Search NASA⌕ Search

SEARCH · Search NASA

Results for “Novel Processing”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 55 records · Page 3

Goodrich Electro-Optical Systems AMSD Progress Update and Test Plans

The goal of the Advanced Mirror System Demonstrator (AMSD) program is to develop and demonstrate technology for low mass primary mirror systems that can be produced at low cost and with short manufacturing times. In addition, specific performance objectives must be demonstrated at ambient and cryogenic temperatures. The Goodrich approach for AMSD is based on a thin facesheet supported through an array of figure-control actuators by a passive, stiff reaction structure. The facesheet is fused silica figured to the desired sphere by a novel process referred to as Stressed Mirror Polishing and light-weighted by water jet milling. The mirror facesheet and the reaction structure are CTE-matched For cryogenic operation. Progress update on the design, the fabrication and the test plans, both ambient and cryogenic, will be presented.

Garcia, Enrique↗

Planetary Defense: Options for Deflection of Near Earth Objects

Several recent near-miss encounters with asteroids and comets have focused attention on the threat of a catastrophic impact with the Earth. This document reviews the historical impact record and current understanding of the number and location of Near Earth Objects (NEO’s) to address their impact probability. Various ongoing projects intended to survey and catalog the NEO population are also reviewed. Details are then given of an MSFC-led study, intended to develop and assess various candidate systems for protection of the Earth against NEO’s. An existing program, used to model the NEO threat, was extensively modified and is presented here. Details of various analytical tools, developed to evaluate the performance of proposed technologies for protection against the NEO threat, are also presented. Trajectory tools, developed to model the outbound path a vehicle would take to intercept or rendezvous with a target asteroid or comet, are described. Also, details are given of a tool that was created to model both the un-deflected inbound path of an NEO as well as the modified, post-deflection, path. The number of possible options available for protection against the NEO threat was too numerous for them to all be addressed within the study; instead, a representative selection were modeled and evaluated. The major output from this work was a novel process by which the relative effectiveness of different threat mitigation concepts can be evaluated during future, more detailed, studies. In addition, several new or modified mathematical models were developed to analyze various proposed protection systems. A summary of the major lessons learned during this study is presented, as are recommendations for future work. It is hoped that this study will serve to raise the level attention about this very real threat and also demonstrate that successful defense is both possible and practicable, provided appropriate steps are taken.

Planets↗

The Highly Robust Electrical Interconnects and Ultrasensitive Biosensors Based on Embedded Carbon Nanotube Arrays

We report on our recent breakthroughs in two different applications using well-aligned carbon nanotube (CNT) arrays on Si chips, including (1) a novel processing solution for highly robust electrical interconnects in integrated circuit manufacturing, and (2) the development of ultrasensitive electrochemical DNA sensors. Both of them rely on the invention of a bottom-up fabrication scheme which includes six steps, including: (a) lithographic patterning, (b) depositing bottom conducting contacts, (c) depositing metal catalysts, (d) CNT growth by plasma enhanced chemical vapor deposition (PECVD), (e) dielectric gap-filling, and (f) chemical mechanical polishing (CMP). Such processes produce a stable planarized surface with only the open end of CNTs exposed, whch can be further processed or modified for different applications. By depositing patterned top contacts, the CNT can serve as vertical interconnects between the two conducting layers. This method is fundamentally different fiom current damascene processes and avoids problems associated with etching and filling of high aspect ratio holes at nanoscales. In addition, multiwalled CNTs (MWCNTs) are highly robust and can carry a current density of 10(exp 9) A/square centimeters without degradation. It has great potential to help extending the current Si technology. The embedded MWCNT array without the top contact layer can be also used as a nanoelectrode array in electrochemical biosensors. The cell time-constant and sensitivity can be dramatically improved. By functionalizing the tube ends with specific oligonucleotide probes, specific DNA targets can be detected with electrochemical methods down to subattomoles.

