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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 487 records · Page 27
All sourcesNASA NTRSDOE OSTI
NASA NTRS1997

Rotordynamic Design Analysis of an Oil-Free Turbocharger

Modern heavy duty diesel engines utilize turbochargers for increased power output. Also, a wide range of power levels can be achieved with one engine displacement through the use of different turbocharger configurations, eliminating the need for several different sized engines. These are the reasons that virtually all diesel truck engines currently marketed use turbochargers. However, because these turbochargers rely on ring seals and oil-lubricated floating sleeve bearings, they often suffer breakdowns. These turbochargers operate at elevated temperatures which often causes the oil to degrade and even coke to the bearing surfaces. This can lead to catastrophic failure, increased particulate emissions from oil leaks, and, in extreme cases, engine fires. Replacing the oil lubricated bearings from these turbochargers with some other device is desirable to eliminate these inherent problems. Foil bearings are compliant selecting bearings lubricated by air and are well suited to high speed, light load applications. Thus, foil bearings present one potential replacement for oil-lubricated sleeve bearings. Their use as such is investigated in this work.

Howard, Samuel A.↗
NASA NTRS1997

Test Report: Direct and Indirect Lightning Effects on Composite Materials

Lightning tests were performed on composite materials as a part of an investigation of electromagnetic effects on the materials. Samples were subjected to direct and remote simulated lightning strikes. Samples included various thicknesses of graphite filament reinforced plastic (GFRP), material enhanced by expanded aluminum foil layers, and material with an aluminum honeycomb core. Shielding properties of the material and damage to the sample surfaces and joints were investigated. Adding expanded aluminum foil layers and increasing the thickness of GFRP improves the shielding effectiveness against lightning induced fields and the ability to withstand lightning strikes. A report describing the lightning strike tests performed by the U.S. Army Redstone Technical Test Center, Redstone Arsenal, AL, STERT-TE-E-EM, is included as an appendix.

Composite materials↗
NASA NTRS1998

Simulated Bladed MMC Disk LCF Validation

The goal of this program was to evaluate the low cycle fatigue behavior of an SCS-6/Ti-6Al-4V sub-component under bi-axial loading conditions at 316 C(600 F). A simulated bladed TMC disk was designed having thirty four blades representing the number that would be used in Allied Signal's JTAGG II impeller. The outer diameter of the bladed ring was 254 mm (10.0 inch) and the inner diameter 114.3 mm (4.50 inch). The outer and inner diameter of the composite zone was 177.8 mm (7.00 inch) and 127.O mm(5.00 inch) respectively. Stress analysis showed that the fatigue life of the bladed composite ring would be about 12000 cycles for the test conditions applied. A modal analysis was conducted which showed that the blades would have sufficient life margin from dynamic excitation. The arbor design was the same as that employed in the spin-to burst test of NAS3-27027. A systematic stress analysis of each part making up the arbor was undertaken to assure the design would meet the low cycle fatigue requirements of the program. The Textron Systems grooved foil-fiber process was chosen to make the SCS-6/Ti-6Al-4V core ring based on the success they had in contract NAS3-27027. Fiber buckling, however, was observed at several locations in the first ring made which rendered it unsuitable for spin testing. The fiber buckling was attributed to cracking of the graphite tooling during the consolidation process. On this basis a second ring was made but it too contained fiber buckling defects. Analysis by Textron indicated that the fiber buckling was most likely due to poor placement of the SCS-6 fiber in the etched grooves of the Ti-6Al-4V foil. This was also a contributor to the defects in the first ring. Since there was little indication of control in the process to manufacture a quality ring a third attempt at making a ring was not undertaken.

Merrick, H. F.↗
NASA NTRS1999

Utilization of Induction Bonding for Automated Fabrication of TIGR

A laboratory study of magnetic induction heat bonding of titanium foil and graphite fiber reinforced polymer prepreg tape, TiGr, demonstrated that the process is a viable candidate for low cost fabrication of aircraft structure made of this new material form. Data were obtained on weld bonding of PIXA and PETI-5 prepreg to titanium. Both the foil and honeycomb forms of titanium were investigated. The process relies on magnetic susceptor heating of titanium, not on high frequency heating of graphite fiber. The experiments showed that with a toroid magnet configuration, good weld bonds might be obtained with heating times of a few seconds. These results suggest the potential is good for the induction heating process to achieve acceptable commercial production rates.

