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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 NTRS2018

TPSAS-NF1676L-32008-DND

Thermosphere climate is controlled in part by cooling to space driven by infrared radiation, primarily from nitric oxide (NO, 5.3μm) and carbon dioxide (CO2, 15μm). The Sounding of the Atmosphere using Broadband Emission Radiometry (SABER) instrument on the Thermosphere-Ionosphere-Mesosphere Energetics and Dynamics (TIMED) satellite has been measuring the vertical distribution of infrared radiation emitted by these species (and others) for nearly 17 years-–more than 6000 days. This data set spans much of Solar Cycle (SC) 23 and all of SC 24 to date. A thermosphere climate index (TCI) has been derived by noting the correlation between 60-day running averages of NO cooling power and three long-term solar and geomagnetic indexes: F10.7 cm solar radio flux, the Ap index of geoeffective solar activity, and the disturbance storm time (Dst) index. A multiple linear regression (MLR) fit of these three parameters to the NO cooling rate over the SABER mission has a better than 0.98 correlation. Applying the MLR constant and coefficients from that fit provides a good estimate of thermospheric cooling back to 1947, the extent of the data available for all three indexes. We examined the percentile distribution of the TCI in quintiles over the five complete solar cycles, and assigned.

Linda Hunt↗
NASA NTRS2005

Study of a 30-M Boom For Solar Sail-Craft: Model Extendibility and Control Strategy

Space travel propelled by solar sails is motivated by the fact that the momentum exchange that occurs when photons are reflected and/or absorbed by a large solar sail generates a small but constant acceleration. This acceleration can induce a constant thrust in very large sails that is sufficient to maintain a polar observing satellite in a constant position relative to the Sun or Earth. For long distance propulsion, square sails (with side length greater than 150 meters) can reach Jupiter in two years and Pluto in less than ten years. Converting such design concepts to real-world systems will require accurate analytical models and model parameters. This requires extensive structural dynamics tests. However, the low mass and high flexibility of large and light weight structures such as solar sails makes them unsuitable for ground testing. As a result, validating analytical models is an extremely difficult problem. On the other hand, a fundamental question can be asked. That is whether an analytical model that represents a small-scale version of a solar-sail boom can be extended to much larger versions of the same boom. To answer this question, we considered a long deployable boom that will be used to support the solar sails of the sail-craft. The length of fully deployed booms of the actual solar sail-craft will exceed 100 meters. However, the test-bed we used in our study is a 30 meter retractable boom at MSFC. We first develop analytical models based on Lagrange s equations and the standard Euler-Bernoulli beam. Then the response of the models will be compared with test data of the 30 meter boom at various deployed lengths. For this stage of study, our analysis was limited to experimental data obtained at 12ft and 18ft deployment lengths. The comparison results are positive but speculative. To observe properly validate the analytic model, experiments at longer deployment lengths, up to the full 30 meter, have been requested. We expect the study to answer the extendibility question of the analytical models. In operation, rapid temperature changes can be induced in solar sails as they transition from day to night and vice versa. This generates time dependent thermally induced forces, which may in turn create oscillation in structural members such as booms. Such oscillations have an adverse effect on system operations, precise pointing of instruments and antennas and can lead to self excited vibrations of increasing amplitude. The latter phenomenon is known as thermal flutter and can lead to the catastrophic failure of structural systems. To remedy this problem, an active vibration suppression system has been developed. It was shown that piezoelectric actuators used in conjunction with a Proportional Feedback Control (PFC) law (or Velocity Feedback Control (VFC) law) can induce moments that can suppress structural vibrations and prevent flutter instability in spacecraft booms. In this study, we will investigate control strategies using piezoelectric transducers in active, passive, and/or hybrid control configurations. Advantages and disadvantages of each configuration will be studied and experiments to determine their capabilities and limitations will be planned. In particular, special attention will be given to the hybrid control, also known as energy recycling, configuration due to its unique characteristics.