Li, Jun↗

Novel Passivating/Antireflective Coatings for Space Solar Cells

We are developing a novel process to grow passivating/antireflective (AR) coatings for terrestrial and space solar cells. Our approach involves a Room Temperature Wet Chemical Growth (RTWCG) process, which was pioneered, and is under development at SPECMAT, Inc., under a Reimbursable Space Act Agreement with NASA Glenn Research Center. The RTWCG passivating/AR coatings with graded index of refraction are applied in one easy step on finished (bare) cells. The RTWCG coatings grown on planar, textured and porous Si, as well as on poly-Si, CuInSe2, and III-V substrates, show excellent uniformity irrespective of surface topography, crystal orientation, size and shape. In this paper we present some preliminary results of the RTWCG coatings on Si and III-V substrates that show very good potential for use as a passivation/AR coating for space solar cell applications. Compared to coatings grown using conventional techniques, the RTWCG coatings have the potential to reduce reflection losses and improve current collection near the illuminated surface of space solar cells, while reducing the fabrication costs.

Faur, Mircea↗

New Materials for Structural Composites and Protective Coatings

The objective of this Phase I project was to create novel conductive materials that are lightweight and strong enough for multiple ground support equipment and Exploration applications. The long-term goal is to combine these materials within specially designed devices to create composites or coatings with diagnostic capabilities, increased strength, and tunable properties such as transparency, electroluminescence, and fire resistance. One such technology application is a smart windows system. In such a system, the transmission of light through a window is controlled by electrical power. In the future, these materials may also be able to absorb sunlight and convert it into electrical energy to produce light, thereby creating a self-sufficient lighting system. This experiment, conducted in collaboration with the Georgia Institute of Technology, demonstrated enhancements in fabricating fiber materials from carbon nanotubes (CNT). These nanotubes were grown as forests in an ultra-high-purity chemical vapor deposition (CVD) furnace and then drawn, using novel processing techniques, into fibers and yarns that would be turned into filaments. This work was submitted to the Journal of Advanced Functional Materials. The CNT fibers were initially tested as filament materials at atmospheric pressure; however, even under high current loads, the filaments produced only random sparking. The CNT fibers were also converted into transparent, hydrophobic, and conductive sheets. Filament testing at low vacuum pressures is in progress, and the technology will be enhanced in 2008. As initial proof of the smart-windows application concept, the use of CNT sheets as composites/ protective coatings was demonstrated in collaboration with Nanocomp Technologies of Concord, New Hampshire.

Source record↗

NASA Satellite Data for Seagrass Health Modeling and Monitoring

Time series derived information for coastal waters will be used to provide input data for the Fong and Harwell model. The current MODIS land mask limits where the model can be applied; this project will: a) Apply MODIS data with resolution higher than the standard products (250-m vs. 1-km). b) Seek to refine the land mask. c) Explore nearby areas to use as proxies for time series directly over the beds. Novel processing approaches will be leveraged from other NASA projects and customized as inputs for seagrass productivity modeling

Spiering, Bruce A.↗

Apparatus for hydrogen and carbon production via carbon aerosol-catalyzed dissociation of hydrocarbons

A novel process and apparatus is disclosed for sustainable, continuous production of hydrogen and carbon by catalytic dissociation or decomposition of hydrocarbons at elevated temperatures using in-situ generated carbon particles. Carbon particles are produced by decomposition of carbonaceous materials in response to an energy input. The energy input can be provided by at least one of a non-oxidative and oxidative means. The non-oxidative means of the energy input includes a high temperature source, or different types of plasma, such as, thermal, non-thermal, microwave, corona discharge, glow discharge, dielectric barrier discharge, or radiation sources, such as, electron beam, gamma, ultraviolet (UV). The oxidative means of the energy input includes oxygen, air, ozone, nitrous oxide (NO.sub.2) and other oxidizing agents. The method, apparatus and process of the present invention is applicable to any gaseous or liquid hydrocarbon fuel and it produces no or significantly less CO.sub.2 emissions compared to conventional processes.

