC2004-57497)

The field of distributed-compliance mechanisms has seen significant work in developing suitable topology optimization tools for their design. These optimal design tools have grown out of the techniques of structural optimization. This paper will build on the previous work in topology optimization and compliant mechanism design by proposing an alternative design space parameterization through control points and adding another step to the process, that of subdivision. The control points allow a specific design to be represented as a solid model during the optimization process. The process of subdivision creates an additional number of control points that help smooth the surface (for example a C(sup 2) continuous surface depending on the method of subdivision chosen) creating a manufacturable design free of some traditional numerical instabilities. Note that these additional control points do not add to the number of design parameters. This alternative parameterization and description as a solid model effectively and completely separates the design variables from the analysis variables during the optimization procedure. The motivation behind this work is to create an automated design tool from task definition to functional prototype created on a CNC or rapid-prototype machine. This paper will describe the proposed compliant mechanism design process and will demonstrate the procedure on several examples common in the literature.

Hull, Patrick V.↗
NASA NTRS1991

Systematic Identification Of Discrepant Hardware

CAMRAD, program designed for rapid input and retrieval of all data used in engineering-to-manufacturing support operations, aids engineer by automating material-review-disposition process. Facilitates research of material-review histories and provides for efficient processing of material-review documents. Three SmartWare project files control operation. Written in Smart programming language and designed to run on IBM PC compatibles with SmartWave version 3.1.

Hanna, Timothy L.↗
NASA NTRS2017

Update on Risk Reduction Activities for a Liquid Advanced Booster for NASA's Space Launch System

The stated goals of NASA's Research Announcement for the Space Launch System (SLS) Advanced Booster Engineering Demonstration and/or Risk Reduction (ABEDRR) are to reduce risks leading to an affordable Advanced Booster that meets the evolved capabilities of SLS and enable competition by mitigating targeted Advanced Booster risks to enhance SLS affordability. Dynetics, Inc. and Aerojet Rocketdyne (AR) formed a team to offer a wide-ranging set of risk reduction activities and full-scale, system-level demonstrations that support NASA's ABEDRR goals. During the ABEDRR effort, the Dynetics Team has modified flight-proven Apollo-Saturn F-1 engine components and subsystems to improve affordability and reliability (e.g., reduce parts counts, touch labor, or use lower cost manufacturing processes and materials). The team has built hardware to validate production costs and completed tests to demonstrate it can meet performance requirements. State-of-the-art manufacturing and processing techniques have been applied to the heritage F-1, resulting in a low recurring cost engine while retaining the benefits of Apollo-era experience. NASA test facilities have been used to perform low-cost risk-reduction engine testing. In early 2014, NASA and the Dynetics Team agreed to move additional large liquid oxygen/kerosene engine work under Dynetics' ABEDRR contract. Also led by AR, the objectives of this work are to demonstrate combustion stability and measure performance of a 500,000 lbf class Oxidizer-Rich Staged Combustion (ORSC) cycle main injector. A trade study was completed to investigate the feasibility, cost effectiveness, and technical maturity of a domestically-produced engine that could potentially both replace the RD-180 on Atlas V and satisfy NASA SLS payload-to-orbit requirements via an advanced booster application. Engine physical dimensions and performance parameters resulting from this study provide the system level requirements for the ORSC risk reduction test article. The test article is scheduled to complete fabrication and assembly soon and continue testing through late 2019. Dynetics has also designed, developed, and built innovative tank and structure assemblies using friction stir welding to leverage recent NASA investments in manufacturing tools, facilities, and processes, significantly reducing development and recurring costs. The full-scale cryotank assembly was used to verify the structural design and prove affordable processes. Dynetics performed hydrostatic and cryothermal proof tests on the assembly to verify the assembly meets performance requirements..

Crocker, Andrew M.↗
NASA NTRS1971

Development of uniform and predictable battery materials for nickel-cadmium aerospace cells

Battery materials and manufacturing methods were analyzed with the aim of developing uniform and predictable battery plates for nickel cadmium aerospace cells. A study is presented for the high temperature electrochemical impregnation process for the preparation of nickel cadmium battery plates. This comparative study is set up as a factorially designed experiment to examine both manufacturing and operational variables and any interaction that might exist between them. The manufacturing variables in the factorial design include plaque preparative method, plaque porosity and thickness, impregnation method, and loading, The operational variables are type of duty cycle, charge and discharge rate, extent of overcharge, and depth of discharge.

Source record↗
NASA NTRS1977

Annual Conference on Nuclear and Space Radiation Effects, 14th, College of William and Mary, Williamsburg, Va., July 12-15, 1977, Proceedings

Topics related to processing and hardness assurance are considered, taking into account the radiation hardening of CMOS technologies, technological advances in the manufacture of radiation-hardened CMOS integrated circuits, CMOS hardness assurance through process controls and optimized design procedures, the application of operational amplifiers to hardened systems, a hard off-the-shelf SG1524 pulse width modulator, and the gamma-induced voltage breakdown anomaly in a Schottky diode. Basic mechanisms are examined, giving attention to chemical and structural aspects of the irradiation behavior of SiO2 films on silicon, experimental observations of the chemistry of the SiO2/Si interface, leakage current phenomena in irradiated SOS devices, the avalanche injection of holes into SiO2, the low-temperature radiation response of Al2O3 gate insulators, and neutron damage mechanisms in silicon at 10 K. Other subjects discussed are related to radiation effects in devices and circuits, space radiation effects, and aspects of simulation, energy deposition, and dosimetry.

