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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 505 records · Page 28
All sourcesNASA NTRSDOE OSTI
NASA NTRS2004

Membrane-Based Water Evaporator for a Space Suit

A membrane-based water evaporator has been developed that is intended to serve as a heat-rejection device for a space suit. This evaporator would replace the current sublimator that is sensitive to contamination of its feedwater. The design of the membrane-based evaporator takes advantage of recent advances in hydrophobic micropore membranes to provide robust heat rejection with much less sensitivity to contamination. The low contamination sensitivity allows use of the heat transport loop as feedwater, eliminating the need for the separate feedwater system used for the sublimator. A cross section of the evaporator is shown in the accompanying figure. The space-suit cooling loop water flows into a distribution plenum, through a narrow annulus lined on both sides with a hydrophobic membrane, into an exit plenum, and returns to the space suit. Two perforated metal tubes encase the membranes and provide structural strength. Evaporation at the membrane inner surface dissipates the waste heat from the space suit. The water vapor passes through the membrane, into a steam duct and is vented to the vacuum environment through a back-pressure valve. The back-pressure setting can be adjusted to regulate the heat-rejection rate and the water outlet temperature.

Ungar, Eugene K.↗
NASA NTRS2011

In-Service Monitoring of Steam Pipe Systems at High Temperatures

An effective, in-service health monitoring system is needed to track water condensation in real time through the walls of steam pipes. The system is required to measure the height of the condensed water from outside the pipe, while operating at temperatures that are as high as 250 C. The system needs to account for the effects of water flow and cavitation. In addition, it is desired that the system does not require perforating the pipes and thereby reducing the structural integrity. Generally, steam pipes are used as part of the district heating system carrying steam from central power stations under the streets to heat, cool, or supply power to high-rise buildings and businesses. This system uses ultrasonic waves in pulse-echo and acquires reflected signal data. Via autocorrelation, it determines the water height while eliminating the effect of noise and multiple reflections from the wall of the pipe. The system performs nondestructive monitoring through the walls of steam pipes, and automatically measures the height of condensed water while operating at the high-temperature conditions of 250 C. For this purpose, the ultrasonic pulse-echo method is used where the time-of-flight of the wave reflections inside the water are measured, and it is multiplied by the wave velocity to determine the height. The pulse-echo test consists of emitting ultrasonic wave pulses from a piezoelectric transducer and receiving the reflections from the top and bottom of the condensed water. A single transducer is used as a transmitter as well as the receiver of the ultrasonic waves. To obtain high resolution, a broadband transducer is used and the frequency can be in the range of 2.25 to 10 MHz, providing sharp pulses in the time domain allowing for higher resolution in identifying the individual reflections.

Bar-Cohen, Yoseph↗
NASA NTRS2011

Experimental Investigation and Analysis of an Annular Pogo Accumulator

An experimental investigation was conducted on a scaled annular pogo accumulator for the Ares I Upper Stage. The test article was representative of the LO2 feedline and preliminary accumulator design, and included multiple designs of a perforated ring connecting the accumulator to the core feedline flow. The system was pulse tested in water over a range of pulse frequency and flow rates. Time dependent measurements of pressure at various locations in the test article were used to extract system compliance, inertance, and resistance. Preliminary results indicated a significant deviation from standard orifice flow theory and suggest a strong dependence on feedline average velocity. In addition, several CFD analyses were conducted to investigate the details of the time variant flow field. Both two-dimensional and three-dimensional simulations were performed with time varying boundary conditions used to represent system pulsing. The CFD results compared well with the sub-scale results and demonstrated the influence of feedline average velocity on the flow into and out of the accumulator. This paper presents updated results of the investigation including a parametric design space for determining resistance characteristics. Using the updated experimental results a new scaling relationship has been defined for shear flow over a cavity. A comparison of sub-scale and full scale CFD simulations provided early verification of the scaling of the fluid flowfield and resistance characteristics.

