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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS2015

Computational Process Modeling for Additive Manufacturing (OSU)

Powder-Bed Additive Manufacturing (AM) through Direct Metal Laser Sintering (DMLS) or Selective Laser Melting (SLM) is being used by NASA and the Aerospace industry to "print" parts that traditionally are very complex, high cost, or long schedule lead items. The process spreads a thin layer of metal powder over a build platform, then melts the powder in a series of welds in a desired shape. The next layer of powder is applied, and the process is repeated until layer-by-layer, a very complex part can be built. This reduces cost and schedule by eliminating very complex tooling and processes traditionally used in aerospace component manufacturing. To use the process to print end-use items, NASA seeks to understand SLM material well enough to develop a method of qualifying parts for space flight operation. Traditionally, a new material process takes many years and high investment to generate statistical databases and experiential knowledge, but computational modeling can truncate the schedule and cost -many experiments can be run quickly in a model, which would take years and a high material cost to run empirically. This project seeks to optimize material build parameters with reduced time and cost through modeling.

Bagg, Stacey↗
NASA NTRS1991

Indigenous lunar construction materials

The utilization of local resources for the construction and operation of a lunar base can significantly reduce the cost of transporting materials and supplies from Earth. The feasibility of processing lunar regolith to form construction materials and structural components is investigated. A preliminary review of potential processing methods such as sintering, hot-pressing, liquification, and cast basalt techniques, was completed. The processing method proposed is a variation on the cast basalt technique. It involves liquification of the regolith at 1200-1300 C, casting the liquid into a form, and controlled cooling. While the process temperature is higher than that for sintering or hot-pressing (1000-1100 C), this method is expected to yield a true engineering material with low variability in properties, high strength, and the potential to form large structural components. A scenario for this processing method was integrated with a design for a representative lunar base structure and potential construction techniques. The lunar shelter design is for a modular, segmented, pressurized, hemispherical dome which could serve as habitation and laboratory space. Based on this design, estimates of requirements for power, processing equipment, and construction equipment were made. This proposed combination of material processing method, structural design, and support requirements will help to establish the feasibility of lunar base construction using indigenous materials. Future work will refine the steps of the processing method. Specific areas where more information is needed are: furnace characteristics in vacuum; heat transfer during liquification; viscosity, pouring and forming behavior of molten regolith; design of high temperature forms; heat transfer during cooling; recrystallization of basalt; and refinement of estimates of elastic moduli, compressive and tensile strength, thermal expansion coefficient, thermal conductivity, and heat capacity. The preliminary design of the lunar shelter showed us that joining is a critical technology needed for building a structure from large segments. The problem of joining is important to the design of any structure that is not completely prefabricated. It is especially important when the structure is subjected to tensile loading by an internal pressure. For a lunar shelter constructed from large segments the joints between these large segments must be strong, and they must permit automated construction. With a cast basalt building material which is brittle, there is the additional problem of connecting the joint with the material and avoiding stress concentration that would cause failure. Thus, a well-defined project which we intend to pursue during this coming year is the design of joints for cast basalt structural elements.

Rogers, Wayne P.↗
NASA NTRS2018

Integrated Computational-Experimental Development of Lithium-Air Batteries for Electric Aircraft

