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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 NTRSDate not supplied

Successes and Failures of Metal Additive Manufacturing for Rocket Engines

NASA has been developing additive manufacturing (AM) for various technical and programmatic advantages for complex rocket engine and aerospace components. This maturation has focused on various AM processes, new alloys, characterizing material properties, developing standards, producing demonstrator parts, and integrating AM hardware in liquid rocket engines through test-fail-fix cycles, as well as application and dissemination of lessons learned of the AM lifecycle. The importance of proper AM processing was made evident in the failure of a Laser Powder Bed Fusion (L-PBF) copper-alloy combustion chamber during a hot-fire test due to a degraded material quality. The hot-fire test aimed to demonstrate high duty cycle under a risk-tolerant development project, where consequences of component failure would be minimal. However, the unintentional component failure emphasized the necessity of robust material characterization and rigorous process control procedures for the safe use of AM components in critical applications. This presentation provides an overview of the development failure, a discussion on the evaluation of the failed chamber and supplemental chambers produced at the same time, a representative material samples that included intentional build witness lines, and a summary of the key results and recommendations from the evaluations. NASA continues to approach AM processes and designs with a level of risk and acceptance of failures that is appropriate for the project objectives, with the overall goal of safe implementation of AM technology and transferring AM technology into commercial space applications. This presentation with provide critical awareness to the community lessons learned on proper implementation of AM.

Additive Manufacturing↗
NASA NTRS1999

Consortium for Materials Development in Space

During FY99 the Consortium for Materials Development in Space (CMDS) was reorganized around the following guidelines: industry driven, product focus, an industry led advisory council, focus on University of Alabama in Huntsville (UAH) core competencies, linkage to regional investment firms to assist commercialization and to take advantage of space flights. The organizational structure of the CMDS changed considerably during the year. The decision was made to reduce the organization to a Director and an Administrative Assistant. The various research projects, including the employees, were transferred to the appropriate UAH research center or college. In addition, an advisory council was established to provide direction and guidance to the CMDS to ensure a strong commercial focus. The council will (i) review CMDS commercial development plans and provide feedback, (ii) perform an annual evaluation of the Center's progress and present the results of this review to the UAH Vice President for Research, (iii) serve as an avenue of communication between the CMDS and its commercial partners, and (iv) serve as an ambassador and advocate for the CMDS.

Source record↗
NASA NTRS2024

Ensuring Safety of Government Personnel During Suborbital Spaceflight

The NASA Suborbital Crew (SubC) project is focused on enabling flights by NASA civil servants, such as scientists and engineers conducting research, on suborbital vehicles. A broader goal is ensuring that commercial human spaceflight is both viable and safe. Within the Commercial Crew Program (CCP), the SubC project is exploring game-changing methods to perform safety assessments to enable NASA personnel to fly on suborbital missions. Commercial suborbital space flight capabilities are anticipated to be more accessible, affordable, and available than missions to the International Space Station and could provide additional opportunities for testing and qualification of space flight hardware, human-tended microgravity research, and further cutting-edge research enabled by the space environment. Although NASA currently permits human tended suborbital payloads for non-civil servants under auspices of NASA’s Flight Opportunities Program, the SubC effort will enable civil servant scientists, researchers, and even engineers to accompany their experiments and tests into the space microgravity environment. Figure 1 illustrates how the SubC program complements other microgravity experimental platforms. The targeted scope for SubC includes end-to-end suborbital capabilities reaching ~80km with several minutes of sustained microgravity (Table 1). The NASA SubC project office is working with the Federal Aviation Administration’s Office of Commercial Space Transportation (FAA-AST) and the commercial suborbital space transportation industry to develop an efficient and holistic approach to a safety review and eventual government participation in suborbital flight. The current FAA certification process for suborbital launches is congressionally mandated to only consider public safety. NASA is responsible for understanding the risks to its employees should they fly on a commercially available suborbital flight. The SubC project is employing a Safety Case approach, applied to commercial suborbital providers, which is not a traditional certification process as was used for the SpaceX Dragon and Boeing Starliner vehicles. Rather, it is an assessment using elements of NASA’s Risk-Informed Safety Case and the Armstrong Flight Research Center’s Airworthiness Assessment process.