Peugeot, John↗
NASA NTRS2012

Configuration Effects on Liner Performance

The acoustic performance of a duct liner depends not only on the intrinsic properties of the liner but also on the configuration of the duct in which it is used. A series of experiments is performed in the NASA Langley Research Center Curved Duct Test Rig (at Mach 0.275) to evaluate the effect of duct configuration on the acoustic performance of single degree of freedom perforate-over-honeycomb liners. The liners form the sidewalls of the duct's test section. Variations of duct configuration include: asymmetric (liner on one side and hard wall opposite) and symmetric (liner on both sides) wall treatment; inlet and exhaust orientation, in which the sound propagates either against or with the flow; and straight and curved flow path. The effect that duct configuration has on the overall acoustic performance, particularly the shift in frequency and magnitude of peak attenuation, is quantified. The redistribution of incident mode content is shown. The liners constitute the side walls of the liner test section and the scatter of incident horizontal order 1 mode by the asymmetric treatment and order 2 mode by the symmetric treatment into order 0 mode is shown. Scatter of order 0 incident modes into higher order modes is also shown. This redistribution of mode content is significant because it indicates that the liner design can be manipulated such that energy is scattered into more highly attenuated modes, thus enhancing liner performance.

Gerhold, Carl H.↗
NASA NTRS2012

Uncertainty Analysis of the Grazing Flow Impedance Tube

This paper outlines a methodology to identify the measurement uncertainty of NASA Langley s Grazing Flow Impedance Tube (GFIT) over its operating range, and to identify the parameters that most significantly contribute to the acoustic impedance prediction. Two acoustic liners are used for this study. The first is a single-layer, perforate-over-honeycomb liner that is nonlinear with respect to sound pressure level. The second consists of a wire-mesh facesheet and a honeycomb core, and is linear with respect to sound pressure level. These liners allow for evaluation of the effects of measurement uncertainty on impedances educed with linear and nonlinear liners. In general, the measurement uncertainty is observed to be larger for the nonlinear liners, with the largest uncertainty occurring near anti-resonance. A sensitivity analysis of the aerodynamic parameters (Mach number, static temperature, and static pressure) used in the impedance eduction process is also conducted using a Monte-Carlo approach. This sensitivity analysis demonstrates that the impedance eduction process is virtually insensitive to each of these parameters.

Brown, Martha C.↗
NASA NTRS2012

Evaluation of Wall Boundary Conditions for Impedance Eduction Using a Dual-Source Method

The accuracy of the Ingard-Myers boundary condition and a recently proposed modified Ingard-Myers boundary condition is evaluated for use in impedance eduction under the assumption of uniform mean flow. The evaluation is performed at three centerline Mach numbers, using data acquired in a grazing flow impedance tube, using both upstream and downstream propagating sound sources, and on a database of test liners for which the expected behavior of the impedance spectra is known. The test liners are a hard-wall insert consisting of 12.6 mm thick aluminum, a linear liner without a facesheet consisting of a number of small diameter but long cylindrical channels embedded in a ceramic material, and two conventional nonlinear liners consisting of a perforated facesheet bonded to a honeycomb core. The study is restricted to a frequency range for which only plane waves are cut on in the hard-wall sections of the flow impedance tube. The metrics used to evaluate each boundary condition are 1) how well it educes the same impedance for upstream and downstream propagating sources, and 2) how well it predicts the expected behavior of the impedance spectra over the Mach number range. The primary conclusions of the study are that the same impedance is educed for upstream and downstream propagating sources except at the highest Mach number, that an effective impedance based on both the upstream and downstream measurements is more accurate than an impedance based on the upstream or downstream data alone, and that the Ingard-Myers boundary condition with an effective impedance produces results similar to that achieved with the modified Ingard-Myers boundary condition.

Watson, W. R.↗
NASA NTRS2012

The Transition-Edge-Sensor Array for the Micro-X Sounding Rocket

The Micro-X sounding rocket program will fly a 128-element array of transition-edge-sensor microcalorimeters to enable high-resolution X-ray imaging spectroscopy of the Puppis-A supernova remnant. To match the angular resolution of the optics while maximizing the field-of-view and retaining a high energy resolution (< 4 eV at 1 keV), we have designed the pixels using 600 x 600 sq. micron Au/Bi absorbers, which overhang 140 x 140 sq. micron Mo/Au sensors. The data-rate capabilities of the rocket telemetry system require the pulse decay to be approximately 2 ms to allow a significant portion of the data to be telemetered during flight. Here we report experimental results from the flight array, including measurements of energy resolution, uniformity, and absorber thermalization. In addition, we present studies of test devices that have a variety of absorber contact geometries, as well as a variety of membrane-perforation schemes designed to slow the pulse decay time to match the telemetry requirements. Finally, we describe the reduction in pixel-to-pixel crosstalk afforded by an angle-evaporated Cu backside heatsinking layer, which provides Cu coverage on the four sidewalls of the silicon wells beneath each pixel.

