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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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NASA NTRS2010

First Demonstration on Direct Laser Fabrication of Lunar Regolith Parts

Establishment of a lunar or Martian outpost necessitates the development of methods to utilize in situ mineral resources for various construction and resource extraction applications. Fabrication technologies are critical for habitat structure development, as well as repair and replacement of tools and parts at the outpost. Herein we report the direct fabrication of lunar regolith simulant parts, in freeform environment, using lasers. We show that raw lunar regolith can be processed at laser energy levels as a low as 2.12 J mm-2 resulting in nanocrystalline and/or amorphous microstructures. Potential applications of laser based fabrication technologies to make useful regolith parts for various applications including load bearing composite structures, radiation shielding, and solar cell substrates is described.

Balla, Vamsi Krishna↗
NASA NTRS2011

Current and Future Parts Management at NASA

This presentation provides a high level view of current and future electronic parts management at NASA. It describes a current perspective of the new human space flight direction that NASA is beginning to take and how that could influence parts management in the future. It provides an overview of current NASA electronic parts policy and how that is implemented at the NASA flight Centers. It also describes some of the technical challenges that lie ahead and suggests approaches for their mitigation. These challenges include: advanced packaging, obsolescence and counterfeits, the global supply chain and Commercial Crew, a new direction by which NASA will utilize commercial launch vehicles to get astronauts to the International Space Station.

Sampson, Michael J.↗
NASA NTRS2010

Mixed Layer Sub-Mesoscale Parameterization - Part 1: Derivation and Assessment

Several studies have shown that sub-mesoscales (SM 1km horizontal scale) play an important role in mixed layer dynamics. In particular, high resolution simulations have shown that in the case of strong down-front wind, the re-stratification induced by the SM is of the same order of the de-stratification induced by small scale turbulence, as well as of that induced by the Ekman velocity. These studies have further concluded that it has become necessary to include SM in ocean global circulation models (OGCMs), especially those used in climate studies. The goal of our work is to derive and assess an analytic parameterization of the vertical tracer flux under baroclinic instabilities and wind of arbitrary directions and strength. To achieve this goal, we have divided the problem into two parts: first, in this work we derive and assess a parameterization of the SM vertical flux of an arbitrary tracer for ocean codes that resolve mesoscales, M, but not sub-mesoscales, SM. In Part 2, presented elsewhere, we have used the results of this work to derive a parameterization of SM fluxes for ocean codes that do not resolve either M or SM. To carry out the first part of our work, we solve the SM dynamic equations including the non-linear terms for which we employ a closure developed and assessed in previous work. We present a detailed analysis for down-front and up-front winds with the following results: (a) down-front wind (blowing in the direction of the surface geostrophic velocity) is the most favorable condition for generating vigorous SM eddies; the de-stratifying effect of the mean flow and re-stratifying effect of SM almost cancel each other out,

Canuto, V. M.↗
NASA NTRS2011

Investigation of the Semicoa SCF9550 and the International Rectifier IRHM57260SE for Single-Event Gate Rapture and Single-Event Burnout : NASA Electronic Parts and Packaging (NEPP) Program Office of Safety and Mission Assurance

Single-event-effect test results for hi-rel total-dose-hardened power MOSFETs are presented in this report. TheSCF9550 from Semicoa and the IRHM57260SE from International Rectifier were tested to NASA test condition/standards and requirements.The IRHM57260SE performed much better when compared to previous testing. These initial results confirm that parts from the Temecula line are marginally comparable to the El Segundo line. The SCF9550 from Semicoa was also tested and represents the initial parts offering from this vendor. Both parts experienced single-event gate rupture (SEGR) and single-event burnout (SEB). All of the SEGR was from gate to drain.

Single Event Gate Rupture↗
NASA NTRS2010

Genesis of Pre-Hurricane Felix (2007): The Role of the Easterly Wave Critical Layer - Part 1