Keel, Leehyun↗
NASA NTRS1998

MAP stability, design, and analysis

The Microwave Anisotropy Probe (MAP) is a follow-on to the Differential Microwave Radiometer (DMR) instrument on the Cosmic Background Explorer (COBE) spacecraft. The design and analysis of the MAP attitude control system (ACS) have been refined since work previously reported. The full spacecraft and instrument flexible model was developed in NASTRAN, and the resulting flexible modes were plotted and reduced with the Modal Significance Analysis Package (MSAP). The reduced-order model was used to perform the linear stability analysis for each control mode, the results of which are presented in this paper. Although MAP is going to a relatively disturbance-free Lissajous orbit around the Earth-Sun L(2) Lagrange point, a detailed disturbance-torque analysis is required because there are only a small number of opportunities for momentum unloading each year. Environmental torques, including solar pressure at L(2), aerodynamic and gravity gradient during phasing-loop orbits, were calculated and simulated. Thruster plume impingement torques that could affect the performance of the thruster modes were estimated and simulated, and a simple model of fuel slosh was derived to model its effect on the motion of the spacecraft. In addition, a thruster mode linear impulse controller was developed to meet the accuracy requirements of the phasing loop burns. A dynamic attitude error limiter was added to improve the performance of the ACS during large attitude slews. The result of this analysis is a stable ACS subsystem that meets all of the mission's requirements.

Ericsson-Jackson, A. J.↗
NASA NTRS2001

Solar Cycle Variations and Equatorial Oscillations: Modeling Study

Solar cycle activity effects (SCAE) in the lower and middle atmosphere, reported in several studies, are difficult to explain on the basis of the small changes in solar radiation that accompany the 11-year cycle, It is therefore natural to speculate that dynamical processes may come into play to produce a leverage. Such a leverage may be provided by the Quasi-Biennial Oscillation (QBO) in the zonal circulation of the stratosphere, which has been linked to solar activity variations. Driven primarily by wave mean flow interaction, the QBO period and its amplitude are variable but are also strongly influenced by the seasonal cycle in the solar radiation. This influence extends to low altitudes referred to as "downward control". Relatively small changes in solar radiative forcing can produce small changes in the period and phase of the QBO, but this in turn can produce measurable differences in the wind field. Thus, the QBO may be an amplifier of solar activity variations and a natural conduit of these variations to lower altitudes. To test this hypothesis, we conducted experiments with a 2D (two-dimensional) version of our Numerical Spectral Model that incorporates Hines' Doppler Spread Parameterization for small-scale gravity waves (GW). Solar cycle radiance variations (SCRV) are accounted for by changing the radiative heating rate on a logarithmic scale from 0.1 % at the surface to 1 % at 50 km to 10% at 100 km. With and without SCRV, but with the same GW flux, we then conduct numerical experiments to evaluate the magnitude of the SCAE in the zonal circulation. The numerical results indicate that, under certain conditions, the SCAE is significant and can extend to lower altitudes where the SCRV is inconsequential. At 20-km the differences in the modeled wind velocities are as large as 5 m/s. For a modeled QBO period of 30 months, we find that the seasonal cycle in the solar forcing (through the Semi-annual Oscillation (SAO)) acts as a strong pacemaker to lockup the phase and period of the QBO. The SCAE then shows up primarily as a distinct but relatively weak amplitude modulation. But with the QBO period between 30 and 34 (or less than 30, presumably) months, the seasonal phase lock is weak. Solar flux radiance variations in the seasonal cycle then cause variations in the QBO period and phase that amplify the SCAE to produce relatively large variations in the wind field. These variations also extend to mid latitudes.

