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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS2002

3-D Flow Field Diagnostics and Validation Studies using Stereoscopic Tracking Velocimetry

The measurement of 3-D three-component velocity fields is of great importance in both ground and space experiments for understanding materials processing and fluid physics. Here, we present the investigation results of stereoscopic tracking velocimetry (STV) for measuring 3-D velocity fields. The effort includes diagnostic technology development, experimental velocity measurement, and comparison with analytical and numerical computation. The advantages of STV stems from the system simplicity for building compact hardware and in software efficiency for continual near-real-time process monitoring. It also has illumination flexibility for observing volumetric flow fields from arbitrary directions. STV is based on stereoscopic CCD observations of particles seeded in a flow. Neural networks are used for data analysis. The developed diagnostic tool is tested with a simple directional solidification apparatus using Succinonitrile. The 3-D velocity field in the liquid phase is measured and compared with results from detailed numerical computations. Our theoretical, numerical, and experimental effort has shown STV to be a viable candidate for reliably quantifying the 3-D flow field in materials processing and fluids experiments.

Cha, Soyoung Stephen↗
NASA NTRS2008

A New Concurrent Multiscale Methodology for Coupling Molecular Dynamics and Finite Element Analyses

The coupling of molecular dynamics (MD) simulations with finite element methods (FEM) yields computationally efficient models that link fundamental material processes at the atomistic level with continuum field responses at higher length scales. The theoretical challenge involves developing a seamless connection along an interface between two inherently different simulation frameworks. Various specialized methods have been developed to solve particular classes of problems. Many of these methods link the kinematics of individual MD atoms with FEM nodes at their common interface, necessarily requiring that the finite element mesh be refined to atomic resolution. Some of these coupling approaches also require simulations to be carried out at 0 K and restrict modeling to two-dimensional material domains due to difficulties in simulating full three-dimensional material processes. In the present work, a new approach to MD-FEM coupling is developed based on a restatement of the standard boundary value problem used to define a coupled domain. The method replaces a direct linkage of individual MD atoms and finite element (FE) nodes with a statistical averaging of atomistic displacements in local atomic volumes associated with each FE node in an interface region. The FEM and MD computational systems are effectively independent and communicate only through an iterative update of their boundary conditions. With the use of statistical averages of the atomistic quantities to couple the two computational schemes, the developed approach is referred to as an embedded statistical coupling method (ESCM). ESCM provides an enhanced coupling methodology that is inherently applicable to three-dimensional domains, avoids discretization of the continuum model to atomic scale resolution, and permits finite temperature states to be applied.

Yamakov, Vesselin↗
NASA NTRS2008

An Embedded Statistical Method for Coupling Molecular Dynamics and Finite Element Analyses

The coupling of molecular dynamics (MD) simulations with finite element methods (FEM) yields computationally efficient models that link fundamental material processes at the atomistic level with continuum field responses at higher length scales. The theoretical challenge involves developing a seamless connection along an interface between two inherently different simulation frameworks. Various specialized methods have been developed to solve particular classes of problems. Many of these methods link the kinematics of individual MD atoms with FEM nodes at their common interface, necessarily requiring that the finite element mesh be refined to atomic resolution. Some of these coupling approaches also require simulations to be carried out at 0 K and restrict modeling to two-dimensional material domains due to difficulties in simulating full three-dimensional material processes. In the present work, a new approach to MD-FEM coupling is developed based on a restatement of the standard boundary value problem used to define a coupled domain. The method replaces a direct linkage of individual MD atoms and finite element (FE) nodes with a statistical averaging of atomistic displacements in local atomic volumes associated with each FE node in an interface region. The FEM and MD computational systems are effectively independent and communicate only through an iterative update of their boundary conditions. With the use of statistical averages of the atomistic quantities to couple the two computational schemes, the developed approach is referred to as an embedded statistical coupling method (ESCM). ESCM provides an enhanced coupling methodology that is inherently applicable to three-dimensional domains, avoids discretization of the continuum model to atomic scale resolution, and permits finite temperature states to be applied.

Saether, E.↗
NASA NTRS2021

Development of an Additive Manufacturing Ecosystem for Qualification of Additive Manufacturing Processes and Materials in Aviation

The major challenges associated with additive manufacturing (AM) are an ability to qualify parts and the costs associated with the technology. Our team will study and mature technologies as detailed below to develop an ecosystem for the qualification of AM machines, which in turn supports the certification of part production. Additive manufacturing offers unique opportunities for the aviation industry in the fabrication of original components and replacement parts. Aggressive use of metals AM has, for example, allowed the rapid development and production of new launch vehicle designs, at substantially reduced costs. Aviation has unique challenges, such as higher production volumes, but the potential value of integrating AM into aviation manufacturing is clear. To implement the ecosystem for AM qualification, the team will run a set of six multi-disciplinary projects. Each of these projects will address a current barrier to AM process qualification, and efficient production.