The primary obstacle to enable NASA's vision of Green Aviation is the extraordinary energy storage requirements for electric aircraft. Significant advances in high energy, rechargeable, safe batteries are required to enable electric aviation. Boeing's SUGAR and NASA studies have identified 400 Wh/kg as the threshold energy density for general aviation and 750 Wh/kg for commercial regional air service. State of the Art Lithium Ion Battery (LIB) technology currently has a density of 200 Wh/kg and is expected to plateau at 300 Wh/kg due to fundamental chemistry limitations making it unsuitable for future electric aircraft. Additional demanding requirements include high power, rechargeability, and high safety. Such battery technology does not currently exist. The recent considerable activity in battery research (DOE, Tesla Gigafactory, etc) overwhelmingly has been geared towards reducing cost and improving safety of LIB technology in order to promote the adoption of electric automobiles; and thus it is expected to have little impact on electric aviation development. New battery materials will be needed for the "Beyond Li Ion" (BLI) technologies required for high energy, safe electric aviation. Li-Air batteries have the highest known theoretical energy density (3400 Wh/kg) and therefore and if realized promises to transform the global transportation system. These high energy batteries have the potential to meet the energy storage challenges of current and future NASA aeronautics and space missions in addition to many terrestrial transportation applications as well. However, this technology requires significant components development and integration, as it is currently unable to achieve aircraft requirements. The objective of this project is to leverage modern computational materials methods combined with battery multiphysics tools to develop radically advanced compatible cathode and electrolyte materials, build several Li-Air cells, and flight-demonstrate the corresponding Li-Air battery packs. A significant problem for current Lithium-Air batteries is large scale decomposition of the battery electrolyte during operation leading to battery failure after a handful of charge/discharge cycles. Therefore, development of large scale, ultra-high energy, rechargeable, and safe Lithium-Air batteries require highly stable electrolytes that are resistant to decomposition under operating conditions. A NASA-based cross-organizational "dream team" of high-powered experts combined integrated supercomputer modeling, fundamental chemistry analysis, advanced material science, and battery cell development to tackle this very challenging, multidisciplinary problem. The ultimate goal for the team is to develop an integrated experimental/computational infrastructure to produce a reliable predictive capability for the selection of optimal components, their fabrication parameters, and "design rules" of novel cell components for advanced ultra-high energy batteries that can meet energy storage challenges of NASA missions and many terrestrial transportation applications.

Li-air battery↗
NASA NTRS1969

Seismographic recording of large rocket engine operation

Recording equipment for rocket engine vibration is adaptable to determining the structural strength of building materials. This seismographic system is portable and is capable of measuring displacements in the direction of three mutually perpendicular axes.

Dalins, I.↗
NASA NTRS1969

The moon's resources.

Lunar soil as building material and extraction of water, oxygen and rocket propellants from lunar materials for lunar colony needs

Lowman, P. D., Jr.↗
NASA NTRS1972

Conceptual design of a lunar colony

A systems engineering study is presented for a proposed lunar colony. The lunar colony was to grow from an existent, 12-man, earth-dependent lunar surface base and was to utilize lunar resources, becoming as earth-independent as possible. An in-depth treatment of some of the aspects of the lunar colony was given. We have found that the use of lunar resources is feasible for oxygen production (both for breathing and for space tug fuel), food production, and building materials. A program is outlined for recycling waste materials developed at the colony as well as a full program for growth and research activity of the colony to a level of 180 colonists. Recommendations for the lunar colony are given.

Dalton, C.↗
NASA NTRS1975

Computer aided flexible envelope designs

Computer aided design methods are presented for the design and construction of strong, lightweight structures which require complex and precise geometric definition. The first, flexible structures, is a unique system of modeling folded plate structures and space frames. It is possible to continuously vary the geometry of a space frame to produce large, clear spans with curvature. The second method deals with developable surfaces, where both folding and bending are explored with the observed constraint of available building materials, and what minimal distortion result in maximum design capability. Alternative inexpensive fabrication techniques are being developed to achieve computer defined enclosures which are extremely lightweight and mathematically highly precise.

Resch, R. D.↗
NASA NTRS1980

Improving Building Construction Specifications in State and Local Governments

State and local governments can benefit from master specifications systems that centralize data on all types of building materials, products, and processes. Most of these systems are organized according to the MASTERFORMAT system, which, along with guide specifications that require the insertion or deletion of standardized information, resulted from the specific needs of users and providers. For jurisdictions preparing their own specifications, staff time and cost are reduced. For those subcontracting the preparation, master specifications provide a means of evaluating the specifications submitted. Current management specification systems described include SPECINTACT, OMSPEC, MASTERPEC, and the NAVFAC, Corps of Engineers, and GSA guide specifications.