Mayr, H. G.↗
DOE OSTI2025

Comprehensive assessment of deep reinforcement learning approaches for economic dispatch in nuclear-driven microgrids

As the electrical grid integrates more variable renewable energy sources such as wind and solar, the demand for distributed and flexible systems to address this increased variability becomes critical. Nuclear-driven microgrids provide a promising solution by offering stable generation to complement intermittent renewables, ensuring grid reliability and operating efficiency. This paper proposes a recurrent deep reinforcement learning framework for optimal economic dispatch in a nuclear-powered microgrid integrating renewable energy sources, small modular reactors, battery storage systems, and balance-of-plant dynamics. A three-agent control architecture is developed, where demand and renewable energy agents act as forecasters, and a reinforcement learning-based dispatch agent performs real-time energy allocation. A nonlinear programming formulation is first used to generate an optimal baseline for benchmarking. The proposed dispatch controller, based on Proximal Policy Optimization enhanced with Long Short-Term Memory networks, exploits temporal correlations in system dynamics by taking advantage of the time series used as inputs to improve policy robustness under uncertainty. Comparative analysis against established deep reinforcement learning methods, including Proximal Policy Optimization with a feedforward architecture, Soft Actor-Critic, and Twin Delayed Deep Deterministic Policy Gradient, demonstrates superior performance. Numerical results indicate that the proposed controller achieves a 0.39% cost reduction relative to the nonlinear programming benchmark and outperforms other learning-based methods by generating additional revenue of up to 0.35%. All reinforcement learning controllers compute dispatch actions in less than 0.3 s, resulting in a computational speedup of more than three orders of magnitude over the nonlinear programming baseline. The findings of this paper highlight their applicability for real-time operation and control in nuclear-integrated microgrids under volatile operating conditions.

24 POWER TRANSMISSION AND DISTRIBUTION↗
NASA NTRS1986

A review of modelling techniques for the open and closed-loop dynamics of large space systems

This paper reviews the steps in the development of mathematical models that can be used to simulate the in-orbit dynamic behavior of large flexible systems. A general continuum formulation is compared with the hybrid coordinate formulation and also a finite element representation of the total system. A review of structural analysis routines emphasizes the use of computer generated graphics to help understand the different modal elastic shape functions of complex systems. Numerical techniques employed to synthesize shape and attitude control laws are summarized. Finally, the modeling of environmental disturbance torques due to the interaction of solar radiation pressure on vibrating and thermally deflected systems is discussed.

Bainum, Peter M.↗
DOE OSTI2024

A Simulation and Optimization Framework for Managing Wind-Driven Loading on PV Systems

As PV modules continue to trend toward larger, thinner, and more flexible forms they grow more susceptible to damage from dynamic wind loading. As a result, understanding the impact of wind on PV systems, particularly when mounted on solar-tracking hardware, and identifying robust, stable array layouts and stow strategies is becoming increasingly important for the PV community. We are developing an open-source software package, PVade (PV aerodynamic design engineering), to simulate the cascading fluid-structure interaction that occurs within solar-tracking arrays to enable researchers to test hardware, layout, and tracker control changes, leading to enhanced stability and a reduction in wind-driven damage. We will give an overview of the PVade software and present the latest outcomes from our ongoing validation campaign in which we compare statistical structural responses with field data. From there, we will present simulated results from a larger, multi-row array and highlight the effect of varying tracker angles on stability as measured by both acceleration and deformation, focusing on the stability differences between positive and negative tilt angles.

fluid structure interaction↗
NASA NTRS1981

The dynamics of a rapidly escaping atmosphere - Applications to the evolution of earth and Venus

A simple model for the rapid escape of a hydrogen thermosphere is presented in order to establish the energy-limited flux of escaping particles. The model assumes that the atmosphere is tightly bound by gravity at the lower boundary, that all the EUV is absorbed in a narrow region where the optical depth is unity, and that the main source of heating is solar EUV. The flux is limited by the amount of EUV energy absorbed, which is in turn controlled by the radial extent of the thermosphere. It is found that, regardless of the amount of hydrogen in the thermosphere, the low temperatures which accompany rapid escape limit its extent and thus constrain the flux. The results are applied to the earth and Venus, showing that the escape of hydrogen from these planets would have been energy-limiting if their primordial atmospheres contained total hydrogen mixing ratios exceeding only a few percent. This conclusion places a constraint on the theory of the origin and evolution of the planets.