Elizabeth C Blome↗
NASA NTRS2021

Micromechanics-based Modeling of Laminated SiC/SiC Ceramic Matrix Composites

The behavior and response of ceramic matrix composites (CMCs), in particular silicon carbide fiber reinforced silicon carbide matrix (SiC/SiC), is affected by many factors such as variation of fiber volume fraction, residual stresses resulting from processing of the composites at high temperature, random microstructures, and the presence of matrix flaws (e.g., voids, pores, cracks etc.) as well as general material nonlinearity and heterogeneity that occurs randomly in a composite. Residual stresses arising from the phase change of constituents are evaluated in this paper and it is shown that they do influence composite strength and need to be properly accounted for. Additionally, the microstructures (location of fiber centers, coating thickness etc.) of advanced CMCs are usually disordered (or random) and fiber diameter and strength typically have a distribution. They rarely resemble the ordered fiber packing (square, rectangular, or hexagonal) that is generally assumed in micromechanics-based models with periodic boundary conditions for computational expediency. These issues raise the question of how should one model such systems effectively? Can an ordered hexagonal packed repeating unit cell (RUC) accurately represent the random microstructure behavior? How many fibers need to be included to enable accurate representation? Clearly, the number of fibers within an RUC must be limited to insure a balance between accuracy and efficiency. NASA’s in-house micromechanics-based code MAC/GMC provides a framework to analyze such RUCs for the overall composite behavior and the FEAMAC computer code provides linkage of MAC/GMC to the commercial FEA code, ABAQUS. The appropriate level of discretization of the RUC as well as the analysis method employed, i.e., Generalized Method of Cells (GMC) or High Fidelity Generalized Method of Cells (HFGMC), is investigated in this paper in the context of a unidirectional as well as a cross-ply laminated CMC. Results including effective composite properties, proportional limit stress (an important design parameter) and fatigue are shown utilizing both GMC as well as HFGMC. Finally, a few multiscale analyses are performed on smooth bar test coupons as well as test coupons with features such as open-hole and double notches using FEAMAC. Best practices and guidance are provided to take these phenomena into account and keep a proper balance between fidelity (accuracy) and efficiency. Following these guidelines can account for important physics of the problem and provide significant advantages when performing large multiscale composite structural analyses.

Ceramic Matrix Composites↗
NASA NTRSDate not supplied

NASA Engineering & Safety Center (NESC) Assessment – Recommendations on Use of Commercial-Off-The-Shelf (COTS) Parts for NASA Missions

This presentation is to provide an update on the NASA Engineering & Safety Center (NESC) Assessment of "Recommendations on Use of Commercial-Off-The-Shelf (COTS) Parts for NASA Missions". Phase I was a published report and Phase II is on-going. Phase I captured the current NASA center practices on using COTS parts while Phase II provides updated NESC recommendation of using COTS parts for NASA missions with different risk classifications.

EEE parts↗
NASA NTRS2012

An Integrated, Layered-Spinel Composite Cathode for Energy Storage Applications

At low operating temperatures, commercially available electrode materials for lithium-ion batteries do not fully meet the energy and power requirements for NASA fs exploration activities. The composite cathode under development is projected to provide the required energy and power densities at low temperatures and its usage will considerably reduce the overall volume and weight of the battery pack. The newly developed composite electrode material can provide superior electrochemical performance relative to a commercially available lithium cobalt system. One advantage of using a composite cathode is its higher energy density, which can lead to smaller and lighter battery packs. In the current program, different series of layered-spinel composite materials with at least two different systems in an integrated structure were synthesized, and the volumetric and gravimetric energy densities were evaluated. In an integrated network of a composite electrode, the effect of the combined structures is to enhance the capacity and power capabilities of the material to levels greater than what is possible in current state-of-the-art cathode systems. The main objective of the current program is to implement a novel cathode material that meets NASA fs low temperature energy density requirements. An important feature of the composite cathode is that it has at least two components (e.g., layered and spinel) that are structurally integrated. The layered material by itself is electrochemically inactive; however, upon structural integration with a spinel material, the layered material can be electrochemically activated, thereby delivering a large amount of energy with stable cycling. A key aspect of the innovation has been the development of a scalable process to produce submicronand micron-scale particles of these composite materials. An additional advantage of using such a composite electrode material is its low irreversible loss (.5%), which is primarily due to the unique activation of the composite. High columbic efficiency (greater than 99%) upon cycling may indicate the formation of a stable SEI (solid-electrolyte interface) layer, which can contribute to long cycle life. The innovation in the current program, when further developed, will enable the system to maintain high energy and power densities at low temperatures, improve efficiency, and further stabilize and enhance the safety of the cell.