Hinkley, Jeffrey A.↗
NASA NTRS1967

A Study to Analyze the Permeation of High Density Gases and Propellant Vapors Through Single Layer Teflon or Teflon Structure Materials and Laminations

This report contains the results of a fifteen month analytical and experimental study of the leakage rate of the pressurant gases (N2, He) and the propellant vapors (N2O4,N2H4) through bladder structures consisting of two layers of Teflon separated by a metallic foil diffusion barrier containing microscopic or larger holes. Results were obtained for the steady state leakage rate through circular holes and long rectangular openings in the barrier for arbitrary thicknesses of the two Teflon layers. The effect of hole shape and relative hole position on the leakage rate were studied. The transient problem was analyzed and it was shown that steady state calculations are adequate for estimating the leakage rate. A computer program entitled "Diffusion Analyzer Program" was developed to calculate the leakage rate, both transient and steady state. Finally, the analytical results were compared to experimentally determined values of the leakage rate through a model laminated bladder structure. The results of the analysis are in good agreement with experiment. The experimental effort (Part II of the Bladder Permeation Program) measured the solubility, diffusion coefficient and permeability of helium, nitrogen and nitrogen tetroxide vapor through Teflon TFE and FEP membranes. Data were obtained in the temperature range of 25 to 100 C at pressures ranging from near vacuum to about 20 atmospheres. Results of the experimental effort were compared with the limited data previously reported. As a verification to the applicability of results to actual bladder systems, counter diffusion tests were performed with a laminated sample containing aluminum foil with a selected group of holes.

Johnson, R. L.↗
NASA NTRS2003

Microfabricated X-Ray Optics Technology Development for the Constellation-X Mission

During the period of this Cooperative Agreement, MIT developed advanced methods for applying silicon micro-stuctures for the precision assembly of foil x-ray optics in support of the Constellution-X Spectroscopy X-ray Telescope (SXT) development effort at Goddard Space Flight Center (GSFC). MIT developed improved methods for fabricating and characterizing the precision silicon micro-combs. MIT also developed and characterized assembly tools and several types of metrology tools in order to characterize and reduce the errors associated with precision assembly of foil optics. Results of this effort were published and presented to the scientific community and the GSFC SXT team.

Schattenburg, Mark L.↗
NASA NTRS2003

The Stardust Mission

The primary goal of the Stardust Mission is to collect >1000 particles >15 micron in diameter from comet Wild2 and return them to Earth in January 2006. The main samples will be captured by 6.1 km/s impact into low density silica aerogel and additional particles will crater into approx. 150 sq cm of 100 micron thick pure aluminum foil that covers the aerogel holding grid. It is expected that the impacts into the aerogel will produce tracks that range from deep narrow cones for non-fragmenting particles to shallower more complex tracks for particles that fragment. The impacts into aluminum foil will produce craters but a significant amount of projectile residue is expected to line the crater walls.

Brownlee, D. E.↗
NASA NTRS2003

Mass and Size Frequency Distribution of the Impact Debris from Disruption of Chondritic Meteorites

Since direct observation of the collision of asteroids in space is not always convenient for earthbound observers, we have undertaken simulations of these collisions using the NASA Ames Vertical Gun Range (AVGR). To simulate the collision of asteroids in space, and aluminum projectiles with velocities ranging from approx.1 to approx.6 km/sec were fired at 70g to approx.200 g fragments of chondritic meteorites. The target meteorite was placed in an evacuated chamber at the AVGR. Detectors, usually four, were set up around the target meteorite. These detectors consisted of aerogel and aluminum foil of varying thickness. The aerogel's purpose was to catch debris after the collision, and the aluminum foil.s purpose was to show the size of the debris particles through the size of the holes in the aluminum foil. Outside the chamber, a camera was set up to record high-speed film of the collision. This camera recorded at either 500 frames per second or 1000 frames per second. Three different types of targets were used for these tests. The first were actual meteorites, which varied in mineralogical composition, density, and porosity. The second type of target was a Hawaiian basalt, consisting of olivine phenocrysts in a porous matrix, which we thought might be similar to the chondritic meteorites, thus providing data for comparison. The final type was made out of Styrofoam. The Styrofoam was thought to simulate very low-density asteroids and comets.

