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At least 487 records · Page 27

Additive Manufacturing at NASA

Additive Manufacturing (AM) is certainly changing the space industry and providing new opportunities to travel to low earth orbit and explore our universe. New design opportunities –not previously possible –for new high performance metal alloys, light-weighting, managing thermal, structural, and dynamic loads are being enabled by AM. This presentation will showcase the vast portfolio of NASA’s AM activities in the last 12 years; transportation from Earth to Destination, Habitat at Destination, Lander from Station to Surface, and Science mission spacecrafts. NASA’s technical excellence is being leveraged heavily in the AM community thru collaborative projects, partnership agreements, tech transfer program. Challenges as well as opportunities will be discussed.

Alison Park↗

Additive Manufactured Hardware Qualification and Certification at NASA

Additive Manufacturing (AM) is certainly changing the space industry and providing new opportunities to travel to low earth orbit and explore our universe New design opportunities –not previously possible –for new high performance metal alloys, light-weighting, managing thermal, structural, and dynamic loads are being enabled by AM. Additively manufactured parts are already being inserted for complext system for NASA programs in critical applications –“ready to fly” Human exploration of space, especially deep space, requires extreme reliability Qualification of AM design/parts/process and Flight Certification

Alison Park↗

Ecological Insights from Transferable Plant Biomass Mapping across the Arctic using High-resolution Structure-from-Motion and LiDAR Data

Warmer temperatures, permafrost thaw, and increased wildfire activity are driving rapid ecological change across the Arctic, significantly altering plant productivity and aboveground biomass (AGB). These rapid changes highlight the urgent need to improve monitoring of vegetation dynamics in the Earth’s northern ecosystems, where high spatiotemporal heterogeneity occurs at scales finer than those captured by traditional satellite observations. The growing use of Unoccupied Aerial Systems (UASs) presents an opportunity to overcome this limitation. Yet, the diversity of UAS platforms, sensors, and data collection and processing workflows presents challenges for developing standardized, generalizable approaches. To address this challenge, we compiled 672 AGB plots co-located with 183 UAS-based Structure-from-Motion (SfM) or Light Detection and Ranging (LiDAR) surveys collected across the Arctic. Here, we: (1) evaluated the generalizability of UAS-derived canopy structure derived from high-resolution SfM and LiDAR for estimating AGB, (2) assessed scaling errors and their sources in two recent satellite-based AGB products derived from Landsat and MODIS, and (3) demonstrated the use of high-resolution AGB maps to quantify biomass variation across tundra plant functional types (PFTs) and to monitor post-fire recovery. Our results show that both SfM and LiDAR accurately captured AGB and its variability across tundra PFTs using a Random Forest (RF) model (overall RMSE: 0.336 kg/m2), with mapping performance varying slightly by region and data source. Using UAS-derived AGB maps as a benchmark, we identified systematic biases in satellite-derived AGB products, largely attributable to the magnitude of AGB and structural heterogeneity within coarse-resolution pixels. Applying our model to repeat UAS surveys following a tundra fire on Seward Peninsula, we observed rapid AGB recovery in non-shrub patches, with biomass recovering to pre-fire levels within 2 years. In contrast, shrub patches recovered more slowly, with AGB gains continuing over 2–4 years through both in-patch growth and lateral expansion (via dispersal) into remaining burned areas. Overall, these findings demonstrate the generalizability of UAS-based SfM and LiDAR data for estimating tundra AGB and highlight the potential of our approach to be broadly applied to generate high-quality AGB data for ecological monitoring and model benchmarking across the Arctic.

Yang, Daryl [ORNL] (ORCID:0000000317057823)↗

Structural Load Alleviation Applied to Next Generation Aircraft and Wind Turbines

Reducing the environmental impact of aviation is a goal of the Subsonic Fixed Wing Project under the Fundamental Aeronautics Program of NASAs Aeronautics Research Mission Directorate. Environmental impact of aviation is being addressed by novel aircraft configurations and materials that reduce aircraft weight and increase aerodynamic efficiency. NASA is developing tools to address the challenges of increased airframe flexibility created by wings constructed with reduced structural material and novel light-weight materials. This talk will present a framework and demonstration of a flight control system using optimal control allocation with structural load feedback and constraints to achieve safe aircraft operation. As wind turbines age, they become susceptible to many forms of blade degradation. Results will be presented on work in progress that uses adaptive contingency control for load mitigation in a wind turbine simulation with blade damage progression modeled.

