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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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Structural response of 3D-printed rubber lattice structures under compressive fatigue
In this work, a new direct UV curing, polyurethane-like, highly stretchable rubber, Elastic ToughRubber 90™ (ETR 90), is demonstrated for 3D printing via photocuring with Texas Instruments DLP® optical systems. An array of test specimens, comprising a sandwich structure with a body-centered cubic lattice core, are 3D printed from ETR 90. The compressive behavior of these specimens is characterized up to 10 k and up to 100 k fatigue-loading cycles. The internal, visually obstructed, structures under loads are visualized using in situ X-ray tomography. All lattice structures remain intact and full recovery is observed, indicating the cyclic durability of the 3D-printed rubber.
Understanding Fracture Aperture and Permeability Evolution due to Carbonate Mineralization Utilizing 3D Printing
Caprock formations are a crucial part of subsurface-engineered systems. Composed largely of shale, caprocks act as natural barriers that prevent the upward migration of fluids, thereby ensuring the containment of stored substances in subsurface formations. Fractures in these formations are potential leakage pathways for stored fluids. Mineral precipitation reactions in these fractures, particularly calcite, can significantly restrict the fluid permeability, reducing leakage potential. However, predictive capabilities of mineral precipitation in fractures and associated permeability evolution are limited due to a lack of fundamental understanding of such reactions in natural samples, complicated by mineral heterogeneity and the complexity of the fracture structure. In this study, 3D-printed fracture samples are used to understand the impact of carbonate mineralization on fracture aperture and permeability evolution. Samples were printed using a digital light processing (DLP) 3D printer and commercial liquid resin. Calcite precipitation was first tested on printed 2D films before conducting plug flow column experiments aimed to understand fracture permeability changes due to mineral precipitation. Contact angle measurement and Fourier transform infrared (FTIR) spectroscopy on printed 2D films show evidence of a substantial amount of surface energy for calcite nucleation and precipitation. Surface topography analysis of printed fractured surfaces reveals comparable values, highlighting the high replicability of the printed samples. During the column experiments, the permeability reduces exponentially due to a decrease in fracture aperture. Reductions in fracture aperture estimated from effluent concentration and 3D X-ray computed tomography (CT) show comparable results. Moreover, 3D X-ray CT images suggest the impact of local flow velocities on precipitation. The insights gained from this research contribute to a deeper understanding of the permeability evolution due to carbonate mineralization in caprock formations.
An algorithm for the solution of dynamic linear programs
The algorithm's objective is to efficiently solve Dynamic Linear Programs (DLP) by taking advantage of their special staircase structure. This algorithm constitutes a stepping stone to an improved algorithm for solving Dynamic Quadratic Programs, which, in turn, would make the nonlinear programming method of Successive Quadratic Programs more practical for solving trajectory optimization problems. The ultimate goal is to being trajectory optimization solution speeds into the realm of real-time control. The algorithm exploits the staircase nature of the large constraint matrix of the equality-constrained DLPs encountered when solving inequality-constrained DLPs by an active set approach. A numerically-stable, staircase QL factorization of the staircase constraint matrix is carried out starting from its last rows and columns. The resulting recursion is like the time-varying Riccati equation from multi-stage LQR theory. The resulting factorization increases the efficiency of all of the typical LP solution operations over that of a dense matrix LP code. At the same time numerical stability is ensured. The algorithm also takes advantage of dynamic programming ideas about the cost-to-go by relaxing active pseudo constraints in a backwards sweeping process. This further decreases the cost per update of the LP rank-1 updating procedure, although it may result in more changes of the active set that if pseudo constraints were relaxed in a non-stagewise fashion. The usual stability of closed-loop Linear/Quadratic optimally-controlled systems, if it carries over to strictly linear cost functions, implies that the saving due to reduced factor update effort may outweigh the cost of an increased number of updates. An aerospace example is presented in which a ground-to-ground rocket's distance is maximized. This example demonstrates the applicability of this class of algorithms to aerospace guidance. It also sheds light on the efficacy of the proposed pseudo constraint relaxation scheme.
Determination of the dispersion constant in a constrained vapor bubble thermosyphon
The isothermal profiles of the extended meniscus in a quartz cuvette were measured in a gravitational field using an image analyzing interferometer which is based on computer enhanced video microscopy of the naturally occurring interference fringes. The experimental results for heptane and pentane menisci were analyzed using the extended Young-Laplace equation. These isothermal results characterized the interfacial force field in-situ at the start of the heat transfer experiments by quantifying the dispersion constant, which is a function of the liquid-solid system and cleaning procedures. The experimentally obtained values of the disjoining pressure and the dispersion constants were compared to that predicted from the DLP theory and good agreements were obtained. The measurements are critical to the subsequent non-isothermal experiments because one of the major variables in the heat sink capability of the CVBT is the dispersion constant. In all previous studies of micro heat pipes the value of the dispersion constant has been 'guesstimated'. One of the major advantages of the current glass cell is the ability to view the extended meniscus at all times. Experimentally. we find that the extended Young-Laplace equation is an excellent model for the force field at the solid-liquid-vapor interfaces.