Eckart, M. E.↗
NASA NTRS2012

Current Density Measurements of an Annular-Geometry Ion Engine

The concept of the annular-geometry ion engine, or AGI-Engine, has been shown to have many potential benefits when scaling electric propulsion technologies to higher power. However, the necessary asymmetric location of the discharge cathode away from thruster centerline could potentially lead to non-uniformities in the discharge not present in conventional geometry ion thrusters. In an effort to characterize the degree of this potential non-uniformity, a number of current density measurements were taken on a breadboard AGI-Engine. Fourteen button probes were used to measure the ion current density of the discharge along a perforated electrode that replaced the ion optics during conditions of simulated beam extraction. Three Faraday probes spaced apart in the vertical direction were also used in a separate test to interrogate the plume of the AGI-Engine during true beam extraction. It was determined that both the discharge and the plume of the AGI-Engine are highly uniform, with variations under most conditions limited to +/-10% of the average current density in the discharge and +/-5% of the average current density in the plume. Beam flatness parameter measured 30 mm from the ion optics ranged from 0.85 - 0.95, and overall uniformity was shown to generally increase with increasing discharge and beam currents. These measurements indicate that the plasma is highly uniform despite the asymmetric location of the discharge cathode.

Shastry, Rohit↗
NASA NTRS2012

Current Density Measurements of an Annular-Geometry Ion Engine

The concept of the annular-geometry ion engine, or AGI-Engine, has been shown to have many potential benefits when scaling electric propulsion technologies to higher power. However, the necessary asymmetric location of the discharge cathode away from thruster centerline could potentially lead to non-uniformities in the discharge not present in conventional geometry ion thrusters. In an effort to characterize the degree of this potential nonuniformity, a number of current density measurements were taken on a breadboard AGI-Engine. Fourteen button probes were used to measure the ion current density of the discharge along a perforated electrode that replaced the ion optics during conditions of simulated beam extraction. Three Faraday probes spaced apart in the vertical direction were also used in a separate test to interrogate the plume of the AGI-Engine during true beam extraction. It was determined that both the discharge and the plume of the AGI-Engine are highly uniform, with variations under most conditions limited to 10% of the average current density in the discharge and 5% of the average current density in the plume. Beam flatness parameter measured 30 mm from the ion optics ranged from 0.85 0.95, and overall uniformity was shown to generally increase with increasing discharge and beam currents. These measurements indicate that the plasma is highly uniform despite the asymmetric location of the discharge cathode.

Shastry, Rohit↗
NASA NTRS2013

ONERA-NASA Cooperative Effort on Liner Impedance Eduction

As part of a cooperation between ONERA and NASA, the liner impedance eduction methods developed by the two research centers are compared. The NASA technique relies on an objective function built on acoustic pressure measurements located on the wall opposite the test liner, and the propagation code solves the convected Helmholtz equation in uniform ow using a finite element method that implements a continuous Galerkin discretization. The ONERA method uses an objective function based either on wall acoustic pressure or on acoustic velocity acquired above the liner by Laser Doppler Anemometry, and the propagation code solves the linearized Euler equations by a discontinuous Galerkin discretization. Two acoustic liners are tested in both ONERA and NASA ow ducts and the measured data are treated with the corresponding impedance eduction method. The first liner is a wire mesh facesheet mounted onto a honeycomb core, designed to be linear with respect to incident sound pressure level and to grazing ow velocity. The second one is a conventional, nonlinear, perforate-over-honeycomb single layer liner. Configurations without and with ow are considered. For the nonlinear liner, the comparison of liner impedance educed by NASA and ONERA shows a sensitivity to the experimental conditions, namely to the nature of the source and to the sample width.

