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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 469 records · Page 26
All sourcesNASA NTRSDOE OSTI
NASA NTRS2013

ISS-based Development of Elements and Operations for Robotic Assembly of A Space Solar Power Collector

We present a concept for an ISS-based optical system assembly demonstration designed to advance technologies related to future large in-space optical facilities deployment, including space solar power collectors and large-aperture astronomy telescopes. The large solar power collector problem is not unlike the large astronomical telescope problem, but at least conceptually it should be easier in principle, given the tolerances involved. We strive in this application to leverage heavily the work done on the NASA Optical Testbed Integration on ISS Experiment (OpTIIX) effort to erect a 1.5 m imaging telescope on the International Space Station (ISS). Specifically, we examine a robotic assembly sequence for constructing a large (meter diameter) slightly aspheric or spherical primary reflector, comprised of hexagonal mirror segments affixed to a lightweight rigidizing backplane structure. This approach, together with a structured robot assembler, will be shown to be scalable to the area and areal densities required for large-scale solar concentrator arrays.

astronomy↗
NASA NTRS2016

Looking Back in Time: Building the James Webb Space Telescope (JWST) Optical Telescope Element

When it launches in 2018, the James Webb Space Telescope (JWST) will look back in time at the earliest stars and galaxies forming in the universe. This talk will look back in time at the development of the JWST telescope. This will include a discussion of the design, technology development, mirror development, wave front sensing and control algorithms, lightweight cryogenic deployable structure, pathfinder telescope, and integration and test program evolution and status. The talk will provide the engineering answers on why the mirrors are made of Beryllium, why there are 18 segments, where and how the mirrors were made, how the mirrors get aligned using the main science camera, and how the telescope is being tested. It will also look back in time at the many dedicated people all over the country who helped build it.

JWST OTE↗
NASA NTRS2016

Meeting the Grand Challenge of Protecting Astronauts Health: Electrostatic Active Space Radiation Shielding for Deep Space Missions

This report describes the research completed during 2011 for the NASA Innovative Advanced Concepts (NIAC) project. The research is motivated by the desire to safely send humans in deep space missions and to keep radiation exposures within permitted limits. To this end current material shielding, developed for low earth orbit missions, is not a viable option due to payload and cost penalties. The active radiation shielding is the path forward for such missions. To achieve active space radiation shielding innovative large lightweight gossamer space structures are used. The goal is to deflect enough positive ions without attracting negatively charged plasma and to investigate if a charged Gossamer structure can perform charge deflections without significant structural instabilities occurring. In this study different innovative configurations are explored to design an optimum active shielding. In addition, to establish technological feasibility experiments are performed with up to 10kV of membrane charging, and an electron flux source with up to 5keV of energy and 5mA of current. While these charge flux energy levels are much less than those encountered in space, the fundamental coupled interaction of charged Gossamer structures with the ambient charge flux can be experimentally investigated. Of interest are, will the EIMS remain inflated during the charge deflections, and are there visible charge flux interactions. Aluminum coated Mylar membrane prototype structures are created to test their inflation capability using electrostatic charging. To simulate the charge flux, a 5keV electron emitter is utilized. The remaining charge flux at the end of the test chamber is measured with a Faraday cup mounted on a movable boom. A range of experiments with this electron emitter and detector were performed within a 30x60cm vacuum chamber with vacuum environment capability of 10-7 Torr. Experiments are performed with the charge flux aimed at the electrostatically inflated membrane structure (EIMS) in both charged and uncharged configurations. The amount of charge shielding behind and around the EIMS was studied for different combinations of membrane structure voltages and electron energies. Both passive and active shielding were observed, with active shielding capable of deflecting nearly all incoming electrons. The pattern of charge distribution around the structure was studied as well as the stability of the structures in the charge flow. The charge deflection experiments illustrate that the EIMS remain inflated during charge deflection, but will experience small amplitude oscillations. Investigations were performed to determine a potential cause of the vibrations. It is postulated these vibrations are due to the charge flux causing local membrane charge distribution changes. As the membrane structure inflation pressure is changed, the shape responds, and causes the observed sustained vibration. Having identified this phenomenon is important when considering electrostatically inflated membrane structures (EIMS) in a space environment. Additionally, this project included a study of membrane material impacts, specifically the impact of membrane thickness. Extremely thin materials presented new challenges with vacuum preparation techniques and rapid charging. The thinner and lighter membrane materials were successfully inflated using electrostatic forces in a vacuum chamber. However, care must be taken when varying the potentials of such lighter structures as the currents can cause local heating and melting of the very thin membranes. Lastly, a preliminary analysis is performed to study rough order of magnitude power requirements for using EIMS for radiation shielding. The EIMS power requirement becomes increasingly more challenging as the spacecraft voltage is increased. As a result, the emphasis is on the deflection of charges away from the spacecraft rather than totally stopping them. This significantly alleviates the initial power requirements. With modest technological development(s) active shielding is emerging to be a viable option.