Watson, A. J.↗
NASA NTRS1994

Advantages of estimating rate corrections during dynamic propagation of spacecraft rates: Applications to real-time attitude determination of SAMPEX

This paper describes real-time attitude determination results for the Solar, Anomalous, and Magnetospheric Particle Explorer (SAMPEX), a gyroless spacecraft, using a Kalman filter/Euler equation approach denoted the real-time sequential filter (RTSF). The RTSF is an extended Kalman filter whose state vector includes the attitude quaternion and corrections to the rates, which are modeled as Markov processes with small time constants. The rate corrections impart a significant robustness to the RTSF against errors in modeling the environmental and control torques, as well as errors in the initial attitude and rates, while maintaining a small state vector. SAMPLEX flight data from various mission phases are used to demonstrate the robustness of the RTSF against a priori attitude and rate errors of up to 90 deg and 0.5 deg/sec, respectively, as well as a sensitivity of 0.0003 deg/sec in estimating rate corrections in torque computations. In contrast, it is shown that the RTSF attitude estimates without the rate corrections can degrade rapidly. RTSF advantages over single-frame attitude determination algorithms are also demonstrated through (1) substantial improvements in attitude solutions during sun-magnetic field coalignment and (2) magnetic-field-only attitude and rate estimation during the spacecraft's sun-acquisition mode. A robust magnetometer-only attitude-and-rate determination method is also developed to provide for the contingency when both sun data as well as a priori knowledge of the spacecraft state are unavailable. This method includes a deterministic algorithm used to initialize the RTSF with coarse estimates of the spacecraft attitude and rates. The combined algorithm has been found effective, yielding accuracies of 1.5 deg in attitude and 0.01 deg/sec in the rates and convergence times as little as 400 sec.

Challa, M. S.↗
DOE OSTI2025

Photosynthesis Protein Collective Vibrations Role in Energy Transfer and Dissipation (Final Technical Report)

This project investigates how low‑frequency collective vibrations of photosynthetic proteins control energy transfer and dissipation, using terahertz (THz) spectroscopy and advanced theoretical analysis. The central hypothesis is that specific long‑range protein scaffold motions, rather than just local chromophore dynamics, steer exciton transport and photoprotection by modulating energy gaps and coupling between pigments.

14 SOLAR ENERGY↗
NASA NTRS1986

Space Station multidisciplinary analysis capability - IDEAS2

A computer-aided engineering tool now in use at NASA for systems engineering and integration analysis of the Space Station is described. This tool, called IDEAS2, combines the spacecraft-specific analysis software from NASA IDEAS (truss synthesizer, rigid body controls, plume impingement, orbital lifetime, orbit heat loads, and life support systems) with the interactive graphics, geometric database, solids modeler, structural and thermal analysis capability of the SDRC I-DEAS to obtain an integrated package suitable for Space Station design. This integrated package was applied to a very recent study of growth scenarios of the Space Station dual keel configuration, in which a comparison was made between designs using a combination of photovoltaic solar arrays and solar dynamic collectors, and those using only solar dynamic collectors.

Baker, M.↗
NASA NTRS1987

Impact of thermal energy storage properties on solar dynamic space power conversion system mass

A 16 parameter solar concentrator/heat receiver mass model is used in conjunction with Stirling and Brayton Power Conversion System (PCS) performance and mass computer codes to determine the effect of thermal energy storage (TES) material property changes on overall PCS mass as a function of steady state electrical power output. Included in the PCS mass model are component masses as a function of thermal power for: concentrator, heat receiver, heat exchangers (source unless integral with heat receiver, heat sink, regenerator), heat engine units with optional parallel redundancy, power conditioning and control (PC and C), PC and C radiator, main radiator, and structure. Critical TES properties are: melting temperature, heat of fusion, density of the liquid phase, and the ratio of solid-to-liquid density. Preliminary results indicate that even though overalll system efficiency increases with TES melting temperature up to 1400 K for concentrator surface accuracies of 1 mrad or better, reductions in the overall system mass beyond that achievable with lithium fluoride (LiF) can be accomplished only if the heat of fusion is at least 800 kJ/kg and the liquid density is comparable to that of LiF (1880 kg/cu m.