Hagh, Nader↗
NASA NTRS1997

Commercializing Defense Technologies and Helping Defense Firms Succeed in Commercial Markets: A Report on the Objectives, Activities, and Accomplishments of the TAP-IN Program

Technology Access for Product Innovation (TAP-IN), the largest technology deployment project funded by TRP, was competitively selected through a national solicitation for proposals. TAP-IN was created to help companies access and apply defense technologies and help defense-dependent companies enter new commercial markets. Defense technologies included technologies developed by DoD, DOE, NASA, and their contractors. TAP-IN was structured to provide region-based technology access services that were able to draw on technology resources nationwide. TAP-IN provided expert assistance in all stages of the commercialization process from concept through prototype design to capital sourcing and marketing strategy. TAP-IN helped companies locate new technology, identify business partners, secure financing, develop ideas for new products, identify new markets, license technology, solve technical problems, and develop company-specific applications of federal technology. TAP-IN leveraged NASA's existing commercial technology network to create an integrated national network of organizations that assisted companies in every state. In addition to NASA's six regional technology transfer centers (RTTCs), TAP-IN included business and technology development organizations in every state, the Industrial Designers Society of America, and the Federal Laboratory Consortium (FLC).

Source record↗
NASA NTRS2002

Second Generation Reusable Launch Vehicle Development and Global Competitiveness of US Space Transportation Industry: Critical Success Factors Assessment

In response to the unrelenting call in both public and private sectors fora to reduce the high cost associated with space transportation, many innovative partially or fully RLV designs (X-34-37) were initiated. This call is directed at all levels of space missions including scientific, military, and commercial and all aspects of the missions such as nonrecurring development, manufacture, launch, and operations. According to Wertz (2000), over thirty years, the cost of space access has remained exceedingly high. For example, London (1996, 1994), Wertz (1996) and Hammond (1999) have discussed in details the reasons for the skyrocket launch costs. The consensus in the popular press is that to decrease the current astronomical cost of access to space, more safer, reliable, and economically viable SGRLVs must be developed. This current skyrocket cost of space launch poses a major constraint to broadening and expanding U.S. economic activities in LEO. As a result, affecting global competitiveness of U. S. CST industry. Foreign firms control greater share of the launch market once dominated by U.S. For example, in the mid 1980s U.S. service providers had approximately 100% of the commercial space launch market revenues, but today U.S. has less than 50% of that market (Graham, 2001). Further, because of the growth potential in the international launch market, countries such as Brazil, India, Japan and Israel are gearing up to enter the global launch market with their own commercial space launch vehicles. Considering this fact, NASA and U.S. space launch industry cannot afford to lag behind. Therefore developing SGRLVs will immeasurably improve the U.S. space transportation capabilities by helping the U.S. to regain the global commercial space markets while supporting the transportation capabilities of NASA's space mission.

Chris I. Enyinda↗
NASA NTRS2014

Air Systems Provide Life Support to Miners

Through a Space Act Agreement with Johnson Space Center, Paragon Space Development Corporation, of Tucson, Arizona, developed the Commercial Crew Transport-Air Revitalization System, designed to provide clean air for crewmembers on short-duration space flights. The technology is now being used to help save miners' lives in the event of an underground disaster.

Source record↗
NASA NTRS2006

BOUSSOLE: A Joint CNRS-INSU, ESA, CNES, and NASA Ocean Color Calibration and Validation Activity

This report presents the Bouee pour l'acquisition de Series Optiques a Long Terme (BOUSSOLE) project, the primary objectives of which are to provide a long-term time series of optical properties in support of a) calibration and validation activities associated with satellite ocean color missions, and b) bio-optical research in oceanic waters. The following are included in the report: 1) an introduction to the rationale for establishing the project; 2) a definition of vicarious calibration and the specific requirements attached to it; 3) the organization of the project and the characteristics of the measurement site--in the northwestern Mediterranean Sea; 4) a qualitative overview of the collected data; 5) details about the buoy that was specifically designed and built for this project; 6) data collection protocols and data processing techniques; 7) a quantitative summary of the collected data, and a discussion of some sample results, including match-up analyses for the currently operational ocean color sensors, namely MERIS, SeaWiFS, and MODIS; and 8) preliminary results of the vicarious radiometric calibration of MERIS, including a tentative uncertainty budget. The results of this match-up analysis allow performance comparisons of various ocean color sensors to be performed, demonstrating the ability of the BOUSSOLE activity, i.e., combining a dedicated platform and commercial-off-the-shelf instrumentation, to provide data qualified to monitor the quality of ocean color products on the long term.