Koushik Datta↗
NASA NTRS1976

Review of NASA activities in materials sciences in space

In the year since the 18th Plenary Meeting of COSPAR, NASA has conducted eight materials processing experiments on the Apollo-Soyuz mission and 17 on two rocket flights. In addition, these three missions have implemented one Soviet and three German experiments. The Apollo-Soyuz results have confirmed and extended the findings of the Skylab experiments on solidification and crystal growth effects and have also established capabilities for separating living cells by electrophoresis and returning them still living to earth. The rocket missions provide repetitive flight opportunities much as the Space Shuttle will do, and they are being used to develop research approaches in which investigators will undertake projects calling for multiple space experiments rather than proposing experiments individually. During the year, NASA has also completed definition work on the major payload facilities planned for its initial materials processing experiment program on the Space Shuttle and Spacelab missions of 1980-81.

Bredt, J. H.↗
NASA NTRS1993

Space Applications Industrial Laser System (SAILS)

A program is underway to develop a YAG laser based materials processing workstation to fly in the cargo bay of the Space Shuttle. This workstation, called Space Applications Industrial Laser System (SAILS), will be capable of cutting and welding steel, aluminum, and Inconel alloys of the type planned for use in constructing the Space Station Freedom. As well as demonstrating the ability of a YAG laser to perform remote (fiber-optic delivered) repair and fabrication operations in space, fundamental data will be collected on these interactions for comparison with terrestrial data and models. The flight system, scheduled to fly in 1996, will be constructed as three modules using standard Get-Away-Special (GAS) canisters. The first module holds the laser head and cooling system, while the second contains a high peak power electrical supply. The third module houses the materials processing workstation and the command and data acquisition subsystems. The laser head and workstation cansisters are linked by a fiber-optic cable to transmit the laser light. The team assembled to carry out this project includes Lumonics Industrial Products (laser), Tennessee Technological University (structural analysis and fabrication), Auburn University Center for Space Power (electrical engineering), University of Waterloo (low-g laser process consulting), and CSTAR/UTSI (data acquisition, control, software, integration, experiment design). This report describes the SAILS program and highlights recent activities undertaken at CSTAR.

Mccay, T. D.↗
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 NTRS2007

Large-Area Permanent-Magnet ECR Plasma Source

A 40-cm-diameter plasma device has been developed as a source of ions for material-processing and ion-thruster applications. Like the device described in the immediately preceding article, this device utilizes electron cyclotron resonance (ECR) excited by microwave power in a magnetic field to generate a plasma in an electrodeless (noncontact) manner and without need for an electrically insulating, microwave-transmissive window at the source. Hence, this device offers the same advantages of electrodeless, windowless design - low contamination and long operational life. The device generates a uniform, high-density plasma capable of sustaining uniform ion-current densities at its exit plane while operating at low pressure [<10(exp -4) torr (less than about 1.3 10(exp -2) Pa)] and input power <200 W at a frequency of 2.45 GHz. Though the prototype model operates at 2.45 GHz, operation at higher frequencies can be achieved by straightforward modification to the input microwave waveguide. Higher frequency operation may be desirable in those applications that require even higher background plasma densities. In the design of this ECR plasma source, there are no cumbersome, power-hungry electromagnets. The magnetic field in this device is generated by a permanent-magnet circuit that is optimized to generate resonance surfaces. The microwave power is injected on the centerline of the device. The resulting discharge plasma jumps into a "high mode" when the input power rises above 150 W. This mode is associated with elevated plasma density and high uniformity. The large area and uniformity of the plasma and the low operating pressure are well suited for such material-processing applications as etching and deposition on large silicon wafers. The high exit-plane ion-current density makes it possible to attain a high rate of etching or deposition. The plasma potential is <3 V low enough that there is little likelihood of sputtering, which, in plasma processing, is undesired because it is associated with erosion and contamination. The electron temperature is low and does not vary appreciably with power.

Foster, John E.↗
NASA NTRS1973

Parts, materials, and processes experience summary, volume 2

This summary provides the general engineering community with the accumulated experience from ALERT reports issued by NASA and the Government-Industry. Data Exchange Program, and related experience gained by Government and industry. It provides expanded information on selected topics by relating the problem area (failure) to the cause, the investigation and findings, the suggestions for avoidance (inspections, screening tests, proper part applications, requirements for manufacturer's plant facilities, etc.), and failure analysis procedures. Diodes, integrated circuits, and transistors are covered in this volume.

Source record↗
NASA NTRS1975

Contamination control in hybrid microelectronic modules. Part 3: Specifications for coating material and process controls

Resin systems for coating hybrids prior to hermetic sealing are described. The resin systems are a flexible silicone junction resin system and a flexible cycloaliphatic epoxy resin system. The coatings are intended for application to the hybrid after all the chips have been assembled and wire bonded, but prior to hermetic sealing of the package. The purpose of the coating is to control particulate contamination by immobilizing particles and by passivating the hybrid. Recommended process controls for the purpose of minimizing contamination in hybrid microcircuit packages are given. Emphasis is placed on those critical hybrid processing steps in which contamination is most likely to occur.