Juhasz, Albert J.↗
NASA NTRS1987

Impact of thermal energy storage properties on solar dynamic space power conversion system mass

A 16 parameter solar concentrator/heat receiver mass model is used in conjunction with Stirling and Brayton Power Conversion System (PCS) performance and mass computer codes to determine the effect of thermal energy storage (TES) material property changes on overall PCS mass as a function of steady state electrical power output. Included in the PCS mass model are component masses as a function of thermal power for: concentrator, heat receiver, heat exchangers (source unless integral with heat receiver, heat sink, regenerator), heat engine units with optional parallel redundancy, power conditioning and control (PC and C), PC and C radiator, main radiator, and structure. Critical TES properties are: melting temperature, heat of fusion, density of the liquid phase, and the ratio of solid-to-liquid density. Preliminary results indicate that even though overall system efficiency increases with TES melting temperature up to 1400 K for concentrator surface accuracies of 1 mrad or better, reductions in the overall system mass beyond that achievable with lithium fluoride (LiF) can be accomplished only if the heat of fusion is at least 800 kJ/kg and the liquid density is comparable to that of LiF (1800 kg/cu m).

Juhasz, Albert J.↗
NASA NTRS1995

Theoretical overview and modeling of the sodium and potassium atmospheres of mercury

A general theoretical overview for the sources, sinks, gas-surface interactions, and transport dynamics of sodium and potassium in the exospheric atmsophere of Mercury is given. Information for these four factors, which control the spatial distribution of these two alkali-group gases about the planet, is incorporated in numerical models. The spatial nature and relative importance of the initial source atom atmosphere and the ambient (ballistic hopping) atom atmosphere are then examined and are shown to be controlled and coupled to a great extent by the extremely large and variable solar radiation acceleration experienced by sodium and potassium as they resonantly scatter solar photons. The lateral (antisunward) transport rate of thermally accommodated sodium and potassium ambient atoms is shown to be driven by the solar radiation acceleration and, over a significant portion of Mercury's orbit about the Sun, is sufficiently rapid to be competitive with the short photoionization lifetimes for these atoms when they are located on the summit surface near or within about 30 deg of the terminator. The lateral transport rate is characterized by a migration time determined by model calculations for an ensemble of atoms initially starting at a point source on the surface (i.e., a numerical spacetime dependent Green's function). Four animations for the spacetime evolution of the sodium (or potassium) atmosphere produced by a point source on the surface are presented on a videotape format. For extended surface sources for sodium and potassium, the local column density is determined by competition between the photoionization lifetimes and the lateral transport times of atoms originating from different surface source locations. Sodium surface source fluxes (referenced to Mercury at perihelion) that are required on the sunlit hemisphere to reproduce the typically observed several megarayleighs of D2 emission-line brightness and the inferred column densities of 1-2 x 10(exp 11) atoms per sq cm range from approximately 2-5 x 10(exp 7) atoms/sq cm/sec. The sodium model is applied to study observational data that document an anticorrelation in the average sodium column density and solar radiation acceleration. Lateral transport driven by the solar radiation acceleration is shown to produce this behavior for combinations of different sources and surface accomodation coefficients. The best fit model fits to the observational data require a significant degree of thermal accommodation of the ambient sodium atoms to the surface and a source rate that decreases as an inverse power of 1.5 to 2 in heliocentric distance.