adaptive control↗

Raylike Structures in the Solar Corona

Recent white light images from the large-angle spectroscopic coronagraph (LASCO) on the Solar and Heliospheric Observatory (SoHO) have revealed almost radially extending coronal structures out to serveral solar raddi which fill the corona at all latitudes, except when they are overshadowed by streamers.

corona Sun raylike structures↗

A Novel Manufacturing Process of Lightweight Automotive Seats: Integration of Additive Manufacturing and Reinforced Polymer Composite

Lightweight automotive seats offer multiple benefits to original equipment manufacturers in terms of cost savings from various aspects, including less material usage, more integrated processes, and compliance with Corporate Average Fuel Economy Standards. Original equipment manufacturers have been focusing on innovative ways to produce light weight automotive seats. The commercially available automotive seats are currently made of multiple metal components combined through welding and fasteners. The use of additive manufacturing and composite structures is particularly useful for light weighting the automotive components. Additive manufacturing (AM) offers multiple advantages over traditional manufacturing processes such as freedom of design thereby enabling complex structural geometries, mass customization and waste minimization, and control over the fiber alignment through deposition in a predetermined pattern. Combining metal inserts with polymer composites through a novel manufacturing process allows design of lightweight and high-performance materials for automotive components.

99 GENERAL AND MISCELLANEOUS↗

A Novel Manufacturing Process of Lightweight Automotive Seats (Integration of Additive Manufacturing and Reinforced Polymer Composite)

Lightweight automotive seats offer multiple benefits to original equipment manufacturers in terms of cost savings from various aspects, including less material usage, more integrated processes, and compliance with Corporate Average Fuel Economy Standards. Original equipment manufacturers have been focusing on innovative ways to produce light weight automotive seats. The commercially available automotive seats are currently made of multiple metal components combined through welding and fasteners. The use of additive manufacturing and composite structures is particularly useful for light weighting the automotive components. Additive manufacturing (AM) offers multiple advantages over traditional manufacturing processes such as freedom of design thereby enabling complex structural geometries, mass customization and waste minimization, and control over the fiber alignment through deposition in a predetermined pattern. Combining metal inserts with polymer composites through a novel manufacturing process allows design of lightweight and high-performance materials for automotive components. However, fabricating these metal polymer composite structures through traditional manufacturing processes limits their mechanical properties due to limited design freedom, lack of control over fiber orientation in composite parts, and poor interfacial bonding between the constituent materials. It is essential to develop a novel manufacturing process to enable high throughput production of lightweight automotive seats using metal and polymer composites. As such it is important to design the automotive seat suitable for manufacturing via this process and perform mechanical characterization on various subcomponents of the seat to ensure that the design and performance requirements provided by the auto manufacturer are met. The aim of this project is to develop a novel manufacturing technique to produce lightweight automotive seat by combining AM with conventional manufacturing processes. The car seat back panel will be designed via topology optimization and numerical simulations to minimize the overall weight while ensuring it meets all the performance requirements. The optimization of the seat back structure will be based on computational stress analysis to maximize the stiffness and minimize the weight. Materials currently used by Ford Motor Company will be adopted for a few subcomponents while the in-house composite materials will be used for the rest of the seat back. The composite and metallic materials will be tested to determine their mechanical properties as these are necessary for simulations. A novel manufacturing process will be developed to integrate AM metal inserts with discontinuous reinforced composite through large scale additive manufacturing and compression overmolding processes. The developed manufacturing technique will be used to fabricated various subcomponents suitable for the seat back design and mechanically tested to determine their properties. The manufacturing of the lightweight seat back design through this process involves integrated AM metal inserts with the composite structure for recliner connection. The manufacturing of the entire seat back which is lightweight through the novel manufacturing process will be discussed. The performance of the designed seat back will be investigated through numerical simulations and shown to meet all the requirements provided by the auto manufacturer. The final goal of developing a novel manufacturing process for lightweight automotive seats is met through design optimization of seat back, manufacturing of subcomponents, mechanical characterization, and validation through numerical simulations. The routes to achieve the final goal of the project and the depth in which they were investigated changed throughout the project due to personnel changes and the COVID-19 pandemic. The project resulted in the development of a novel manufacturing process to integrate metal inserts with tailored polymer composite preforms through overmolding. Leveraging this proven manufacturing process, a lightweight seat back was designed through topology optimization and numerical simulations. The designed seat back uses AM metal inserts and compression overmolding of tailored polymer composite preforms obtained via large scale additive manufacturing. The metal polymer composite structures fabricated through this process exhibited enhancement in stiffness and improved ductility upon testing. Overall, the project provided an alternative design and manufacturing technique for automotive seat back that enables weight saving while meeting the safety and performance requirements.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