Radiation↗
NASA NTRS2015

Ames Modular Common Spacecraft Bus

The Ames Modular Common Spacecraft Bus is a lightweight carbon composite structure designed to accommodate launch loads and provide attenuation of impact loads. It is also designed for ease of manufacturing and assembly. The modularity of the design is intended not only for multiple mission configurations,but also parallelism in development and assembly. The system-level components were drawn from low-cost flight-proven product lines.

Common bus↗
NASA NTRSDate not supplied

A Theoretical Model of Static and Dynamic Field-of-View (FOV) using NASA's Neutral Buoyancy Laboratory (NBL)

Developing an objective field-of-view methodology for studying vehicle window placement has been somewhat difficult. It is not surprising that considerable effort has been directed at specific problems of visibility from vehicles. Aeronautical design engineers know when designing an aircraft cockpit, the pilot must have an adequate view for approaching and landing on an airfield. However, compromise between the ergonomic preference for the largest possible viewing envelope and the practicalities of arranging a structure that is lightweight and strong will always plague the cockpit’s transparent area’s size and shape. The human’s visual sense, when operating any kind of vehicle, is the main source of the vast majority of information needed to drive or fly safely. However, vehicle design can affect a driver’s visual performance for satisfying their need for information. For any vehicle, be it an automobile or a spacecraft, the visibility quantity is the sum total of the visual access to the environment as defined by the window placement of that vehicle. The Alternate Multiple Mission Space Exploration Vehicle (AMMSEV) configuration is much like a large cargo truck where there is no direct visual access to the rear of the vehicle or the rear sides of the vehicle; thus, making the forward and side views of greater importance to the situational awareness of the crew if obstructions are creating visual issues. The National Aeronautics and Space Administration (NASA) tested a new theoretical model for Field-of-View (FOV) of spacecraft windows in NASA’s own Neutral Buoyancy Laboratory (NBL). The NBL is an essential tool for design, testing and development of future space exploration hardware for upcoming NASA operational missions. Using water, with its natural propensity for giving a human the perception of dynamic body motion under a weightless or partial gravity conditions, gives human factors investigators a vigorous space-like environment to study new methods of collecting dynamic field-of-view for future exploration vehicle designs.

Human Factors↗
DOE OSTI2025

Mechanical Properties and Interfacial Bonding of Overmolded Polymer Composite Lattice Structures

This study investigates the mechanical properties and interfacial bonding of Polyamide 12 filled with Glass Fiber (PA12/GF) lattice structures overmolded with Nylon 66 (PA66) and Thermoplastic Polyurethane (TPU). The PA12/GF lattices, designed in Gyroid, Isotruss, and Octahedral geometries, were produced using the Selective Laser Sintering (SLS) technique. The thermal characteristics of both the lattice and overmolding materials were analyzed using Differential Scanning Calorimetry (DSC) and Thermogravimetric Analysis (TGA). The mechanical performance and interfacial bonding were evaluated through mechanical testing and microstructural analysis. The results indicate that overmolding improved flexural strength and impact resistance of the PA12/GF lattices. For instance, the plain PA12/GF Isotruss lattice exhibited a flexural strength of 15.5 MPa. By overmolding it with TPU the flexural strength increased by up to 137%, while PA66-overmolding resulted in an increase of 371%, achieving a flexural strength of 73 MPa. In terms of impact resistance, TPU-overmolding improved performance significantly, with an increase of 1800% (Gyroid) compared to the plain lattice. Microstructural analysis revealed good adhesion at the interface, especially when both the lattice and overmolding materials were thoroughly dried prior to the overmolding process to minimize interfacial porosity. This study highlights the potential of using overmolding to enhance lattice structures performance, offering lightweight and cost-efficient solutions for automotive applications.