Muradov, Nazim Z.↗

GMI Instrument Spin Balance Method, Optimization, Calibration, and Test

The Global Microwave Imager (GMI) instrument must spin at a constant rate of 32 rpm continuously for the 3 year mission life. Therefore, GMI must be very precisely balanced about the spin axis and CG to maintain stable scan pointing and to minimize disturbances imparted to the spacecraft and attitude control on-orbit. The GMI instrument is part of the core Global Precipitation Measurement (GPM) spacecraft and is used to make calibrated radiometric measurements at multiple microwave frequencies and polarizations. The GPM mission is an international effort managed by the National Aeronautics and Space Administration (NASA) to improve climate, weather, and hydro-meteorological predictions through more accurate and frequent precipitation measurements. Ball Aerospace and Technologies Corporation (BATC) was selected by NASA Goddard Space Flight Center to design, build, and test the GMI instrument. The GMI design has to meet a challenging set of spin balance requirements and had to be brought into simultaneous static and dynamic spin balance after the entire instrument was already assembled and before environmental tests began. The focus of this contribution is on the analytical and test activities undertaken to meet the challenging spin balance requirements of the GMI instrument. The novel process of measuring the residual static and dynamic imbalances with a very high level of accuracy and precision is presented together with the prediction of the optimal balance masses and their locations.

Ayari, Laoucet↗

GMI Instrument Spin Balance Method, Optimization, Calibration and Test

The Global Microwave Imager (GMI) instrument must spin at a constant rate of 32 rpm continuously for the 3-year mission life. Therefore, GMI must be very precisely balanced about the spin axis and center of gravity (CG) to maintain stable scan pointing and to minimize disturbances imparted to the spacecraft and attitude control on-orbit. The GMI instrument is part of the core Global Precipitation Measurement (GPM) spacecraft and is used to make calibrated radiometric measurements at multiple microwave frequencies and polarizations. The GPM mission is an international effort managed by the National Aeronautics and Space Administration (NASA) to improve climate, weather, and hydro-meteorological predictions through more accurate and frequent precipitation measurements. Ball Aerospace and Technologies Corporation (BATC) was selected by NASA Goddard Space Flight Center to design, build, and test the GMI instrument. The GMI design has to meet a challenging set of spin balance requirements and had to be brought into simultaneous static and dynamic spin balance after the entire instrument was already assembled and before environmental tests began. The focus of this contribution is on the analytical and test activities undertaken to meet the challenging spin balance requirements of the GMI instrument. The novel process of measuring the residual static and dynamic imbalances with a very high level of accuracy and precision is presented together with the prediction of the optimal balance masses and their locations.

Ayari, Laoucet↗

Let's Exploit Available Knowledge on Vegetation Fluorescence

The potential to measure vegetation fluorescence from space (1) and to derive from it direct information on the gross primary productivity (GPP) of terrestrial ecosystems is probably the most thrilling development in remote sensing and global ecology of recent years, as it moves Earth observation techniques from the detection of canopy biophysics (e.g., fraction of absorbed radiation) and biochemistry (chlorophyll and nitrogen content) to the realm of ecosystem function. The existence of a functional relationship between fluorescence and photosynthesis has been elucidated over the last decade by several laboratories, notably as part of the preliminary studies of the European Space Agency Fluorescence Explorer (FLEX) Earth Explorer Mission. The empirical observation presented by Guanter et al. (2) of a linear relationship between fluorescence radiance and GPP, however, provides the first experimental confirmation of the feasibility of the approach— already thoroughly tested at leaf level—at the desired scale, despite the confounding effects associated with the satellite detection of such a faint signal. A word of clarification is needed here. The use of fluorescence as a probe of leaf photochemistry has been a staple of plant ecophysiology for decades, rooted in a sound understanding of photosynthetic energy dissipation. However, most past studies had to rely for the interpretation of results on active (pulse-saturated) techniques, making them unsuitable for remote-sensing applications. Over recent years, however, novel process based models have been developed for the interpretation of steady-state, solar-induced fluorescence at the leaf to canopy scale (3). We are therefore in a position to move beyond the mere empirical observation of an association between GPP and fluorescence radiance. In particular, Guanter et al. (2) base their analysis on the assumption of a constant ratio between photosynthetic and fluorescence light use efficiencies (equation 3 in ref. 2).We know, however, that the ratio is not constant, but changes widely in response to light, CO2, stomatal limitations, and extreme stress (4, 5). What’s more, we can make sense of such changes, thus extracting valuable information from the very scatter that is apparent in their data. However, this process will require the availability of more tailored instruments, such as the one planned for the FLEX mission. As already stressed by Guanter et al. (2), the spatial resolution of the Global Ozone Monitoring Experiment-2 sensor (40 × 80 km) makes it difficult to compare meaningfully the fluorescence signal with ground measurements, when only 60–70% of the footprint consists of the desired land-cover type (table S1 in ref. 2), suggesting that this could be largely responsible for the low signals observed in European grasslands. Moreover, the overpass time of the MetOp-A satellite (9:30 AM) implies that fluorescence is generally measured under light-limiting conditions, when fluorescence is only marginally affected by stomatal closure even under stress conditions. This result could explain the seasonal mismatch with daily GPP observed in natural ecosystems in the absence of irrigation (figure 4 in ref. 2). We hope, therefore, that this welcome contribution to this fast-advancing field will help demonstrate the potential of the new technique, and pave the way for more refined studies under both a technological and scientific point of view.