Smyth, William H.↗
NASA NTRS2002

Are Solar Activity Variations Amplified by the QBO: A Modeling Study

Solar cycle activity effects (SCAE) in the lower and middle atmosphere, reported in several studies, are difficult to explain on the basis of the small changes in solar radiation that accompany the 11-year cycle. It is therefore natural to speculate that dynamical processes may come into play to produce a leverage. Such a leverage may be provided by the Quasi-Biennial Oscillation (QBO) in the zonal circulation of the stratosphere, which has been linked to solar activity variations. Driven primarily by wave mean flow interaction, the QBO period and its amplitude are variable but are also strongly influenced by the seasonal cycle in the solar radiation. This influence extends to low altitudes and is referred to as 'downward control'. Small changes in the solar radiative forcing may produce small changes in the period and phase of the QBO, but these in turn may produce measurable differences in the wind field. Thus, the QBO may be an amplifier of solar activity variations and a natural conduit of these variations to lower altitudes. To test this hypothesis, we conducted experiments with a 2D version of our Numerical Spectral Model that incorporates Hines' Doppler Spread Parameterization for small-scale gravity waves (GW). Solar cycle radiance variations (SCRV) are accounted for by changing the radiative heating rate on a logarithmic scale from 0.1% at the surface to 1% at 50 km to 10% at 100 km. With and without SCRV, but with the same GW flux, we then conduct numerical experiments to evaluate the magnitude of the SCAE in the zonal circulation. The numerical results indicate that, under certain conditions, the SCAE is significant and can extend to lower altitudes where the SCRV is small. For a modeled QBO period of 30 months, we find that the seasonal cycle in the solar forcing acts as a strong pacemaker to lock up the phase and period of the QBO. The SCAE then shows up primarily as a distinct but relatively weak amplitude modulation. But with a different QBO period between 30 and 34 (or less than 30, presumably) months, the seasonal phase lock is weak. Solar flux variations in the seasonal cycle then cause variations in the QBO period and phase. These amplify the SCAE to produce relatively large variations in the wind field. The SCAE in this case extends to mid-latitudes.

Mengel, J. G.↗
NASA NTRS2003

Coupling the Solar-Wind/IMF to the Ionosphere through the High Latitude Cusps

Magnetic merging is a primary means for coupling energy from the solar wind into the magnetosphere-ionosphere system. The location and nature of the process remain as open questions. By correlating measurements form diverse locations and using large-scale MHD models to put the measurements in context, it is possible to constrain out interpretations of the global and meso-scale dynamics of magnetic merging. Recent evidence demonstrates that merging often occurs at high latitudes in the vicinity of the cusps. The location is in part controlled by the clock angle in the interplanetary magnetic field (IMF) Y-Z plane. In fact, B(sub Y) bifurcated the cusp relative to source regions. The newly opened field lines may couple to the ionosphere at MLT locations of as much as 3 hr away from local noon. On the other side of noon the cusp may be connected to merging sites in the opposite hemisphere. In face, the small convection cell is generally driven by opposite hemisphere merging. B(sub X) controls the timing of the interaction and merging sites in each hemisphere, which may respond to planar features in the IMF at different times. Correlation times are variable and are controlled by the dynamics of the tilt of the interplanetary electric field phase plane. The orientation of the phase plane may change significantly on time scales of tens of minutes. Merging is temporally variable and may be occurring at multiple sites simultaneously. Accelerated electrons from the merging process excite optical signatures at the foot of the newly opened field lines. All-sky photometer observations of 557.7 nm emissions in the cusp region provide a "television picture" of the merging process and may be used to infer the temporal and spatial variability of merging, tied to variations in the IMF.

Maynard, Nelson C.↗
NASA NTRS2008

25th Space Simulation Conference. Environmental Testing: The Earth-Space Connection