Talabi, Isaac [ORNL] (ORCID:0000000340215594)↗
NASA NTRS2015

Structural Sizing Methodology for the Tendon-Actuated Lightweight In-Space MANipulator (TALISMAN) System

The Tendon-Actuated Lightweight In-Space MANipulator (TALISMAN) is a versatile long-reach robotic manipulator that is currently being tested at NASA Langley Research Center. TALISMAN is designed to be highly mass-efficient and multi-mission capable, with applications including asteroid retrieval and manipulation, in-space servicing, and astronaut and payload positioning. The manipulator uses a modular, periodic, tension-compression design that lends itself well to analytical modeling. Given the versatility of application for TALISMAN, a structural sizing methodology was developed that could rapidly assess mass and configuration sensitivities for any specified operating work space, applied loads and mission requirements. This methodology allows the systematic sizing of the key structural members of TALISMAN, which include the truss arm links, the spreaders and the tension elements. This paper summarizes the detailed analytical derivations and methodology that support the structural sizing approach and provides results from some recent TALISMAN designs developed for current and proposed mission architectures.

Jones, Thomas C.↗
NASA NTRSDate not supplied

History of Structural Stitching Development for Aerospace Applications

Layered composite structures are a commonly used, lightweight option for aerospace vehicles today. However, these structures are prone to delamination between plies as well as separation between co-cured sections such as skins and flanges. In addition, delamination can easily be induced by impact damage from events such as tool drops and hailstones. Since such delaminations are often not visible from the external surface of the structure, additional material or fasteners must be included in the design to ensure the structure will maintain the required load-carrying ability through its lifetime. However, adding extra material increases weight and reduces structural efficiency and adding fasteners and their associated holes reduces manufacturing efficiency and adds the requirement to inspect the holes since they could become crack initiation points. Alternate means to reduce delaminations could be beneficial. An alternative to these options is to build the structure with through-thickness reinforcement, such as using stitching threads, to limit delamination, increase out-of-plane strength, and provide a method to join structural elements together without fasteners. The history of through-thickness stitching as it could be applied to aerospace vehicles is described in this paper.

carbon-epoxy↗
NASA NTRS2006

Manufacturing Precise, Lightweight Paraboloidal Mirrors

A process for fabricating a precise, diffraction- limited, ultra-lightweight, composite- material (matrix/fiber) paraboloidal telescope mirror has been devised. Unlike the traditional process of fabrication of heavier glass-based mirrors, this process involves a minimum of manual steps and subjective judgment. Instead, this process involves objectively controllable, repeatable steps; hence, this process is better suited for mass production. Other processes that have been investigated for fabrication of precise composite-material lightweight mirrors have resulted in print-through of fiber patterns onto reflecting surfaces, and have not provided adequate structural support for maintenance of stable, diffraction-limited surface figures. In contrast, this process does not result in print-through of the fiber pattern onto the reflecting surface and does provide a lightweight, rigid structure capable of maintaining a diffraction-limited surface figure in the face of changing temperature, humidity, and air pressure. The process consists mainly of the following steps: 1. A precise glass mandrel is fabricated by conventional optical grinding and polishing. 2. The mandrel is coated with a release agent and covered with layers of a carbon- fiber composite material. 3. The outer surface of the outer layer of the carbon-fiber composite material is coated with a surfactant chosen to provide for the proper flow of an epoxy resin to be applied subsequently. 4. The mandrel as thus covered is mounted on a temperature-controlled spin table. 5. The table is heated to a suitable temperature and spun at a suitable speed as the epoxy resin is poured onto the coated carbon-fiber composite material. 6. The surface figure of the optic is monitored and adjusted by use of traditional Ronchi, Focault, and interferometric optical measurement techniques while the speed of rotation and the temperature are adjusted to obtain the desired figure. The proper selection of surfactant, speed or rotation, viscosity of the epoxy, and temperature make it possible to obtain the desired diffraction-limited, smooth (1/50th wave) parabolic outer surface, suitable for reflective coating. 7. A reflective coat is applied by use of conventional coating techniques. 8. Once the final figure is set, a lightweight structural foam is applied to the rear of the optic to ensure stability of the figure.

Hermann, Frederick Thomas↗
NASA NTRS1978

Fabrication of composite shell structure for advanced space transportation

It is pointed out that future space missions, such as those involving spacecraft and structural assemblies to be used in geosynchronous orbits, will require ultralightweight composite structures to achieve maximum payloads. Of equal importance is the requirement to provide designs that are cost-competitive with metal designs. For space structures that must resist buckling, graphite-epoxy materials offer an attractive potential for providing lightweight, low-cost structural components that will meet future space mission requirements. A description is presented of a program which was conducted to evaluate the merits of graphite-epoxy cylindrical shells and to continue the development of a design data base for ultralightweight structures. An objective of the program was to design, fabricate, and test a corrugated graphite-epoxy cylinder 10 ft in diameter and 10 ft long.