Space↗

Solid-state Architecture Batteries for Enhanced Rechargeability and Safety (SABERS)

All-electric vertical take-off and landing vehicles (eVTOL) for urban air mobility (UAM) concepts face numerous challenging technical barriers before their introduction into the consumer marketplace. The most challenging of these technical barriers to overcome is developing an energy storage system capable of meeting the rigorous aerospace safety and performance criteria. The performance metrics for eVTOL craft, such as specific energy and cycle life, are at least 2 times greater than those of electric automobiles. Furthermore, safety is essential for operation of commercial electric aerovehicles. Preliminary systems level analysis studies have indicated that there are five key properties which must be optimized for successful implementation of battery systems. Those five key criteria are safety, energy density, power, packaging design and scalability. Current state-of-the-art (SOA) lithium-ion batteries meet or exceed the requirements for electric aviation in the areas of power and scalability, yet are insufficient in the key performance criteria of energy, safety and packaging design. The SABERS concept proposes a battery that meets all five key performance criteria through the development of a solid-state architecture cell design utilizing high energy density and power density sulfur-selenium cathode with a lithium metal anode. Data will be presented demonstrating high performing sulfur - selenium cathode that offers a balanced energy to power density ratio, which can be tailored to the specific application by altering the stoichiometric ratios of sulfur to selenium. This cathode is being developed by implementing NASA patented holey graphene technology as a highly conductive, ultra-lightweight electrode scaffold. Novel processing methods allow developing solid-state electrolyte that is a safe, non-flammable replacement to the highly flammable liquid organic electrolytes currently used in SOA lithium-ion batteries. The all solid-state lithium-sulfur-selenium cell design enables the implementation of a bipolar stack configuration, which has the advantages of reducing overall cell weight, reducing the amount of interfaced connections for the cell, and minimizing cooling requirements for the battery. In particular, the solid-state design allows for a serial stacking configuration to enable dense packaging of the cells within the bipolar stack. Lastly, optimization of battery components occurs through a robust and rigorous combination of various computational modeling techniques covering multiple length scales. The expected result will be a solid-state battery with operational temperatures from 0 °C to 150 °C which provides the required energy density, discharge rate, and inherent safety to meet strict aerospace performance criteria.

solid state batteries↗

Synchronous Separation, Seaming, Sealing and Sterilization (S4) using Brazing for Sample Containerization and Planetary Protection

The return of samples back to Earth in future missions would require protection of our planet from the risk of bringing uncontrolled biological materials back with the samples. This protection would require “breaking the chain of contact (BTC)”, where any returned material reaching Earth for further analysis would have to be sealed inside a container with extremely high confidence. Therefore, the acquired samples would need to be contained while destroying any potential biological materials that may contaminate the external surface of the container. A novel process that could be used to contain returning samples has been developed and demonstrated in a quarter scale size. The process consists of brazing using non-contact induction heating that synchronously separates, seams, seals and sterilizes (S4) the container. The use of brazing involves melting at temperatures higher than 500°C and this level of heating assures sterilization of the exposed areas since all carbon bonds (namely, organic materials) are broken at this temperature. The mechanism consists of a double wall container with inner and outer shells having Earth-clean interior surfaces. The process consists of two-steps, Step-1: the double wall container halves are fabricated and brazed (equivalent to production on Earth); and Step-2 is the S4 process and it is the equivalent to the execution on-orbit around Mars. In a potential future mission, the double wall container would be split into two halves and prepared on Earth. The potential on-orbit execution would consist of inserting the orbiting sample (OS) container into one of the halves and then mated to the other half and brazed. The latest results of this effort will be described and discussed in this manuscript.