BioMoSS: Biocidal MoS2 for Disinfection of Spacecraft Potable Water Systems

It has been reported in the literature that few-layered, vertically-aligned molybdenum disulfide (FLV-MoS2) can produce biocidal agents for water disinfection with great effectiveness under visible light excitation. The nano-structure, with limited layers and small domain size increases the band gap of the MoS2 in the visible region such that visible light can be used to drive the production of reactive oxygen species (ROS) for biocidal control. This paper will present the BioMoSS (biocidal MoS2) for space applications concept and present initial results of the investigation into turning the FLV-MoS2 into a viable biocidal system.

Delzeit, Lance↗

A multi-satellite study of the nature of wavelike structures in the magnetospheric plasma

An intercomparison is made of the wavelike structures in the data from the light ion mass spectrometer and the fluxgate magnetometer on OGO 5. The wavelike structures appear simultaneously in the data from both experiments. The waves contain both transverse and compressional modes and exhibit periods of 100 to 200 seconds. The waves are usually observed outside the plasmapause and are located primarily on the dayside of the magnetosphere. One possible cause of the apparent density fluctuation is a velocity modulation of the thermal plasma which causes the particles to drift into and out of the ion spectrometer.

Shelley, E. G.↗

Apollo light flash investigations

The visual phenomenon of light flashes resulting from high energy, heavy cosmic rays penetrating the command module structure and crewmembers' eyes is investigated. Light flash events observed during dedicated sessions on Apollo 15, 16, 17 are described along with a Monte Carlo simulation of the exposure of an astronaut to cosmic radiation during a mission. Results of the Apollo Light Flash Moving Emulsion Detector experiment developed for Apollo 16 and 17 to obtain a direct record of incident cosmic ray particles are correlated with crewmembers' reports of light flashes.

W. Zachary Osborne↗

Morphology and Structure of ZnO Films Synthesized by Off-Axis Sputtering Deposition

ZnO is a wide-band-gap oxide material that has many applications. A new potential application of ZnO material is for light emitting devices since its structure and electrical properties are similar to that of the GaN material (a blue laser candidate). It also is a good substrate for fabricating GaN-based devices. Off-axis sputtering technique has revealed great potential in synthesizing excellent oxide materials because the negative ion bombardment is greatly reduced when adatoms condense on substrates. The surface of films grown by off-axis sputtering will be much smoother than that produced in a regular sputtering configuration. A growth mechanism is studied by investigating the morphology and structure of ZnO films under different growth conditions and orientations. ZnO films are deposited on (0001) sapphire and quartz substrates by off- axis sputtering deposition at various oxygen/argon mixture ratios and pressures and at different temperatures. All films reveal highly textured structures on quartz substrates and epitaxial growth on sapphire substrates. Two off-axis configurations, vertical and horizontal orientations are conducted to study the process of film growth, surface morphology, and film structure. X-ray diffraction, scanning probe microscopy, and electrical measurements are used to characterize these films. Detailed results will be discussed in the presentation. Keywords: ZnO, Photonic material, Off-axis sputtering, Growth mechanism

Zhu, Shen↗

Development of gallium aluminum phosphide electroluminescent diodes

Work done on the development of gallium aluminum phosphide alloys for electroluminescent light sources is described. The preparation of this wide band gap semiconductor alloy, its physical properties (particularly the band structure, the electrical characteristics, and the light emitting properties) and work done on the fabrication of diode structures from these alloys are broadly covered.