Primus, Julien↗
NASA NTRS2013

Hydrogen-Enhanced Lunar Oxygen Extraction and Storage Using Only Solar Power

The innovation consists of a thermodynamic system for extracting in situ oxygen vapor from lunar regolith using a solar photovoltaic power source in a reactor, a method for thermally insulating the reactor, a method for protecting the reactor internal components from oxidation by the extracted oxygen, a method for removing unwanted chemical species produced in the reactor from the oxygen vapor, a method for passively storing the oxygen, and a method for releasing high-purity oxygen from storage for lunar use. Lunar oxygen exists in various types of minerals, mostly silicates. The energy required to extract the oxygen from the minerals is 30 to 60 MJ/kg O. Using simple heating, the extraction rate depends on temperature. The minimum temperature is approximately 2,500 K, which is at the upper end of available oven temperatures. The oxygen is released from storage in a purified state, as needed, especially if for human consumption. This method extracts oxygen from regolith by treating the problem as a closed batch cycle system. The innovation works equally well in Earth or Lunar gravity fields, at low partial pressure of oxygen, and makes use of in situ regolith for system insulation. The innovation extracts oxygen from lunar regolith using a method similar to vacuum pyrolysis, but with hydrogen cover gas added stoichiometrically to react with the oxygen as it is produced by radiatively heating regolith to 2,500 K. The hydrogen flows over and through the heating element (HE), protecting it from released oxygen. The H2 O2 heat of reaction is regeneratively recovered to assist the heating process. Lunar regolith is loaded into a large-diameter, low-height pancake reactor powered by photovoltaic cells. The reactor lid contains a 2,500 K HE that radiates downward onto the regolith to heat it and extract oxygen, and is shielded above by a multi-layer tungsten radiation shield. Hydrogen cover gas percolates through the perforated tungsten shielding and HE, preventing oxidation of the shielding and HE, and reacting with the oxygen to form water vapor. The water vapor is filtered through solid regolith to remove unwanted extraction byproducts, and then condensed to a liquid state and stored at 300 to 325 K. Conversion to usable oxygen is achieved by pumping liquid water into a high-pressure electrolyzer, storing the gaseous oxygen at high pressure for use, and diverting the hydrogen back to the reactor or to storage. The results from this design effort show that this oxygen-generating concept can be developed in an efficient system with low specific mass. Advantages include use of regolith as an oxygen source, filter, and thermal insulator. The system can be tested in Earth gravity and can be expected to operate similarly in lunar gravity. The system is scalable, either by increasing the power level and output of a standard module, or by employing multiple modules.

Burton, rodney↗
NASA NTRS2013

Development of the Circulation Control Flow Scheme Used in the NTF Semi-Span FAST-MAC Model

The application of a circulation control system for high Reynolds numbers was experimentally validated with the Fundamental Aerodynamic Subsonic Transonic Modular Active Control semi-span model in the NASA Langley National Transonic Facility. This model utilized four independent flow paths to modify the lift and thrust performance of a representative advanced transport type of wing. The design of the internal flow paths highlights the challenges associated with high Reynolds number testing in a cryogenic pressurized wind tunnel. Weight flow boundaries for the air delivery system were identified at mildly cryogenic conditions ranging from 0.1 to 10 lbm/sec. Results from the test verified system performance and identified solutions associated with the weight-flow metering system that are linked to internal perforated plates used to achieve flow uniformity at the jet exit.

Jones, Gregory S.↗
NASA NTRS2013

UltraSail CubeSat Solar Sail Flight Experiment

UltraSail is a next-generation, highrisk, high-payoff sail system for the launch, deployment, stabilization, and control of very large (km2 class) solar sails enabling high payload mass fractions for interplanetary and deep space spacecraft. UltraSail is a non-traditional approach to propulsion technology achieved by combining propulsion and control systems developed for formation- flying microsatellites with an innovative solar sail architecture to achieve controllable sail areas approaching 1 km2, sail subsystem area densities approaching 1 g/m2, and thrust levels many times those of ion thrusters used for comparable deep space missions. UltraSail can achieve outer planetary rendezvous, a deep-space capability now reserved for high-mass nuclear and chemical systems. There is a twofold rationale behind the UltraSail concept for advanced solar sail systems. The first is that sail-andboom systems are inherently size-limited. The boom mass must be kept small, and column buckling limits the boom length to a few hundred meters. By eliminating the boom, UltraSail not only offers larger sail area, but also lower areal density, allowing larger payloads and shorter mission transit times. The second rationale for UltraSail is that sail films present deployment handling difficulties as the film thickness approaches one micrometer. The square sail requires that the film be folded in two directions for launch, and similarly unfolded for deployment. The film is stressed at the intersection of two folds, and this stress varies inversely with the film thickness. This stress can cause the film to yield, forming a permanent crease, or worse, to perforate. By rolling the film as UltraSail does, creases are prevented. Because the film is so thin, the roll thickness is small. Dynamic structural analysis of UltraSail coupled with dynamic control analysis shows that the system can be designed to eliminate longitudinal torsional waves created while controlling the pitch of the blades, while using solar photon pressure to slew the spin axis. Vacuum tests have also verified that electrostatic and molecular adhesion forces can substantially be eliminated by making the film electrically conductive, reducing the peel force of the film off the storage roll to levels of 100s of micro-N. The innovation demonstrated the capability of deploying a six-micron aluminum- coated film from a reel through a slit in vacuum. The innovation also demonstrated a spin-stabilized method for deploying a long reel of solar sail film using solar pressure to spin-up and orbit raise the satellite, and also a gravity gradient method for deploying a long reel of solar sail film using solar pressure to orbit raise the satellite. The solar sail mass fraction of 25% is consistent with high specific impulse ion systems, but without the added weight and cost of a power source and processing unit. The large sail area, coupled with low film density, is giving UltraSail a high payload fraction. The UltraSail deployment scheme unrolls a micrometerscale reflection-coated polyimide film from a storage mandrel to a maximum length of several kilometers with the aid of a blade tip satellite.