Penton, A. P.↗
NASA NTRS2006

Surface Control of Cold Hibernated Elastic Memory Self-Deployable Structure

A new class of simple, reliable, lightweight, low packaging volume and cost, self-deployable structures has been developed for use in space and commercial applications. This technology called 'cold hibernated elastic memory' (CHEM) utilizes shape memory polymers (SMP)in open cellular (foam) structure or sandwich structures made of shape memory polymer foam cores and polymeric composite skins. Some of many potential CHEM space applications require a high precision deployment and surface accuracy during operation. However, a CHEM structure could be slightly distorted by the thermo-mechanical processing as well as by thermal space environment Therefore, the sensor system is desirable to monitor and correct the potential surface imperfection. During these studies, the surface control of CHEM smart structures was demonstrated using a Macro-Fiber Composite (MFC) actuator developed by the NASA LaRC and US Army ARL. The test results indicate that the MFC actuator performed well before and after processing cycles. It reduced some residue compressive strain that in turn corrected very small shape distortion after each processing cycle. The integrated precision strain gages were detecting only a small flat shape imperfection indicating a good recoverability of original shape of the CHEM test structure.

glass transition temperature Tg↗
NASA NTRS1991

Open-Section Composite Structural Elements

Report describes investigation of manufacture and mechanical properties of graphite-fiber/aluminum-matrix open-section structural elements; e.g., channels and angle bars. Conducted with view toward using such elements to build lightweight, thermally stable truss structures in outer space. Other applications transport to, and assembly at, remote or otherwise uninviting locations. Advantages include shapes permitting high packing density during shipment, convenient paths for routing tubes, hoses, and cables; accessibility of both inner and outer surfaces for repair; and ease of attachment of additional hardware. Easier and require less equipment to fabricate, and more amenable to automated fabrication and assembly at remote site. Disadvantages, not as resistant to some kinds of deformation under load.

Loftin, T. A.↗
NASA NTRS2010

Polyimide Aerogels with Three-Dimensional Cross-Linked Structure

Polyimide aerogels with three-dimensional cross-linked structure are made using linear oligomeric segments of polyimide, and linked with one of the following into a 3D structure: trifunctional aliphatic or aromatic amines, latent reactive end caps such as nadic anhydride or phenylethynylphenyl amine, and silica or silsesquioxane cage structures decorated with amine. Drying the gels supercritically maintains the solid structure of the gel, creating a polyimide aerogel with improved mechanical properties over linear polyimide aerogels. Lightweight, low-density structures are desired for acoustic and thermal insulation for aerospace structures, habitats, astronaut equipment, and aeronautic applications. Aerogels are a unique material for providing such properties because of their extremely low density and small pore sizes. However, plain silica aerogels are brittle. Reinforcing the aerogel structure with a polymer (X-Aerogel) provides vast improvements in strength while maintaining low density and pore structure. However, degradation of polymers used in cross-linking tends to limit use temperatures to below 150 C. Organic aerogels made from linear polyimide have been demonstrated, but gels shrink substantially during supercritical fluid extraction and may have lower use temperature due to lower glass transition temperatures. The purpose of this innovation is to raise the glass transition temperature of all organic polyimide aerogel by use of tri-, tetra-, or poly-functional units in the structure to create a 3D covalently bonded network. Such cross-linked polyimides typically have higher glass transition temperatures in excess of 300 400 C. In addition, the reinforcement provided by a 3D network should improve mechanical stability, and prevent shrinkage on supercritical fluid extraction. The use of tri-functional aromatic or aliphatic amine groups in the polyimide backbone will provide such a 3D structure.

Panek, John↗
NASA NTRS1972

Electron beam welding of aircraft structures

Requirements for advanced aircraft have led to more extensive use of titanium alloys and the resultant search for joining processes which can produce lightweight, high strength airframe structures efficiently. As a result, electron beam welding has been investigated. The following F-14A components are now being EB welded in production and are mainly annealed Ti-6Al-4V except for the upper wing cover which is annealed Ti-6Al-6V-2Sn: F-14A wing center section box, and F-14A lower and upper wing covers joined to wing pivot fitting assemblies. Criteria for selection of welding processes, the EB welding facility, development work on EB welding titanium alloys, and F-14A production and sliding seal electron beam welding are reported.