Antoine, David↗
NASA NTRS1998

Macroeconomic Benefits of Low-Cost Reusable Launch Vehicles

The National Aeronautics and Space Administration (NASA) initiated its Reusable Launch Vehicle (RLV) Technology Program to provide information on the technical and commercial feasibility of single-stage to orbit (SSTO), fully-reusable launchers. Because RLVs would not depend on expendable hardware to achieve orbit, they could take better advantage of economies of scale than expendable launch vehicles (ELVs) that discard costly hardware on ascent. The X-33 experimental vehicle, a sub-orbital, 60%-scale prototype of Lockheed Martin's VentureStar SSTO RLV concept, is being built by Skunk Works for a 1999 first flight. If RLVs achieve prices to low-earth orbit of less than $1000 US per pound, they could hold promise for eliciting an elastic response from the launch services market. As opposed to the capture of existing market, this elastic market would represent new space-based industry businesses. These new opportunities would be created from the next tier of business concepts, such as space manufacturing and satellite servicing, that cannot earn a profit at today's launch prices but could when enabled by lower launch costs. New business creation contributes benefits to the US Government (USG) and the US economy through increases in tax revenues and employment. Assumptions about the costs and revenues of these new ventures, based on existing space-based and aeronautics sector businesses, can be used to estimate the macroeconomic benefits provided by new businesses. This paper examines these benefits and the flight prices and rates that may be required to enable these new space industries.

Shaw, Eric J.↗
NASA NTRS1993

Synergistic control center development utilizing commercial technology and industry standards

The development of the Control Center Complex (CCC), a synergistic control center supporting both the Space Station Freedom and the Space Shuttle Program, is described. To provide maximum growth and flexibility, the CCC uses commercial off-the-shelf technology and industry standards. The discussion covers the development philosophy, CCC architecture, data distribution, the software platform concept, workstation platform, commercial tools for the CCC, and benefits of synergy.

Anderson, Brian L.↗
NASA NTRS1993

The Iridium (tm) system: Personal communications anytime, anyplace

The Iridium system is designed to provide handheld personal communications between diverse locations around the world at any time and without prior knowledge of the location of the personal units. This paper provides an overview of the system, the services it provides, its operation, and an overview of the commercial practices and relatively high volume satellite production techniques which will make the system cost effective. A constellation of 66 satellites will provide an orbiting, spherical-shell, infrastructure for this global calling capability. The satellites act as tall cellular towers and allow convenient operation for portable handheld telephones. The system will provide a full range of services including voice, paging, data, geolocation, and fax capabilities. Motorola is a world leader in the production of high volume, high quality, reliable telecommunications hardware. One of Iridium's goals is to apply these production techniques to high reliability space hardware. Concurrent engineering, high performance work teams, advanced manufacturing technologies, and improved assembly and test methods are some of the techniques that will keep the Iridium system cost effective. Mobile, global, flexible personal communications are coming that will allow anyone to call or receive a call from/to anyplace at anytime. The Iridium system will provide communications where none exist today. This connectivity will allow increased information transfer, open new markets for various business endeavors, and in general increase productivity and development.

Hatlelid, John E.↗
NASA NTRS2017

Simulation Evaluation of Pilot Inputs for Real Time Modeling During Commercial Flight Operations

Aircraft dynamics characteristics can only be identified from flight data when the aircraft dynamics are excited sufficiently. A preliminary study was conducted into what types and levels of manual piloted control excitation would be required for accurate Real-Time Parameter IDentification (RTPID) results by commercial airline pilots. This includes assessing the practicality for the pilot to provide this excitation when cued, and to further understand if pilot inputs during various phases of flight provide sufficient excitation naturally. An operationally representative task was evaluated by 5 commercial airline pilots using the NASA Ice Contamination Effects Flight Training Device (ICEFTD). Results showed that it is practical to use manual pilot inputs only as a means of achieving good RTPID in all phases of flight and in flight turbulence conditions. All pilots were effective in satisfying excitation requirements when cued. Much of the time, cueing was not even necessary, as just performing the required task provided enough excitation for accurate RTPID estimation. Pilot opinion surveys reported that the additional control inputs required when prompted by the excitation cueing were easy to make, quickly mastered, and required minimal training.