Carroll, David↗
NASA NTRS2014

Analytic Ballistic Performance Model of Whipple Shields

The dual-wall Whipple shield is the shield of choice for lightweight, long-duration flight. The shield uses an initial sacrificial wall to initiate fragmentation and melt an impacting threat that expands over a void before hitting a subsequent shield wall of a critical component. The key parameters to this type of shield are the rear wall and its mass which stops the debris, as well as the minimum pressure generated under threat particle impact of the sacrificial wall and the amount of void that is available for expansion. Ensuring the minimum pressure is sufficiently high to achieve large scale fragmentation/melt of the threat particle enables the expansion of the threat and reduces the momentum flux of the debris on the rear wall. Three key factors in the minimum pressure achieved are the thickness of the sacrificial wall relative to the characteristic dimension of the impacting particle, the density and material cohesion contrast of the sacrificial wall relative to the threat particle and the impact speed. The mass of the rear wall and the sacrificial wall are desirable to minimize for launch costs and dynamic concerns making it important to have an understanding of the effects of density contrast and impact speed. In this paper a fourth key parameter is identified related to fragmentation, which corresponds to the ratio of the size of the projectile relative to the transition from brittle to ductile hole growth in the projectile. Ballistic limit equations have been developed to define the failure limits of a MMOD shield, generally in terms of projectile diameter (or mass), impact velocity, and angle. Within the range of impact velocities relevant for Earth-orbiting spacecraft, three distinct regions of penetration phenomenology have been identified for Whipple shields: center dot Low velocity: the projectile is eroded (and possibly deformed) during its passage through the bumper plate, but is not fragmented. Thus, perforation of the rear wall is by a fragment with a mass and speed equal to or less than the original impactor. center dot Intermediate (shatter) velocity: impact velocities are sufficient to induce projectile fragmentation upon impact with the bumper plate, resulting in a coarse debris cloud with large solid fragments. Increasing velocity within the shatter regime results in increased fragmentation, and eventually melting, of the projectile and bumper fragments, generating a finer and more evenly dispersed debris cloud. Failure of the rear wall is a complicated combination of modes observed at low- and hypervelocity. center dot Hypervelocity: the projectile and holed-out bumper material is completely, or nearly completely, melted and/or vaporized by the initial impact. The resultant debris cloud impacts over a dispersed area of the rear wall, loading it impulsively and inducing failure through rupture or petalling. While each of these regimes are well observed with extensive empirical methods to describe these regions, differences in impactor materials, configurations of shields and questions about the limitations of the attainable impact speeds have left questions that are difficult to answer from completely empirical methods.

Miller, J. E.↗
NASA NTRS2014

Investigating the Present Day Cosmic Dust Flux at the Earth's Surface: Initial Results from the Kwajalein Micrometeorite Collection

Examination of impact craters on the Long Duration Exposure Facility satellite indicate a present day micrometeoroid flux of approx. 30,000 tonnes [1 after 2]. But what portion of this material arrives at the Earth's surface as micrometeorites? Studies of available micrometeorite collections from deep sea sediments [e.g. 3], Greenland blue ice [e.g. 4] and the South Pole water well [e.g. 1] may be complicated by terrestrial weathering and, in some cases, collection bias (magnetic separation for deep sea sediments) and poorly constrained ages. We have recently set up a micrometeorite collection station on Kwajalein Island in the Republic of the Marshall Islands in the Pacific Ocean, using high volume air samplers to collect particles directly from the atmosphere. By collecting in this way, the terrestrial age of the particles is known, the weathering they experience is minimal, and we are able to constrain particle arrival times. Collecting at this location also exploits the considerably reduced anthropogenic background [5]. Method: High volume air samplers were installed on top of the two-story airport building on Kwajalein. These were fitted with polycarbonate membrane filters with 5μm diameter perforations. The flow rates were set to 0.5m3/min, and filters were changed once a week. After collection, filters were washed to remove salt and concentrate particles [see 5] in preparation for analysis by SEM. Results and Discussion: A selection of filters have been prepared and surveyed. Due to their ease of identification our initial investigations have focused on particles resembling cosmic spherules. The spheres can be divided into three main groups: 1. Silicate spherules rich in Al, Ca, K and Na (to varying degrees), 2. Silicate spherules rich in Mg and Fe and 3. Fe-rich spherules. Group 1 spherules are often vesiculated and can occur as aggregates. They are similar in appearance and composition to volcanic microspheres [e.g. 6] and are thus likely terrestrial in origin (volcanic). Those of groups 2 and 3, however, typically exhibit quenched surface textures consistent with cosmic spherules. Initial results suggest there is significant variation in the abundance of these groups from filter to filter. Work is ongoing to fully characterize these spherules and to constrain their flux with time.