Chicotka, R. J.↗

Physics of Hard Spheres Experiment: Significant and Quantitative Findings Made

Direct examination of atomic interactions is difficult. One powerful approach to visualizing atomic interactions is to study near-index-matched colloidal dispersions of microscopic plastic spheres, which can be probed by visible light. Such spheres interact through hydrodynamic and Brownian forces, but they feel no direct force before an infinite repulsion at contact. Through the microgravity flight of the Physics of Hard Spheres Experiment (PHaSE), researchers have sought a more complete understanding of the entropically driven disorder-order transition in hard-sphere colloidal dispersions. The experiment was conceived by Professors Paul M. Chaikin and William B. Russel of Princeton University. Microgravity was required because, on Earth, index-matched colloidal dispersions often cannot be density matched, resulting in significant settling over the crystallization period. This settling makes them a poor model of the equilibrium atomic system, where the effect of gravity is truly negligible. For this purpose, a customized light-scattering instrument was designed, built, and flown by the NASA Glenn Research Center at Lewis Field on the space shuttle (shuttle missions STS 83 and STS 94). This instrument performed both static and dynamic light scattering, with sample oscillation for determining rheological properties. Scattered light from a 532- nm laser was recorded either by a 10-bit charge-coupled discharge (CCD) camera from a concentric screen covering angles of 0 to 60 or by sensitive avalanche photodiode detectors, which convert the photons into binary data from which two correlators compute autocorrelation functions. The sample cell was driven by a direct-current servomotor to allow sinusoidal oscillation for the measurement of rheological properties. Significant microgravity research findings include the observation of beautiful dendritic crystals, the crystallization of a "glassy phase" sample in microgravity that did not crystallize for over 1 year in 1g (Earth's gravity), and the emergence of face-centered-cubic (FCC) crystals late in the coarsening process (as small crystallites lost particles to the slow ripening of large crystallites). Significant quantitative findings from the microgravity experiments have been developed describing complex interactions among crystallites during the growth process, as concentration fields overlap in the surrounding disordered phase. Time-resolved Bragg scattering under microgravity captures one effect of these interactions quite conclusively for the sample at a volume fraction of 0.528. From the earliest time until the sample is almost fully crystalline, the size and overall crystallinity grow monotonically, but the number of crystallites per unit volume (number density) falls. Apparently nucleation is slower than the loss of crystallites because of the transfer of particles from small to large crystals. Thus, coarsening occurs simultaneously with growth, rather than following the completion of nucleation and growth as is generally assumed. In the same sample, an interesting signature appears in the apparent number density of crystallites and the volume fraction within the crystallites shortly before full crystallinity is reached. A brief upturn in both indicates the creation of more domains of the size of the average crystallite simultaneous with the compression of the crystallites. Only the emergence of dendritic arms offers a reasonable explanation. The arms would be "seen" by the light scattering as separate domains whose smaller radii of curvature would compress the interior phase. In fiscal year 1999, numerous papers, a doctoral dissertation, and the PHaSE final report were produced. Although this flight project has been completed, plans are in place for a follow-on colloid experiment by Chaikin and Russel that employs a light microscope within Glenn's Fluids and Combustion Facility on the International Space Station. PHaSE is providing us with a deeper understanding of the nure of phase transitions. The knowledge derived has added to the understanding of condensed matter. In addition, the burgeoning study of the dynamics of colloidal self-assembly may lead to the development of a range of photonic materials that control the desirable properties of light. Thus, applications of ordered colloidal structures include not only ultrastructure ceramics, but also photonic crystals and photothermal nanosecond light-switching devices. Industries dealing with semiconductors, electro-optics, ceramics, and composites stand to benefit from such advancements.

Doherty, Michael P.↗

Triboluminescent Materials for Smart Optical Damage Sensors for Space Applications

There is a need to develop a new technique of damage detection for composites, which could detect cracking or delamination from any desired location within a material structure in real time. Recently, triboluminescent materials have been proposed as smart sensors of structural damage. To sense the damage, these materials can be epoxy bonded, coated in a polymer matrix, or embedded in a composite host structure. When the damage or fracture takes place in the host structure, the resultant fracture of triboluminescent crystals creates a light emission. This will warn in real time that structural damage has occurred. The triboluminescent emission of the candidate phosphor has to be bright enough that the light reaching from the point of fracture to the detector through a fiber optic cable is detectable. There are a large number of triboluminescent materials, but few satisfy the above criterion. The authors have synthesized an organic material known as Europium tetrakis (dibenzoylmethide) triethylammonium (EuD4TEA), which is a potential candidate for application as a damage sensor and could be made into a wireless sensor with the addition of microchip, antenna, and electronics. Preliminary results on the synthesis and characterization of this material are presented.