Witt, R. H.↗
NASA NTRS2005

Structural Benchmark Tests of Composite Combustion Chamber Support Completed

A series of mechanical load tests was completed on several novel design concepts for extremely lightweight combustion chamber support structures at the NASA Glenn Research Center (http://www.nasa.gov/glenn/). The tests included compliance evaluation, preliminary proof loadings, high-strain cyclic testing, and finally residual strength testing of each design (see the photograph on the left). Loads were applied with single rollers (see the photograph on the right) or pressure plates (not shown) located midspan on each side to minimize the influence of contact stresses on corner deformation measurements. Where rollers alone were used, a more severe structural loading was produced than the corresponding equal-force pressure loading: the maximum transverse shear force existed over the entire length of each side, and the corner bending moments were greater than for a distributed (pressure) loading. Failure modes initiating at the corner only provided a qualitative indication of the performance limitations since the stress state was not identical to internal pressure. Configurations were tested at both room and elevated temperatures. Experimental results were used to evaluate analytical prediction tools and finite-element methodologies for future work, and they were essential to provide insight into the deformation at the corners. The tests also were used to assess fabrication and bonding details for the complicated structures. They will be used to further optimize the design of the support structures for weight performance and the efficacy of corner reinforcement.

Krause, David L.↗
NASA NTRS2008

Seal Technology for Hypersonic Vehicle and Propulsion: An Overview

Hypersonic vehicles and propulsion systems pose an extraordinary challenge for structures and materials. Airframes and engines require lightweight, high-temperature materials and structural configurations that can withstand the extreme environment of hypersonic flight. Some of the challenges posed include very high temperatures, heating of the whole vehicle, steady-state and transient localized heating from shock waves, high aerodynamic loads, high fluctuating pressure loads, potential for severe flutter, vibration, and acoustic loads and erosion. Correspondingly high temperature seals are required to meet these aggressive requirements. This presentation reviews relevant seal technology for both heritage (e.g. Space Shuttle, X-15, and X-38) vehicles and presents several seal case studies aimed at providing lessons learned for future hypersonic vehicle seal development. This presentation also reviews seal technology developed for the National Aerospace Plane propulsion systems and presents several seal case studies aimed at providing lessons learned for future hypersonic propulsion seal development.

Steinetz, Bruce M.↗
NASA NTRS2003

New Method Developed To Purify Single Wall Carbon Nanotubes for Aerospace Applications

Single wall carbon nanotubes have attracted considerable attention because of their remarkable mechanical properties and electrical and thermal conductivities. Use of these materials as primary or secondary reinforcements in polymers or ceramics could lead to new materials with significantly enhanced mechanical strength and electrical and thermal conductivity. Use of carbon-nanotube-reinforced materials in aerospace components will enable substantial reductions in component weight and improvements in durability and safety. Potential applications for single wall carbon nanotubes include lightweight components for vehicle structures and propulsion systems, fuel cell components (bipolar plates and electrodes) and battery electrodes, and ultra-lightweight materials for use in solar sails. A major barrier to the successful use of carbon nanotubes in these components is the need for methods to economically produce pure carbon nanotubes in large enough quantities to not only evaluate their suitability for certain applications but also produce actual components. Most carbon nanotube synthesis methods, including the HiPCO (high pressure carbon monoxide) method developed by Smalley and others, employ metal catalysts that remain trapped in the final product. These catalyst impurities can affect nanotube properties and accelerate their decomposition. The development of techniques to remove most, if not all, of these impurities is essential to their successful use in practical applications. A new method has been developed at the NASA Glenn Research Center to purify gram-scale quantities of single wall carbon nanotubes. This method, a modification of a gas phase purification technique previously reported by Smalley and others, uses a combination of high-temperature oxidations and repeated extractions with nitric and hydrochloric acid. This improved procedure significantly reduces the amount of impurities (catalyst and nonnanotube forms of carbon) within the nanotubes, increasing their stability significantly. The onset of decomposition of the purified nanotubes (determined by thermal gravimetric analysis in air) is more than 300 C higher than that of the crude nanotubes. Transmission electron microscopy analysis of nanotubes purified by this method reveals near complete removal of iron catalyst particles. Analysis of the nanotubes using inductively coupled plasma spectroscopy revealed that the iron content of the nanotubes was reduced from 22.7 wt% in the crude nanotubes to less than 0.02 wt%. X-ray photoelectron spectroscopy revealed a decrease in iron content after purification as well as an increase in oxygen content due to the formation of carboxylic acid groups on the surface of the nanotubes. Nanotubes purified by this improved method can be readily dispersed in common organic solvents, in particular N,N-dimethylformamide, using prolonged ultrasonic treatment. These dispersions can then be used to incorporate single wall carbon nanotubes into polymer films.

Lebron, Marisabel↗