VanVeghten, T. W.↗
NASA NTRS2004

Genesis Preliminary Examination Plans

The purpose of preliminary examination of the Genesis sample collectors is to provide information on the condition and availability of collector materials to the science community as a basis for allocation requests. Similarly, the information will be used by the Genesis Sample Allocation sub-committee of CAPTEM to determine the optimum allocation scheme, and by the Genesis Curator to determine the processing sequence for allocation production. The plan includes a decision process and detailed examination and documentation protocol for whole arrays and individual collectors (wafers, concentrator targets, bulk metallic glass, gold foil, and polished aluminum). It also includes a plan for communicating the information obtained to the scientific community. The plan does not include a detailed plan for preliminary examination of the SRC lid foil collectors, the process for removal of individual collectors from their frames, or for the subsequent subdivision of collector materials for allocation.

K M McNamara↗
NASA NTRS2004

Future Issues and Approaches to Health Monitoring and Failure Prevention for Oil-Free Gas Turbines

Recent technology advances in foil air bearings, high temperature solid lubricants and computer based modeling has enabled the development of small Oil-Free gas turbines. These turbomachines are currently commercialized as small (<100 kW) microturbine generators and larger machines are being developed. Based upon these successes and the high potential payoffs offered by Oil-Free systems, NASA, industry, and other government entities are anticipating Oil-Free gas turbine propulsion systems to proliferate future markets. Since an Oil-Free engine has no oil system, traditional approaches to health monitoring and diagnostics, such as chip detection, oil analysis, and possibly vibration signature analyses (e.g., ball pass frequency) will be unavailable. As such, new approaches will need to be considered. These could include shaft orbit analyses, foil bearing temperature measurements, embedded wear sensors and start-up/coast down speed analysis. In addition, novel, as yet undeveloped techniques may emerge based upon concurrent developments in MEMS technology. This paper introduces Oil-Free technology, reviews the current state of the art and potential for future turbomachinery applications and discusses possible approaches to health monitoring, diagnostics and failure prevention.

DellaCorte, Christopher↗
NASA NTRS2005

Genesis Field Recovery

The Genesis mission returned to Earth on September 8, 2004 after a nearly flawless three-year mission to collect solar matter. The intent was to deploy a drogue chute and parafoil high over the Utah desert and to catch the fragile payload capsule in mid-air by helicopter. The capsule would then be opened in a clean-room constructed for that purpose at UTTR, and a nitrogen purge was to be installed before transporting the science canister to JSC. Unfortunately, both chutes failed to deploy, causing the capsule to fall to the desert floor at a speed of nearly 200 MPH. Still, Genesis represents a milestone in the US space program, comprising the first sample return since the Apollo Missions as well as the first return of materials exposed to the space environment outside of low Earth orbit and beyond the Earth s magnetosphere for an extended period. We have no other comparable materials in all of our collections on Earth. The goal of the Genesis Mission was to collect a representative sample of the composition of the solar wind and thus, the solar nebula from which our solar system originated. This was done by allowing the naturally accelerated species to implant shallowly in the surfaces of ultra-pure, ultra-clean collector materials. These collectors included single crystal silicon (FZ and CZ), sapphire, silicon carbide; those materials coated with aluminum, silicon, diamond like carbon, and gold; and isotopically enriched polycrystalline diamond and amorphous carbon. The majority of these materials were distributed on five collector arrays. Three of the materials were housed in an electrostatic concentrator designed to increase the flux of low-mass ions. There was also a two-inch diameter bulk metallic glass collector and a gold foil, polished aluminum, and molybdenum coated platinum foil collector. An excellent review of the Genesis collector materials is offered in reference [1].