The formation of pre Hurricane Felix (2007) in a tropical easterly wave is examined in a two-part study using the Weather Research and Forecasting (WRF) model with a high-resolution nested grid configuration that permits the representation of cloud system processes. The simulation commences during the wave stage of the precursor African easterly-wave disturbance. Here the simulated and observed developments are compared, while in Part II of the study various large-scale analyses, physical parameterizations, and initialization times are explored to document model sensitivities. In this first part the authors focus on the wave/vortex morphology, its interaction with the adjacent intertropical convergence zone complex, and the vorticity balance in the neighborhood of the developing storm. Analysis of the model simulation points to a bottom-up development process within the wave critical layer and supports the three new hypotheses of tropical cyclone formation proposed recently by Dunkerton, Montgomery, and Wang. It is shown also that low-level convergence associated with the ITCZ helps to enhance the wave signal and extend the "wave pouch" from the jet level to the top of the atmospheric boundary layer. The region of a quasi-closed Lagrangian circulation within the wave pouch provides a focal point for diabatic merger of convective vortices and their vortical remnants. The wave pouch serves also to protect the moist air inside from dry air intrusion, providing a favorable environment for sustained deep convection. Consistent with the authors' earlier findings, the tropical storm forms near the center of the wave pouch via system-scale convergence in the lower troposphere and vorticity aggregation. Components of the vorticity balance are shown to be scale dependent, with the immediate effects of cloud processes confined more closely to the storm center than the overturning Eliassen circulation induced by diabatic heating, the influence of which extends to larger radii.

Wang, Zhuo↗
NASA NTRS2010

Genesis of Pre-Hurricane Felix (2007): Warm Core Formation, Precipitation Evolution, and Predictability - Part 2

This is the second of a two-part study examining the simulated formation of Atlantic Hurricane Felix (2007) in a cloud-representing framework. Here several open issues are addressed concerning the formation of the storm's warm core, the evolution and respective contribution of stratiform versus convective precipitation within the parent wave's pouch, and the sensitivity of the development pathway reported in Part I to different model physics options and initial conditions. All but one of the experiments include ice microphysics as represented by one of several parameterizations, and the partition of convective versus stratiform precipitation is accomplished using a standard numerical technique based on the high-resolution control experiment. The transition to a warm-core tropical cyclone from an initially cold-core, lower tropospheric wave disturbance is analyzed first. As part of this transformation process, it is shown that deep moist convection is sustained near the pouch center. Both convective and stratiform precipitation rates increase with time. While stratiform precipitation occupies a larger area even at the tropical storm stage, deep moist convection makes a comparable contribution to the total rain rate at the pregenesis stage, and a larger contribution than stratiform processes at the storm stage. The convergence profile averaged near the pouch center is found to become dominantly convective with increasing deep moist convective activity there. Low-level convergence forced by interior diabatic heating plays a key role in forming and intensifying the near-surface closed circulation, while the midlevel convergence associated with stratiform precipitation helps to increase the midlevel circulation and thereby contributes to the formation and upward extension of a tropospheric-deep cyclonic vortex. Sensitivity tests with different model physics options and initial conditions demonstrate a similar pregenesis evolution. These tests suggest that the genesis location of a tropical storm is largely controlled by the parent wave's critical layer, whereas the genesis time and intensity of the protovortex depend on the details of the mesoscale organization, which is less predictable. Some implications of the findings are discussed.

Wang, zhuo↗
NASA NTRS2012

Use of Commercial Electrical, Electronic and Electromechanical (EEE) Parts in NASA's Commercial Crew Program (CCP)

NASA's Commercial Crew and Cargo Program (CCP) is stimulating efforts within the private sector to develop and demonstrate safe, reliable, and cost-effective space transportation capabilities. One initiative involves investigating the use of commercial electronic parts. NASA's CCP asked the NASA Engineering and Safety Center (NESC) to collect data to help frame the technical, cost, and schedule risk trades associated with electrical, electronic and electromechanical (EEE) parts selection and specifically expressed desire of some of the CCP partners to employ EEE parts of a lower grade than traditionally used in most NASA safety-critical applications. This document contains the outcome from the NESC's review and analyses.

Gonzalex, Oscar↗
NASA NTRS2014

Statistical Aspects of North Atlantic Basin Tropical Cyclones During the Weather Satellite Era, 1960-2013: Part 1