Salazar, Eduardo↗

Potential of Materials to Impact Megawatt-Scale Electric Machines

High specific power density, megawatt-scale electric machines (motors and generators) are needed to enable megawatt-scale electric aircraft propulsion systems for single isle aircraft. Thermally insulating electrical insulation materials in the stator windings limits the ability to thermally manage the heat produced in these machines. Polymer-ceramic composites along with novel processing techniques offer viable options to improve the thermal conductivity of the electrical insulation system. This paper outlines current National Aeronautics and Space Administration’s Glenn Research Center efforts of developing several polymer-ceramic systems and processing techniques as they relate to electric machine insulation (including potting). There is also analysis of how these factors relate to machine performance.

electric macnhine↗

An Efficient Approach to Collect Inlet Characterization Data

This report considers a novel process to acquire performance data for supersonic mixed compression inlets that is faster, and therefore less costly, than the previous one. In the previous process, measurements were recorded in discrete increments. The backpressuring actuator was advanced, there was a pause to allow for airflow fluctuations to diminish, and then the measurements were recorded. While this process was methodical, reliable and accurate, it consumed significant wind-on time. In general, high-speed wind tunnels are expensive to operate considering maintenance, energy and human resource requirements. Furthermore, many facilities, such as blowdown wind tunnels, are limited in the duration that they can maintain the desired test condition. Consequently, a quick method to collect the measurements is desired. A favored approach has the actuator moving in a continuous fashion with measurements recorded as the actuator continuously progresses through the increment points. This approach, identified as the dynamic inlet characteristic data acquisition procedure, uses in situ dynamic high-speed pressure sensors to measure pressure signals. While faster, continuous movement adds dynamic effects to the data. To better understand these dynamic effects and other potential influences, a study was undertaken to compare wind tunnel measurements taken at discrete actuator position points with data gathered during continuous actuator movement. Specially, plots of inlet pressure recovery versus mass capture ratio, or total pressure characteristic curves, were examined. The data were measured during experiments in the NASA Glenn Research Center Abe Silverstein 10- by 10-Foot Supersonic Wind Tunnel (SWT) with an inlet propulsion test article. In this report, the wind tunnel experiment and the study objectives are described. The processes to reduce the data and for analysis are explained. A discussion of the results along with features noted in the data is given. Finally, conclusions from this study that may be used to guide future wind tunnel experiment planning are presented.

Inlet↗

An Efficient Approach to Collect Inlet Characterization Data

This report considers a novel process to acquire performance data for supersonic mixed compression inlets that is faster, and therefore less costly, than the previous one. In the previous process, measurements were recorded in discrete increments. The backpressuring actuator was advanced, there was a pause to allow for airflow fluctuations to diminish, and then the measurements were recorded. While this process was methodical, reliable and accurate, it consumed significant wind-on time. In general, high-speed wind tunnels are expensive to operate considering maintenance, energy and human resource requirements. Furthermore, many facilities, such as blowdown wind tunnels, are limited in the duration that they can maintain the desired test condition. Consequently, a quick method to collect the measurements is desired. A favored approach has the actuator moving in a continuous fashion with measurements recorded as the actuator continuously progresses through the increment points. This approach, identified as the dynamic inlet characteristic data acquisition procedure, uses in situ dynamic high-speed pressure sensors to measure pressure signals. While faster, continuous movement adds dynamic effects to the data. To better understand these dynamic effects and other potential influences, a study was undertaken to compare wind tunnel measurements taken at discrete actuator position points with data gathered during continuous actuator movement. Specially, plots of inlet pressure recovery versus mass capture ratio, or total pressure characteristic curves, were examined. The data were measured during experiments in the NASA Glenn Research Center Abe Silverstein 10- by 10-Foot Supersonic Wind Tunnel (SWT) with an inlet propulsion test article. In this report, the wind tunnel experiment and the study objectives are described. The processes to reduce the data and for analysis are explained. A discussion of the results along with features noted in the data is given. Finally, conclusions from this study that may be used to guide future wind tunnel experiment planning are presented.