Wozniakiewicz, P. J.↗
NASA NTRS2013

Screen Channel Liquid Acquisition Device Outflow Tests in Liquid Hydrogen

This paper presents experimental design and test results of the recently concluded 1-g inverted vertical outflow testing of two 325x2300 full scale liquid acquisition device (LAD) channels in liquid hydrogen (LH2). One of the channels had a perforated plate and internal cooling from a thermodynamic vent system (TVS) to enhance performance. The LADs were mounted in a tank to simulate 1-g outflow over a wide range of LH2 temperatures (20.3 - 24.2 K), pressures (100 - 350 kPa), and flow rates (0.010 - 0.055 kg/s). Results indicate that the breakdown point is dominated by liquid temperature, with a second order dependence on mass flow rate through the LAD. The best performance is always achieved in the coldest liquid states for both channels, consistent with bubble point theory. Higher flow rates cause the standard channel to break down relatively earlier than the TVS cooled channel. Both the internal TVS heat exchanger and subcooling the liquid in the propellant tank are shown to significantly improve LAD performance.

Liquid Acquisition Device↗
NASA NTRS2015

HVI Ballistic Limit Characterization of Fused Silica Thermal Panes

Fused silica window systems are used heavily on crewed reentry vehicles, and they are currently being used on the next generation of US crewed spacecraft, Orion. These systems improve crew situational awareness and comfort, as well as, insulating the reentry critical components of a spacecraft against the intense thermal environments of atmospheric reentry. Additionally, these materials are highly exposed to space environment hazards like solid particle impacts. This paper discusses impact studies up to 10 km/s on a fused silica window system proposed for the Orion spacecraft. A ballistic limit equation that describes the threshold of perforation of a fuse silica pane over a broad range of impact velocities, obliquities and projectile materials is discussed here.

Miller, J. E.↗
NASA NTRS2014

A Fully Non-metallic Gas Turbine Engine Enabled by Additive Manufacturing

The Non-Metallic Gas Turbine Engine project, funded by NASA Aeronautics Research Institute (NARI), represents the first comprehensive evaluation of emerging materials and manufacturing technologies that will enable fully nonmetallic gas turbine engines. This will be achieved by assessing the feasibility of using additive manufacturing technologies for fabricating polymer matrix composite (PMC) and ceramic matrix composite (CMC) gas turbine engine components. The benefits of the proposed effort include: 50 weight reduction compared to metallic parts, reduced manufacturing costs due to less machining and no tooling requirements, reduced part count due to net shape single component fabrication, and rapid design change and production iterations. Two high payoff metallic components have been identified for replacement with PMCs and will be fabricated using fused deposition modeling (FDM) with high temperature capable polymer filaments. The first component is an acoustic panel treatment with a honeycomb structure with an integrated back sheet and perforated front sheet. The second component is a compressor inlet guide vane. The CMC effort, which is starting at a lower technology readiness level, will use a binder jet process to fabricate silicon carbide test coupons and demonstration articles. The polymer and ceramic additive manufacturing efforts will advance from monolithic materials toward silicon carbide and carbon fiber reinforced composites for improved properties. Microstructural analysis and mechanical testing will be conducted on the PMC and CMC materials. System studies will assess the benefits of fully nonmetallic gas turbine engine in terms of fuel burn, emissions, reduction of part count, and cost. The proposed effort will be focused on a small 7000 lbf gas turbine engine. However, the concepts are equally applicable to large gas turbine engines. The proposed effort includes a multidisciplinary, multiorganization NASA - industry team that includes experts in ceramic materials and CMCs, polymers and PMCs, structural engineering, additive manufacturing, engine design and analysis, and system analysis.

manufacturing↗