A tropical cyclone is described as a warm-core, nonfrontal, synoptic-scale system that originates over tropical or subtropical waters, having organized deep convection and closed surface wind circulation (counterclockwise in the Northern Hemisphere) about a well defined center. When its sustained wind speed equals 34-63 kt, it is called a tropical (or subtropical) storm and is given a name (i.e., alternating male and female names, beginning in 1979); when its sustained wind speed equals 64-95 kt, it is called a hurricane (at least in the Eastern Pacific and North Atlantic basin); and when its sustained wind speed equals 96 kt or higher, it is called an intense or major hurricane (i.e., categories 3-5 on the Saffir-Simpson Hurricane Wind Scale). Although tropical cyclones have been reported and described since the voyages of Columbus, a detailed record of their occurrences extends only from 1851 to the present, with the most reliable portion extending only from about 1945 to the present, owing to the use of near-continuous routine reconnaissance aircraft monitoring flights and the use of satellite imagery (beginning in 1960; see Davis). Even so, the record may still be incomplete, possibly missing at least one tropical cyclone per yearly hurricane season, especially prior to the use of continuous satellite monitoring. In fact, often an unnamed tropical cyclone is included in the year-end listing of events at the conclusion of the season, following post-season analysis (e.g., as happened in 2011 and 2013, each having one unnamed event). In this two-part Technical Publication (TP), statistical aspects of the North Atlantic basin tropical cyclones are examined for the interval 1960-2013, the weather satellite era. Part 1 examines some 25 parameters of tropical cyclones (e.g., frequencies, peak wind speed (PWS), accumulated cyclone energy (ACE), etc.), while part 2 examines the relationship of these parameters against specific climate-related factors. These studies are a continuation of nearly two decades of previous tropical cyclone-related investigations.

Wilson, Robert M.↗
NASA NTRS2015

A Fully Non-Metallic Gas Turbine Engine Enabled by Additive Manufacturing Part I: System Analysis, Component Identification, Additive Manufacturing, and Testing of Polymer Composites

The research and development activities reported in this publication were carried out under NASA Aeronautics Research Institute (NARI) funded project entitled "A Fully Nonmetallic Gas Turbine Engine Enabled by Additive Manufacturing." The objective of the project was to conduct evaluation of emerging materials and manufacturing technologies that will enable fully nonmetallic gas turbine engines. The results of the activities are described in three part report. The first part of the report contains the data and analysis of engine system trade studies, which were carried out to estimate reduction in engine emissions and fuel burn enabled due to advanced materials and manufacturing processes. A number of key engine components were identified in which advanced materials and additive manufacturing processes would provide the most significant benefits to engine operation. The technical scope of activities included an assessment of the feasibility of using additive manufacturing technologies to fabricate gas turbine engine components from polymer and ceramic matrix composites, which were accomplished by fabricating prototype engine components and testing them in simulated engine operating conditions. The manufacturing process parameters were developed and optimized for polymer and ceramic composites (described in detail in the second and third part of the report). A number of prototype components (inlet guide vane (IGV), acoustic liners, engine access door) were additively manufactured using high temperature polymer materials. Ceramic matrix composite components included turbine nozzle components. In addition, IGVs and acoustic liners were tested in simulated engine conditions in test rigs. The test results are reported and discussed in detail.

acoustic liners↗
NASA NTRS2003

Active Control of Low-Speed Fan Tonal Noise Using Actuators Mounted in Stator Vanes: Part III Results

A test program to demonstrate simplification of Active Noise Control (ANC) systems relative to standard techniques was performed on the NASA Glenn Active Noise Control Fan from May through September 2001. The target mode was the m = 2 circumferential mode generated by the rotor-stator interaction at 2BPF. Seven radials (combined inlet and exhaust) were present at this condition. Several different error-sensing strategies were implemented. Integration of the error-sensors with passive treatment was investigated. These were: (i) an in-duct linear axial array, (ii) an induct steering array, (iii) a pylon-mounted array, and (iv) a near-field boom array. The effect of incorporating passive treatment was investigated as well as reducing the actuator count. These simplified systems were compared to a fully ANC specified system. Modal data acquired using the Rotating Rake are presented for a range of corrected fan rpm. Simplified control has been demonstrated to be possible but requires a well-known and dominant mode signature. The documented results here in are part III of a three-part series of reports with the same base title. Part I and II document the control system and error-sensing design and implementation.

Sutliff, Daniel L.↗
NASA NTRS2015

Fabrication of Flex Joint Utilizing Additively Manufactured Parts

The Selective Laser Melting (SLM) manufacturing technique has been utilized in the manufacture of a flex joint typical of those found in rocket engine and main propulsion system ducting. The SLM process allowed for the combination of parts that are typically machined separately and welded together. This resulted in roughly a 65% reduction of the total number of parts, roughly 70% reduction in the total number of welds, and an estimated 60% reduction in the number of machining operations. The majority of the new design was in three SLM pieces. These pieces, as well as a few traditionally fabricated parts, were assembled into a complete unit, which has been pressure tested. The design and planned cryogenic testing of the unit will be presented.