McNamara, K. M.↗
NASA NTRS2002

Refractive Secondary Solar Concentrator Demonstrated High-Temperature Operation

Space applications that utilize solar thermal energy--such as electric power conversion systems, thermal propulsion systems, and furnaces--require highly efficient solar concentration systems. The NASA Glenn Research Center is developing the refractive secondary concentrator, which uses refraction and total internal reflection to efficiently concentrate and direct solar energy. When used in combination with advanced lightweight primary concentrators, such as inflatable thin films, the refractive secondary concentrator enables very high system concentration ratios and very high temperatures. Last year, Glenn successfully demonstrated a secondary concentrator throughput efficiency of 87 percent, with a projected efficiency of 93 percent using an antireflective coating. Building on this achievement, Glenn recently successfully demonstrated high-temperature operation of the secondary concentrator when it was used to heat a rhenium receiver to 2330 F. The high-temperature demonstration of the concentrator was conducted in Glenn's 68-ft long Tank 6 thermal vacuum facility equipped with a solar simulator. The facility has a rigid panel primary concentrator that was used to concentrate the light from the solar simulator onto the refractive secondary concentrator. NASA Marshall Space Flight Center provided a rhenium cavity, part of a solar thermal propulsion engine, to serve as the high-temperature receiver. The prototype refractive secondary concentrator, measuring 3.5 in. in diameter and 11.2 in. long, is made of single-crystal sapphire. A water-cooled splash shield absorbs spillage light outside of the 3.5-in. concentrator aperture. Multilayer foil insulation composed of tungsten, molybdenum, and niobium is used to minimize heat loss from the hightemperature receiver. A liquid-cooled canister calorimeter is used to measure the heat loss through the multilayer foil insulation.

Wong, Wayne A.↗
NASA NTRS2002

Heat Treatment Used to Strengthen Enabling Coating Technology for Oil-Free Turbomachinery

The PS304 high-temperature solid lubricant coating is a key enabling technology for Oil- Free turbomachinery propulsion and power systems. Breakthroughs in the performance of advanced foil air bearings and improvements in computer-based finite element modeling techniques are the key technologies enabling the development of Oil-Free aircraft engines being pursued by the Oil-Free Turbomachinery team at the NASA Glenn Research Center. PS304 is a plasma spray coating applied to the surface of shafts operating against foil air bearings or in any other component requiring solid lubrication at high temperatures, where conventional materials such as graphite cannot function.

Edmonds, Brian J.↗
NASA NTRS2006

Heat Transfer In High-Temperature Multilayer Insulation

The combined radiation/conduction heat transfer in high-temperature multilayer insulations for typical reentry of reusable launch vehicles from low Earth orbit was investigated experimentally and numerically. The high-temperature multilayer insulation investigated consisted of gold-coated reflective foils separated by alumina fibrous insulation spacers. The steady-state heat transfer through four multilayer insulation configurations was investigated experimentally over the temperature range of 300-1300 K and environmental pressure range of 1.33 10(exp -5)-101.32 kPa. It was shown that including the reflective foils reduced the effective thermal conductivity compared to fibrous insulation sample at 1.5 times the density of the multilayer sample. A finite volume numerical model was developed to solve the governing combined radiation/conduction heat transfer equations. The radiation heat transfer in the fibrous insulation spacers was modeled using the modified two-flux approximation assuming anisotropic scattering and gray medium. The numerical model was validated by comparison with steady-state experimental data. The root mean square deviation between the predicted and measured effective thermal conductivity of the samples was 9.5%.