Data Acquisition↗

Bulk YBa2Cu3O(x) superconductors through pressurized partial melt growth processing

A novel pressurized partial melt growth process has been developed for producing large pieces of bulk Y-Ba-Cu-O superconductors. During long-time partial melt growth stage, an additional driving force for solidification is obtained by using pressurized oxygen gas. The microstructure and superconducting properties of the resulting samples were investigated. It was found that this new technique can eliminate porosity and inhomogeneity, promote large-scale grain-texturing, and improve interdomain coupling as well.

Hu, S.↗

A Novel Additive Manufacturing Process Metric for Predicting Spatter-related Porosity in Laser Powder Bed Fusion

Components fabricated using the powder bed fusion laser beam metallic (PBF) additive manufacturing (AM) process comprise a multitude of sequential weld passes. Porosity defects resulting from weld pass inconsistencies are a concern for PBF materials and have a strong adverse effect on the mechanical properties. In an effort to understand and avoid spatter induced porosity, this work aims to provide a novel computational technique that can be used to quantify and predict the sequence-sensitive impact of spatter upon the PBF process stability and consequential porosity in as-printed material. A novel spatter impact AM model-based process metric (AM-PM) is introduced to model and quantify the impact that spatter has on the PBF process. The occurrence of spatter induced porosity is studied using thermal rise, lack of fusion, and spatter impact AM-PMs synchronized with porosity measured by high-resolution X-ray computed tomography. Six cylindrical specimens were designed to compare the AM-PM correlations with porosity across two different laser powers and three hatch scanning strategies. A point field based computational approach is shown to be effective for testing the influence of the different AM-PMs and interrogating the physical process conditions underlying the porosity formation. Further, characterization using optical metallography and scanning electron microscopy indicated that both keyhole and lack of fusion porosity correlated with the spatter impact AM-PM, which can be exploited to predict and control spatter related porosity by the hatch strategy. Efforts to predict porosity composition within PBF material should incorporate the PBF process disturbances that can result from spatter. The spatter impact AM-PM can be readily incorporated into the development of defect prediction models at the part scale.

Additive Manufacturing↗

Novel Catalysts and Processing Technologies for Production of Aerospace Fuels from Non-Petroleum Raw Materials

Transportation fuels production (including aerospace propellants) from non-traditional sources (gases, waste materials, and biomass) has been an active area of research and development for decades. Reducing terrestrial waste streams simultaneous with energy conversion, plentiful biomass, new low-cost methane sources, and/or extra-terrestrial resource harvesting and utilization present significant technological and business opportunities being realized by a new generation of visionary entrepreneurs. We examine several new approaches to catalyst fabrication and new processing technologies to enable utilization of these nontraditional raw materials. Two basic processing architectures are considered: a single-stage pyrolysis approach that seeks to basically re-cycle hydrocarbons with minimal net chemistry or a two-step paradigm that involves production of supply or synthesis gas (mainly carbon oxides and H2) followed by production of fuel(s) via Sabatier or methanation reactions and/or Fischer-Tröpsch synthesis. Optimizing the fraction of product stream relevant to targeted aerospace (and other transportation) fuels via modeling, catalyst fabrication and novel reactor design are described. Energy utilization is a concern for production of fuels for either terrestrial or space operations; renewable sources based on solar energy and/or energy efficient processes may be mission enabling. Another important issue is minimizing impurities in the product stream(s), especially those potentially posing risks to personnel or operations through (catalyst) poisoning or (equipment) damage. Technologies being developed to remove (and/or recycle) heteroatom impurities are briefly discussed as well as the development of chemically robust catalysts whose activities are not diminished during operation. The potential impacts on future missions by such new approaches as well as balance of system issues are addressed.

space processing↗