Eddleman, David↗
NASA NTRS2015

A Fully Nonmetallic Gas Turbine Engine Enabled by Additive Manufacturing of Ceramic Composites: Additive Manufacturing and Characterization of Ceramic Composites - Part III

This publication is the third part of a three part report of the project entitled "A Fully Nonmetallic Gas Turbine Engine Enabled by Additive Manufacturing" funded by NASA Aeronautics Research Institute (NARI). The objective of this project was to conduct additive manufacturing to produce ceramic matrix composite materials and aircraft engine components by the binder jet process. Different SiC powders with median sizes ranging from 9.3 to 53.0 microns were investigated solely and in powder blends in order to maximize powder packing. Various infiltration approaches were investigated to include polycarbosilane (SMP-10), phenolic, and liquid silicon. Single infiltrations of SMP-10 and phenolic only slightly filled in the interior. When the SMP-10 was loaded with sub-micron sized SiC powders, the infiltrant gave a much better result of filling in the interior. Silicon carbide fibers were added to the powder bed to make ceramic matrix composite materials. Microscopy showed that the fibers were well distributed with no preferred orientation on the horizontal plane and fibers in the vertical plane were at angles as much as 45deg. Secondary infiltration steps were necessary to further densify the material. Two to three extra infiltration steps of SMP-10 increased the density by 0.20 to 0.55 g/cc. However, the highest densities achieved were 2.10 to 2.15 g/cc. Mechanical tests consisting of 4 point bend tests were conducted. Samples from the two CMC panels had higher strengths and strains to failure than the samples from the two nonfiber reinforced panels. The highest strengths were from Set N with 65 vol% fiber loading which had an average strength of 66 MPa. Analysis of the fracture surfaces did not reveal pullout of the reinforcing fibers. Blunt fiber failure suggested that there was not composite behavior. The binder jet additive manufacturing method was used to also demonstrate the fabrication of turbine engine vane components of two different designs and sizes. The binder jet method has benefits over the conventional manufacturing of CMCs in that prototype and production parts can be fabricated quickly and economically with no tooling and extensive hand layup.

Additive Manufacturing↗
NASA NTRS2016

The NASA Electronic Parts and Packaging (NEPP) Program: NEPP Overview - Automotive Electronics

The results of NASAs studies into the appropriateness of using U.S. Automotive electronic parts in NASA spaceflight systems will be presented. The first part of the presentation provides an overview of the United States Automotive Electronics Council's AECQ standardization program, the second part provides a summary of the results of NASA's procurement and testing experiences and other lessons learned along with preliminary test results.

Reliability↗
NASA NTRS2016

Cleaning and Cleanliness Measurement of Additive Manufactured Parts

The successful acquisition and utilization of piece parts and assemblies for contamination sensitive applications requires application of cleanliness acceptance criteria. Contamination can be classified using many different schemes. One common scheme is classification as organic, ionic and particulate contaminants. These may be present in and on the surface of solid components and assemblies or may be dispersed in various gaseous or liquid media. This discussion will focus on insoluble particle contamination on the surfaces of piece parts and assemblies. Cleanliness of parts can be controlled using two strategies, referred to as gross cleanliness and precision cleanliness. Under a gross cleanliness strategy acceptance is based on visual cleanliness. This approach introduces a number of concerns that render it unsuitable for controlling cleanliness of high technology products. Under the precision cleanliness strategy, subjective, visual assessment of cleanliness is replaced by objective measurement of cleanliness. When a precision cleanliness strategy is adopted there naturally arises the question: How clean is clean enough? The methods for establishing objective cleanliness acceptance limits will be discussed.

Mitchell, Mark A.↗
NASA NTRS2017

Thermophysical Properties of Cold and Vacuum Plasma Sprayed Cu-Cr-X Alloys, NiAl and NiCrAlY Coatings: Electrical and Thermal Conductivity, Thermal Diffusivity, and Total Hemispherical Emissivity - Part 1

This two-part paper reports the thermophysical properties of several cold and vacuum plasma sprayed monolithic Cu and Ni-based alloy coatings. Part I presents the electrical and thermal conductivity, thermal diffusivity, and total hemispherical emissivity data while Part II reports the specific heat capacity data for these coatings. Metallic copper alloys, stoichiometric NiAl and NiCrAlY coatings were fabricated by either the cold sprayed or the vacuum plasma spray deposition processes for thermal property measurements between 77 and 1223 K. The temperature dependencies of the thermal conductivities, thermal diffusivities, electrical conductivities and total hemispherical emissivities of these cold and vacuum sprayed monolithic coatings are reported in this paper. The electrical and thermal conductivity data correlate reasonably well for Cu-8%Cr-1%Al, Cu-23%Cr-5%Al and NiAl in accordance with the Wiedemann-Franz (WF) law although a better fit is obtained using the Smith-Palmer relationship. The Lorentz numbers determined from the WF law are close to the theoretical value.