Determination of the dispersion constant in a constrained vapor bubble thermosyphon
The isothermal profiles of the extended meniscus in a quartz cuvette were measured in a gravitational field using an image analyzing interferometer which is based on computer enhanced video microscopy of the naturally occurring interference fringes. The experimental results for heptane and pentane menisci were analyzed using the extended Young Laplace Equation. These isothermal results characterized the interfacial force field in-siru at the start of the heat transfer experiments by quantifying the dispersion constant, which is a function of the liquid-solid system and cleaning procedures. The experimentally obtained values of the disjoining pressure and the dispersion constants were compared to that predicted from the DLP theory and good agreements were obtained. The measurements are critical to the subsequent non-isothermal experiments because one of the major variables in the heat sink capability of the Constrained Vapor Bubble Thermosyphon, CVBT, is the dispersion constant. In all previous studies of micro heat pipes the value of the dispersion constant has been 'estimated'. One of the major advantages of the current glass cell is the ability to view the extended meniscus at all times. Experimentally, we find that the extended Young-Laplace Equation is an excellent model for the force field at the solid-liquid-vapor interfaces.
Demonstration of the Wide-Field Imaging Interferometer Testbed Using a Calibrated Hyperspectral Image Projector
The Wide-field Imaging Interferometer testbed (WIIT) at NASA's Goddard Space Flight Center uses a dual-Michelson interferometric technique. The WIIT combines stellar interferometry with Fourier-transform interferometry to produce high-resolution spatial-spectral data over a large field-of-view. This combined technique could be employed on future NASA missions such as the Space Infrared Interferometric Telescope (SPIRIT) and the Sub-millimeter Probe of the Evolution of Cosmic Structure (SPECS). While both SPIRIT and SPECS would operate at far-infrared wavelengths, the WIIT demonstrates the dual-interferometry technique at visible wavelengths. The WIIT will produce hyperspectral image data, so a true hyperspectral object is necessary. A calibrated hyperspectral image projector (CHIP) has been constructed to provide such an object. The CHIP uses Digital Light Processing (DLP) technology to produce customized, spectrally-diverse scenes. CHIP scenes will have approximately 1.6-micron spatial resolution and the capability of . producing arbitrary spectra in the band between 380 nm and 1.6 microns, with approximately 5-nm spectral resolution. Each pixel in the scene can take on a unique spectrum. Spectral calibration is achieved with an onboard fiber-coupled spectrometer. In this paper we describe the operation of the CHIP. Results from the WIIT observations of CHIP scenes will also be presented.
Visible-Infrared Hyperspectral Image Projector
The VisIR HIP generates spatially-spectrally complex scenes. The generated scenes simulate real-world targets viewed by various remote sensing instruments. The VisIR HIP consists of two subsystems: a spectral engine and a spatial engine. The spectral engine generates spectrally complex uniform illumination that spans the wavelength range between 380 nm and 1,600 nm. The spatial engine generates two-dimensional gray-scale scenes. When combined, the two engines are capable of producing two-dimensional scenes with a unique spectrum at each pixel. The VisIR HIP can be used to calibrate any spectrally sensitive remote-sensing instrument. Tests were conducted on the Wide-field Imaging Interferometer Testbed at NASA s Goddard Space Flight Center. The device is a variation of the calibrated hyperspectral image projector developed by the National Institute of Standards and Technology in Gaithersburg, MD. It uses Gooch & Housego Visible and Infrared OL490 Agile Light Sources to generate arbitrary spectra. The two light sources are coupled to a digital light processing (DLP(TradeMark)) digital mirror device (DMD) that serves as the spatial engine. Scenes are displayed on the DMD synchronously with desired spectrum. Scene/spectrum combinations are displayed in rapid succession, over time intervals that are short compared to the integration time of the system under test.
Additive Manufacturing and Working Fluid Characterization of Ceramic Heat Pipes
In this work, additively manufactured (AM) aluminum nitride (AlN) ceramic heat pipes were developed to improve spacecraft heat rejection capabilities beyond the current state-of-the-art metal systems. A low sintering temperature aluminum nitride slurry is developed for digital light processing printing (DLP) and the optimal debinding curves are examined. Printed AlN parts are characterized via SEM and optical profilometry. AlN 3D-printed parts are also tested for compatibility with aluminum bromide, aluminum chloride, and iodine, among other proposed working fluids at 350-600 K in an inert atmosphere, with reactivity measured via SEM and Fourier transform infrared spectroscopy (FTIR).
PRODUCTION OF GLASS-TO-METAL SEALS USING ADDITIVE MANUFACTURING TECHNIQUES
Glass-to-metal (GtM) seals are hermetic barriers between glass and metal components, often used in the electronic and vacuum industries. Creating the seals traditionally requires heating all the components to the glass melting temperature, where the glass will flow and bond to the metal. Due to the manufacturing constraints of the individual components and sealing conditions there are geometric and material restrictions. Additive manufacturing techniques were used to make GtM seals to reduce these restrictions. Hermetic, single pin seals were produced using printed metal shells, by selective laser melting (SLM), and digital light processing (DLP) printed glass preforms. Glass preforms were printed with photosensitive resin mixed with a silicate sealing glass powder in a 1:2 weight ratio. Thermal analysis, TGA/DSC, and screening experiments were used to determine an organic removal schedule. Video techniques determined a sintering schedule by producing a densification curve at different isothermal holds which were fit with a viscous sintering model. Single pin seals were also produced use a laser assisted manufacturing (LAM) process as an alternative to the conventional furnace sealing process. A Nd:YAG laser was focused on a solid glass preform, heating the glass to form the glass-metal bond. The sealing glass was doped with a transition metal oxide, Fe2O3 or CuO, to increase absorption of the laser wavelength. The interface of hermetic LAM seals were analyzed using electron microscopy, compared to conventional prepared seals, finding a reduction of interfacial morphologies.
Accuracy of stereolithography printed alumina with digital light processing
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