Daryabeigi, Kamran↗
NASA NTRS2007

A New High-Speed Oil-Free Turbine Engine Rotordynamic Simulator Test Rig

A new test rig has been developed for simulating high-speed turbomachinery rotor systems using Oil-Free foil air bearing technology. Foil air bearings have been used in turbomachinery, primarily air cycle machines, for the past four decades to eliminate the need for oil lubrication. The goal of applying this bearing technology to other classes of turbomachinery has prompted the fabrication of this test rig. The facility gives bearing designers the capability to test potential bearing designs with shafts that simulate the rotating components of a target machine without the high cost of building "make-and-break" hardware. The data collected from this rig can be used to make design changes to the shaft and bearings in subsequent design iterations. This paper describes the new test rig and demonstrates its capabilities through the initial run with a simulated shaft system.

Howard, Samuel A.↗
NASA NTRS2007

Overview of the Results of the Organics PET Study of the Cometary Samples from Comet Wild 2 by the Stardust Mission

STARDUST is the first mission designed to bring samples back to Earth from a known comet. The captured samples were successfully returned to Earth on 15 Jan 2006, after which they were subjected to a preliminary examination by a number of teams of scientists from around the world. This abstract describes the efforts of the Organics Preliminary Examination Team (PET). More detailed discussions of specific analyses of the samples can be found in other papers presented at this meeting by individual members of the Organics PET (see the author list above for team members). The studied Wild 2 gas and dust samples were collected by impact onto aerogel tiles and Al foils when the spacecraft flew through the coma of 81P/Wild 2 on 2 Jan 2004 at a relative velocity of approx.6.1 kilometers per second. After recovery of the Sample Return Capsule (SRC) on 15 Jan 2006, the aerogel collector trays were removed in a clean room at JSC. After documentation of the collection, selected aerogel tiles and aluminum foils were removed and aerogel and cometary samples extracted for study.

Sandford, S. A.↗
NASA NTRS2007

Non-Random Spatial Distribution of Impacts in the Stardust Cometary Collector

In January 2004, the Stardust spacecraft flew through the coma of comet P81/Wild2 at a relative speed of 6.1 km/sec. Cometary dust was collected at in a 0.1 sq m collector consisting of aerogel tiles and aluminum foils. Two years later, the samples successfully returned to earth and were recovered. We report the discovery that impacts in the Stardust cometary collector are not distributed randomly in the collecting media, but appear to be clustered on scales smaller than approx.10 cm. We also report the discovery of at least two populations of oblique tracks. We evaluated several hypotheses that could explain the observations. No hypothesis was consistent with all the observations, but the preponderance of evidence points toward at least one impact on the central Whipple shield of the spacecraft as the origin of both clustering and low-angle oblique tracks. High-angle oblique tracks unambiguously originate from a noncometary impact on the spacecraft bus just forward of the collector. Here we summarize the observations, and review the evidence for and against three scenarios that we have considered for explaining the impact clustering found on the Stardust aerogel and foil collectors.

Westphal, Andrew J.↗
NASA NTRS1978

Food Packaging Materials

The photos show a few of the food products packaged in Alure, a metallized plastic material developed and manufactured by St. Regis Paper Company's Flexible Packaging Division, Dallas, Texas. The material incorporates a metallized film originally developed for space applications. Among the suppliers of the film to St. Regis is King-Seeley Thermos Company, Winchester, Ma'ssachusetts. Initially used by NASA as a signal-bouncing reflective coating for the Echo 1 communications satellite, the film was developed by a company later absorbed by King-Seeley. The metallized film was also used as insulating material for components of a number of other spacecraft. St. Regis developed Alure to meet a multiple packaging material need: good eye appeal, product protection for long periods and the ability to be used successfully on a wide variety of food packaging equipment. When the cost of aluminum foil skyrocketed, packagers sought substitute metallized materials but experiments with a number of them uncovered problems; some were too expensive, some did not adequately protect the product, some were difficult for the machinery to handle. Alure offers a solution. St. Regis created Alure by sandwiching the metallized film between layers of plastics. The resulting laminated metallized material has the superior eye appeal of foil but is less expensive and more easily machined. Alure effectively blocks out light, moisture and oxygen and therefore gives the packaged food long shelf life. A major packaging firm conducted its own tests of the material and confirmed the advantages of machinability and shelf life, adding that it runs faster on machines than materials used in the past and it decreases product waste; the net effect is increased productivity.

Source record↗