Raj, S. V.↗
NASA NTRS2018

The Hitomi X-Ray Observatory, Part 2

When it was launched on 17 February 2016, the Hitomi X-ray Observatory carried four kinds of new-generation x-ray instruments—the Soft X-ray Spectrometer (SXS), the Soft X-ray Imager (SXI), the Hard X-ray Imager (HXI), and the Soft Gamma-ray Detector (SGD). All four instruments were turned on and were in the process of activation at the time of loss of contact on 26 March 2016. In the time it was operational, Hitomi was able to provide researchers with a trove of ground-breaking scientific results. Initial results demonstrated that the instruments were meeting or exceeding requirements and that Hitomi was on its way to pioneering a new era of broad-band and high-resolution x-ray spectroscopy. The results published here summarize the in-flight instrument performance, calibration, and data processing accomplishments of the observatory. Of the papers accepted for publication in this special section, 17 were presented in Part 1 in the January-March 2018 issue of JATIS (Journal of Astronomical Telescopes, Instruments, and Systems). Ten more papers are presented here as Part 2 in the April-June 2018 issue. These papers cover the detailed in-flight performance of the four state-of the-art instruments on-board the Hitomi X-Ray Observatory. These instruments were extremely diverse in their design and principles of operation, ranging from low temperature x-ray calorimeters for high-resolution spectroscopy, CCDs (Charge-Coupled Devices) for wide field imaging, high fill-factor grazing incidence x-ray optics, including multilayer x-ray optics and silicon strip and CdTe strip detectors for high-energy imaging, and a Si/CdTe Compton cameras for extending the bandpass out to 600 kiloelectronvolts. All of these instruments operated as expected and for sufficient time to validate their operating principles and carry out first light scientific investigations, published elsewhere. Collectively, these instruments, all co-aligned and operated simultaneously, provided a tool for astronomers with unprecedented resolution and broadband sensitivity for investigating high-energy processes throughout the universe. These papers serve as part of the Hitomi legacy and will guide the next generation of instruments planned for future missions.

Kelley, Richard L.↗
NASA NTRS2020

A Digital Twin Feasibility Study (Part II):Non-Deterministic Predictions of Fatigue Life Using In-Situ Diagnostics and Prognostics

The Digital Twin (DT) concept has the potential to revolutionize the way systems and their components are designed, managed, maintained, and operated across a vast number of fields from engineering to healthcare. The focus of this work is the implementation of DT for the health management of fatigue critical structures. This paper is the second part of a two-part series. The first of the series demonstrated the use of multi-scale, initiation-to-failure crack growth modeling to form non-deterministic predictions of fatigue life. In this second part, a general method for reducing uncertainty in fatigue life predictions is presented that couples in-situ diagnostics and prognostics in a probabilistic framework. Monte Carlo methods and high-fidelity finite element models are used to (i) generate probabilistic estimates of crack state throughout the life of the same geometrically complex test specimen and (ii) predict fatigue life with decreasing uncertainty as more of these diagnoses are obtained. The ability to predict accurately and in the presence of uncertainty is demonstrated, suggesting that the proposed DT method is feasible for fatigue life prognosis and should be pursued further with a focus on increasing application realism.

Patrick E Leser↗
NASA NTRS2020

Recommendations on Use of Commercial-Off-The-Shelf (COTS) Electrical, Electronic, and Electromechanical (EEE) Parts for NASA Missions

The NASA Electronic Parts & Packaging Program Manager, requested a NASA Engineering and Safety Center independent assessment to summarize Commercial Crew Program and NASA Centers’ current and best practices, and lessons learned, on use of commercial-off-the-shelf (COTS) for all mission risk classifications, and provide recommendations that could lead to future NASA Electronic Parts and Packaging Program and/or Agency guidance on COTS parts. This document contains the outcome of the assessment.

Commercial-Off-The-Shelf↗