Topics covered include: Methods of Helium Injection and Removal for Heat Transfer Augmentation; The ESA Large Space Simulator Mechanical Ground Support Equipment for Spacecraft Testing; Temperature Stability and Control Requirements for Thermal Vacuum/Thermal Balance Testing of the Aquarius Radiometer; The Liquid Nitrogen System for Chamber A: A Change from Original Forced Flow Design to a Natural Flow (Thermo Siphon) System; Return to Mercury: A Comparison of Solar Simulation and Flight Data for the MESSENGER Spacecraft; Floating Pressure Conversion and Equipment Upgrades of Two 3.5kw, 20k, Helium Refrigerators; Affect of Air Leakage into a Thermal-Vacuum Chamber on Helium Refrigeration Heat Load; Special ISO Class 6 Cleanroom for the Lunar Reconnaissance Orbiter (LRO) Project; A State-of-the-Art Contamination Effects Research and Test Facility Martian Dust Simulator; Cleanroom Design Practices and Their Influence on Particle Counts; Extra Terrestrial Environmental Chamber Design; Contamination Sources Effects Analysis (CSEA) - A Tool to Balance Cost/Schedule While Managing Facility Availability; SES and Acoustics at GSFC; HST Super Lightweight Interchangeable Carrier (SLIC) Static Test; Virtual Shaker Testing: Simulation Technology Improves Vibration Test Performance; Estimating Shock Spectra: Extensions beyond GEVS; Structural Dynamic Analysis of a Spacecraft Multi-DOF Shaker Table; Direct Field Acoustic Testing; Manufacture of Cryoshroud Surfaces for Space Simulation Chambers; The New LOTIS Test Facility; Thermal Vacuum Control Systems Options for Test Facilities; Extremely High Vacuum Chamber for Low Outgassing Processing at NASA Goddard; Precision Cleaning - Path to Premier; The New Anechoic Shielded Chambers Designed for Space and Commercial Applications at LIT; Extraction of Thermal Performance Values from Samples in the Lunar Dust Adhesion Bell Jar; Thermal (Silicon Diode) Data Acquisition System; Aquarius's Instrument Science Data System (ISDS) Automated to Acquire, Process, Trend Data and Produce Radiometric System Assessment Reports; Exhaustive Thresholds and Resistance Checkpoints; Reconfigurable HIL Testing of Earth Satellites; FPGA Control System for the Automated Test of MicroShutters; Ongoing Capabilities and Developments of Re-Entry Plasma Ground Tests at EADS-ASTRIUM; Operationally Responsive Space Standard Bus Battery Thermal Balance Testing and Heat Dissipation Analysis; Galileo - The Serial-Production AIT Challenge; The Space Systems Environmental Test Facility Database (SSETFD), Website Development Status; Simulated Reentry Heating by Torching; Micro-Vibration Measurements on Thermally Loaded Multi-Layer Insulation Samples in Vacuum; High Temperature Life Testing of 80Ni-20Cr Wire in a Simulated Mars Atmosphere for the Sample Analysis at Mars (SAM) Instrument Suit Gas Processing System (GPS) Carbon Dioxide Scrubber; The Planning and Implementation of Test Facility Improvements; and Development of a Silicon Carbide Molecular Beam Nozzle for Simulation Planetary Flybys and Low-Earth Orbit.

Packard, Edward↗
DOE OSTI2024

Abrasive Waterjet Machining

The abrasive waterjet machining process was introduced in the 1980s as a new cutting tool; the process has the ability to cut almost any material. Currently, the AWJ process is used in many world-class factories, producing parts for use in daily life. A description of this process and its influencing parameters are first presented in this paper, along with process models for the AWJ tool itself and also for the jet–material interaction. The AWJ material removal process occurs through the high-velocity impact of abrasive particles, whose tips micromachine the material at the microscopic scale, with no thermal or mechanical adverse effects. The macro-characteristics of the cut surface, such as its taper, trailback, and waviness, are discussed, along with methods of improving the geometrical accuracy of the cut parts using these attributes. For example, dynamic angular compensation is used to correct for the taper and undercut in shape cutting. The surface finish is controlled by the cutting speed, hydraulic, and abrasive parameters using software and process models built into the controllers of CNC machines. In addition to shape cutting, edge trimming is presented, with a focus on the carbon fiber composites used in aircraft and automotive structures, where special AWJ tools and manipulators are used. Examples of the precision cutting of microelectronic and solar cell parts are discussed to describe the special techniques that are used, such as machine vision and vacuum-assist, which have been found to be essential to the integrity and accuracy of cut parts. The use of the AWJ machining process was extended to other applications, such as drilling, boring, milling, turning, and surface modification, which are presented in this paper as actual industrial applications. To demonstrate the versatility of the AWJ machining process, the data in this paper were selected to cover a wide range of materials, such as metal, glass, composites, and ceramics, and also a wide range of thicknesses, from 1 mm to 600 mm. The trends of Industry 4.0 and 5.0, AI, and IoT are also presented.

36 MATERIALS SCIENCE↗