Martos, Borja↗
NASA NTRS2000

Commercial Contributions to the Success of the HEDS Enterprise: A Working Model

The future of NASA involves the exploration of space beyond the confines of orbit about the Earth. This includes robotic investigations and Human Exploration and Development of Space (HEDS). The HEDS Strategic Plan states: "HEDS will join with the private sector to stimulate opportunities for commercial development in space as a key to future settlement. Near-term efforts will emphasize joint pilot projects that provide clear benefit to Earth from the development of near-Earth space." In support of this endeavor, NASA has established the Commercial Development of Space as a prime goal and is exploring all the ways in which NASA might make contributions to this development. NASA has long supported the development of space for commercial use. In 1985 it formally established and provided funds to support a program which created a number of joint ventures between universities and industry for this purpose. These were known as Centers for the Commercial Development of Space (CCDS). In 1999 NASA established a broader policy on commercialization with the aim of encouraging near-term commercial investment in conjunction with the International Space Station. Joint pilot projects will be initiated to stimulate this near-term investment. The long-term development of commercial concepts utilizing space access continues through the activities of the Commercial Space Centers (CSC), a sub-set of the original CCDS group. These Centers primarily require access to space for the conduct of their work. The remainder of the initial Centers focus on the development of tools and infrastructure to support users of the space environment. It is in this arena that long term development for commercial use and infrastructure development will occur. This paper will provide a retrospective examination of the Commercial Centers, the variety of models employed, the lessons learned, and the progress to date. This review will provide the bases for how successful models can be employed to accelerate private investment in the development of the infrastructure necessary for the success of the HEDS enterprise.

Nall, Mark↗
NASA NTRS2007

Simulation of Unique Pressure Changing Steps and Situations in Psa Processes

A more rigorous cyclic adsorption process simulator is being developed for use in the development and understanding of new and existing PSA processes. Unique features of this new version of the simulator that Ritter and co-workers have been developing for the past decade or so include: multiple absorbent layers in each bed, pressure drop in the column, valves for entering and exiting flows and predicting real-time pressurization and depressurization rates, ability to account for choked flow conditions, ability to pressurize and depressurize simultaneously from both ends of the columns, ability to equalize between multiple pairs of columns, ability to equalize simultaneously from both ends of pairs of columns, and ability to handle very large pressure ratios and hence velocities associated with deep vacuum systems. These changes to the simulator now provide for unique opportunities to study the effects of novel pressure changing steps and extreme process conditions on the performance of virtually any commercial or developmental PSA process. This presentation will provide an overview of the cyclic adsorption process simulator equations and algorithms used in the new adaptation. It will focus primarily on the novel pressure changing steps and their effects on the performance of a PSA system that epitomizes the extremes of PSA process design and operation. This PSA process is a sorbent-based atmosphere revitalization (SBAR) system that NASA is developing for new manned exploration vehicles. This SBAR system consists of a 2-bed 3-step 3-layer system that operates between atmospheric pressure and the vacuum of space, evacuates from both ends of the column simultaneously, experiences choked flow conditions during pressure changing steps, and experiences a continuously changing feed composition, as it removes metabolic CO2 and H20 from a closed and fixed volume, i.e., the spacecraft cabin. Important process performance indicators of this SBAR system are size, and the corresponding CO2 and H20 removal efficiencies, and N2 and O2 loss rates. Results of the fundamental behavior of this PSA process during extreme operating conditions will be presented and discussed.

Ebner, Armin D.↗
NASA NTRS1969

Tape reading fixture

Commercially available roller type desk pad provides an efficient and orderly manner of handling rolled paper tapes for proofreading. The fixture, which is modified to accept Flex-O-Writer or similar tapes and roll them in either direction, reduces the chance of damaging or soiling the tapes through repeated handling.

Source record↗
NASA NTRS1972

Improved sampling of compressed gases for condensable hydrocarbon content

Sampling process was developed which uses commercially available high pressure filters and provides measurements in fraction of time required by older methods. Measurements show no significant difference in results between low pressure and high pressure samples. Filter method is slightly more accurate than scrubber technique.

Peterson, M. H.↗