Stahl, R. H.↗
NASA NTRS1989

Strut-node joint conjugates for the assembly of semi-permanent or reusable truss structures

When strut and node components are used for truss construction an assembly problem occurs if a strut must be fitted between nodes whose separation distance is either closer or farther than the design intended. This condition is the result of normal dimensional variations that occur in any manufacturing process. In such circumstances two actions would permit continued assembly: change the effective strut length, and move the nodes. Assuming continued assembly is the most attractive alternative, attention is focused on accomplishing these actions as part of the assembly process.

Brewer, W. V.↗
NASA NTRS1991

Proposal for a low cost close air support aircraft for the year 2000: The Raptor

The Raptor is a proposed low cost Close Air Support (CAS) aircraft for the U.S. Military. The Raptor incorporates a 'cranked arrow' wing planform, and uses canards instead of a traditional horizontal tail. The Raptor is designed to be capable of responsive delivery of effective ordnance in close proximity to friendly ground forces during the day, night, and 'under the weather' conditions. Details are presented of the Raptor's mission, configuration, performance, stability and control, ground support, manufacturing, and overall cost to permit engineering evaluation of the proposed design. A description of the design process and analysis methods used is also provided.

Brown, Jerome D.↗
NASA NTRS2007

Innovative Concept for a Heavy-Load Aircraft Utilizing a Two-Dimensional Wing

Heavy-load aircraft of conventional wing-body-tail design have become very large. Excessive size of such aircraft may present problems in the manufacturing process. In addition, large wing spans may cause some difficulties in ground handling. Increasing lift loads on large span cantilever wings will also increase the strength of the wing tip vortex. The concept presented herein proposes a means for substantially increasing the lift load capability of an aircraft without increasing the overall length and span of the configuration. The concept has a rectangular wing with a relatively low span and a large chord to provide the area required for high lift. Large fuselages are attached at each wing tip to provide the volume required for heavy loading. The fuselages serve as endplates for the wing and should preclude tip flow so that two-dimensional flow might be established on the wing. Elimination of the wing tip flow should prevent the formation of a tip vortex and eliminate the tip vortex hazard to trailing aircraft. Exploratory wind tunnel tests of such an aircraft concept have been conducted. Lessons learned from these tests are discussed herein in an effort to determine the validity of the concept.

Spearman, M. Leroy↗
NASA NTRSDate not supplied

Optical Design of Multi-field Integral Field Unit Spectrograph for the ORCAS Keck Instrument Development II (ORKID II) Instrument

We have designed an Integral Field Unit for the ORCAS Keck Instrument Development II (ORKID II) Instrument. Building on the success of the ORKID camera which achieved 15.2 masec PSF FWHM visible light imaging, ORKID II will add Integral Field Spectroscopy to analyze Active Galactic Nuclei (AGN), supernovae redshift and brightness, and other observations. Several design options have been explored based on image slicers manufactured by the Canon Corporation’s machining process. Field layouts can include up to three disparate spatial sampling, with a lower limit of 6.7 masec. Spectral resolutions are considered from R 100 to R 10,000.

Space Instrumentation↗
NASA NTRSDate not supplied

Principles of Directed Energy Deposition for Aerospace Applications

Metal Additive Manufacturing is changing how components are being fabricated for rocket propulsion and aerospace applications. Many additive manufacturing technologies are evolving, and active research is being conducted across academia, industry, and government to advance processes, materials, design, post-processing, and applications. While much focus has been on Laser Powder Bed Fusion (L-PBF) techniques, several large-scale techniques are also rapidly evolving using directed energy deposition (DED) techniques. This lecture will provide an overview of various DED technologies, a comparison among the technologies, various materials, parameters used to deposit, and several examples of DED applications for propulsion and aerospace components.

Additive Manufacturing↗
NASA NTRS2019

The Implementation of Maximum Likelihood Estimation in Space Launch System Vehicle Design

As NASA’s Space Launch System (SLS) approaches first launch, the design has matured to a point where the manufacturing uncertainty has decreased now that many of the components of the launch vehicle have been manufactured and the flight engines have been successfully tested. Prior to this point, a method was required to qualify and capture the impact of the differences between simulation and reality, as well as any uncertainties in the SLS design. Two primary categories of uncertainty arise during the launch vehicle design process. The first represents flight-day uncertainties including dispersions due to winds and temperatures. These are typically examined by performing a Monte Carlo on 6 Degree of Freedom (6-DOF) simulations. The second category of uncertainties represents any manufacturing variations that are present at the individual component level of the launch vehicle design. These variations are constructed using statistical masses and tend to become better understood and refined as the design cycle matures, finally resulting in the launch vehicle as constructed and tested.

Stein, W. B.↗
NASA NTRS2019

Additive Manufacturing Technologies for Aerospace Applications

An overview will be provided on NASA GRC activities in additive manufacturing (AM) technology development for advanced high performance, propulsion component designs in electric motors and turbine engine systems in future electrified aircraft. AM offers significant benefits over conventional manufacturing to fabricate components that are more compact, lighter weight, geometrically complex, innovatively cooled, integrated, multi-material, and multifunctional. For turbine engine applications, silicon carbide (SiC) based composites are being pursued using binder jetting. For electric motor applications, additive processes are being applied toward optimized component designs to include the housing, rotor, and stators with 3-D printing and wire imbedded coils and with direct printed 3-phase coils. The will be an emphasis on capabilities in additive manufacturing.

Halbig, Michael C.↗