Himmel, R. P.↗
NASA NTRS1978

Interactive data-processing system for metallurgy

Equipment indicates that system can rapidly and accurately process metallurgical and materials-processing data for wide range of applications. Advantages include increase in contract between areas on image, ability to analyze images via operator-written programs, and space available for storing images.

Rathz, T. J.↗
NASA NTRS1978

Study of iron-borate materials systems processed in space

It was calculated that an FeBO3B2O3 glass-ceramic containing only 1 mole% FeBO3 would be equivalent for magnetooptic application to a YIG crystal of equal thickness. An Fe2O3B2O3 composition containing 2 mole% FeBO3 equivalent (98B) could be converted largely to a dense green, though opaque, FeBO3 glass-ceramic through suitable heat treatments. However, phase separation (and segregation) and Fe+3 reduction could not be entirely avoided with the various procedures that were employed. From light scattering calculations, it was estimated that about 100 A to allow 90% light transmission through a 1 cm thick sample. However, the actual FeBO3 crystallite sizes obtained in 98B were of the order of 1 micron or greater.

Neilson, G. F.↗
NASA NTRS1979

Analysis and evaluation in the production process and equipment area of the low-cost solar array project

The energy consumed in manufacturing silicon solar cell modules was calculated for the current process, as well as for 1982 and 1986 projected processes. In addition, energy payback times for the above three sequences are shown. The module manufacturing energy was partitioned two ways. In one way, the silicon reduction, silicon purification, sheet formation, cell fabrication, and encapsulation energies were found. In addition, the facility, equipment, processing material and direct material lost-in-process energies were appropriated in junction formation processes and full module manufacturing sequences. A brief methodology accounting for the energy of silicon wafers lost-in-processing during cell manufacturing is described.

Goldman, H.↗
NASA NTRS1981

Material and processing needs for silicon solar cells in space

The technical concerns of NASA in the area of space grade solar cells are summarized. Solar power needs are projected through 1987. The degradation of solar cell performance due to the effects of radiation on impurities and crystal defects and the improved performance of float zone silicon are illustrated. The reduction of oxygen and carbon in float zone silicon allows for much faster low temperature annealing of the defects. The effects of improved crystal purity on cell performance are summarized.

Brandhorst, H. W., Jr.↗
NASA NTRS1987

Low cost tooling material and process for graphite and Kevlar composites

An Extruded Sheet Tooling Compound (ESTC) was developed for use in quickly building low cost molds for fabricating composites. The ESTC is a very highly mineral-filled resin system formed into a 6 mm thick sheet. The sheet is laid on the pattern, vacuum (bag) is applied to remove air from the pattern surface, and the assembly is heat cured. The formed ESTC is then backed and/or framed and ready for use. The cured ESTC exhibits low coefficient of thermal expansion and maintains strength at temperatures of 180 to 200 C. Tools were made and used successfully for: Compression molding of high strength epoxy sheet molding compound, stamping of aluminum, resin transfer molding of polyester, and liquid resin molding of polyester. Several variations of ESTC can be made for specific requirements. Higher thermal conductivity can be achieved by using an aluminum particle filler. Room temperature gel is possible to allow use of foam patterns.

Childs, William I.↗
NASA NTRS1991

NASA/Ames Research Center's science and applications aircraft program

NASA-Ames Research Center operates a fleet of seven Science and Applications Aircraft, namely the C-141/Kuiper Airborne Observatory (KAO), DC-8, C-130, Lear Jet, and three ER-2s. These aircraft are used to satisfy two major objectives, each of equal importance. The first is to acquire remote and in-situ scientific data in astronomy, astrophysics, earth sciences, ocean processes, atmospheric physics, meteorology, materials processing and life sciences. The second major objective is to expedite the development of sensors and their attendant algorithms for ultimate use in space and to simulate from an aircraft, the data to be acquired from spaceborne sensors. NASA-Ames Science and Applications Aircraft are recognized as national and international facilities. They have performed and will continue to perform, operational missions from bases in the United States and worldwide. Historically, twice as many investigators have requested flight time than could be accommodated. This situation remains true today and is expected to increase in the years ahead. A major advantage of the existing fleet of aircraft is their ability to cover a large expanse of the earth's ecosystem from the surface to the lower stratosphere over large distances and time aloft. Their large payload capability allows a number of scientists to use multi-investigator sensor suites to permit simultaneous and complementary data gathering. In-flight changes to the sensors or data systems have greatly reduced the time required to optimize the development of new instruments. It is doubtful that spaceborne systems will ever totally replace the need for airborne science aircraft. The operations philosophy and capabilities exist at NASA-Ames Research Center.

Hall, G. Warren↗