Aggarwal, M. D.↗

Phase transformations and exsolution in lunar and terrestrial calcic plagioclases.

A coarse domain structure had been discovered in plagioclase in an electron microscopic study of lunar rocks reported by Christie et al. (1971). The domain structures are described in more detail, and their significance in the light of current knowledge concerning the crystal structures of the plagioclases is discussed. An exsolution texture is also described. On the basis of the scale of exsolution it appears that the Apollo 11 and 12 basalts examined cooled more rapidly than the Apollo 14 basalt, which in turn cooled more rapidly than the Stillwater rock.

Heuer, A. H.↗

Structure of ion acoustic solitons and shock waves in a two-component plasma.

Time-independent solitary waves and shocks are investigated in a two-component plasma using a fluid model and kinetic theory. It is found that very small concentrations of a light ion can drastically alter the structure, changing the potential maximum by an order of magnitude. For a fixed Mach number, a critical density ratio of light to heavy ions is found at which the potential maximum changes discontinuously from a value large enough to reflect the light ions to one which allows them to traverse the shock front and enter the downstream flow. The downstream oscillatory structure normally seen in a shock is completely quenched by dissipation due to light ion reflection at concentrations of 3-8% He in an Ar plasma for typical electron to ion temperature ratios and Mach number values.

White, R. B.↗

Thermal Properties of Hybrid Carbon Nanotube/Carbon Fiber Polymer

Carbon fiber reinforced polymer (CFRP) composites possess many advantages for aircraft structures over conventional aluminum alloys: light weight, higher strength- and stiffness-to-weight ratio, and low life-cycle maintenance costs. However, the relatively low thermal and electrical conductivities of CFRP composites are deficient in providing structural safety under certain operational conditions such as lightning strikes. One possible solution to these issues is to interleave carbon nanotube (CNT) sheets between conventional carbon fiber (CF) composite layers. However, the thermal and electrical properties of the orthotropic hybrid CNT/CF composites have not been fully understood. In this study, hybrid CNT/CF polymer composites were fabricated by interleaving layers of CNT sheets with Hexcel (Registered Trademark) IM7/8852 prepreg. The CNT sheets were infused with a 5% solution of a compatible epoxy resin prior to composite fabrication. Orthotropic thermal and electrical conductivities of the hybrid polymer composites were evaluated. The interleaved CNT sheets improved the in-plane thermal conductivity of the hybrid composite laminates by about 400% and the electrical conductivity by about 3 orders of magnitude.

Kang, Jin Ho↗

Solar Wind Speed Structure in the Inner Corona at 3-12 Ro

Estimates of solar wind speed obtained by Armstrong et al. [1986] based on 1983 VLA multiple-station intensity scintillation measurements inside 12 R(sub o) have been correlated with the electron density structure observed in white-light coronagraph measurements. The observed large- scale and apparently systematic speed variations are found to depend primarily on changes in heliographic latitude and longitude, which leads to the first results on large-scale speed structure in the acceleration region of the solar wind. Over an equatorial hole, solar wind speed is relatively steady, with peak-to-peak variations of 50 km/s and an average of 230 km/s. In contrast, the near-Sun flow speed across the streamer belt shows regular large-scale variations in the range of 100-300 km/s. Based on four groups of data, the gradient is 36 km/s per degree in heliocentric coordinates (corresponding to a rise of 260 km/s over a spatial distance on the Sun of two arcmin) with a standard deviation of 2.4 km/s per degree. The lowest speeds most likely coincide with the stalks of coronal streamers observed in white-light measurements. The detection of significant wind shear over the streamer belt is consistent with in situ and scintillation measurements showing that the density spectrum has a power-law form characteristic of fully developed turbulence over a much broader range of scales than in neighboring regions.

Woo, Richard↗