Source record↗
NASA NTRS1985

One application of mega-geomorphology in education

One advantage of a synoptic view displaying landform assemblages provided by imagery is that one can often identify geomorphic processes which have shaped the region and which may affect the habitability of the area over a human life time. Considering the continued growth of the world population and the resultant pressure and the exploitation of land, usually without any consideration given to geologic processes, it is imperative that we attempt to educate as large a segment of the population as we can about geologic processes and how they influence land use. Space platform imagery which exhibits regional landscapes can be used: (1) to show students the impact of geologic processes over relatively short periods of time (e.g., the Mount St. Helens lateral blast); (2) to display the effects of poor planning because of a lack of knowledge of the local geologic processes (e.g., the 1973 image of the Mississippi River flood around St. Louis, MO); and (3) to show the association of certain types of landforms with building materials and other resources (e.g., drumlins and gravel deposits).

Blair, R. W., Jr.↗
NASA NTRS1988

Power requirements for mining and microwave processing of extraterrestrial resources

Research in progress on the use of nuclear power in mining the Martian moons for volatiles and hydrocarbons as well as to power microwave generators for processing both lunar regolith and the spoils from the Martian mines into building materials is described. Previous work on mining the Martian moons developed estimates for the costs and power requirements for extracting and shipping any volatiles that might be found on Phobos and Diemos. The costs were compared to the cost of shipping the same volatiles from Earth and it was found that the mining operation would break even for launch costs from Earth as low as ninety dollars per pound (198 dollars/kg). Above this figure the mines would generate a profit. Based on the results of recent work on the microwave processing of lunar regolith it was decided to refine the concept description. Work under way and to be reported deals with a better definition of the power required for mine operations, nuclear propulsion, and microwave materials processing.

Raymond S. Leonard↗
NASA NTRS1988

The role of presolar dust in the formation of the solar system

The characteristics of presolar dust are discussed and evidence is provided to support the possibility that presolar dust was the primary building material for the meteorites and terrestrial planets. The material in the sun's parent molecular cloud is divided into eight reservoirs. The results show that presolar dust and objects made from processed dust make up the vast majority of the material in primitive chondrites. The present theory is able to account for the chemical and oxygen isotopic variations between meteorite classes, the formation of chondrules, the accretion of chondrites, and parent body metamorphism.

Huss, Gary R.↗
NASA NTRS1990

Momentum harvesting techniques for solar system travel

Astronomers are lately estimating there are 400,000 Earth visiting asteroids larger than 100 meters in diameter. These asteroids are accessible sources of building materials, propellants, oxygen, water, and minerals which also constitute a huge momentum reserve, potentially usable for travel throughout the solar system. To use this momentum, these stealthy objects must be tracked and the extraction of the momentum wanted must be learned. Momentum harvesting by momentum transfer from asteroid to spacecraft, and by using the momentum of the extraterrestrial material to help deliver itself to the destination are discussed. A net and tether concept is the suggested means of asteroid capture, the basic momentum exchange process. The energy damping characteristics of the tether will determine the velocity mismatch that can be tolerated, and hence the amount of momentum that can be harvested per capture. As it plays out of its reel, drag on the tether steadily accelerates the spacecraft. A variety of concepts for riding and using the asteroid after capture are discussed. The hitchhiker uses momentum transfer only. The beachcomber, the caveman, the swinger, the prospector, and the rock wrecker also take advantage of raw asteroidal materials. The chemist and the hijacker go further, they process the asteroid into propellant. Or, an 'asteroid railway system' could evolve with each hijacked asteroid becoming a scheduled train. Travelers could board the space railway system assured that water, oxygen, and propellants await them.

Willoughby, Alan J.↗
NASA NTRS1991

Momentum harvesting techniques for solar system travel

Astronomers are lately estimating there are 400,000 earth visiting asteroids larger than 100 meters in diameter. These asteroids are uniquely accessible sources of building materials, propellants, oxygen, water, and minerals. They also constitute a huge momentum reserve, potentially usable for travel throughout the solar system. To use this momentum, these stealthy objects must be tracked and the ability to extract the desired momentum obtained. Momentum harvesting by momentum transfer from asteroid to spacecraft, and by using the momentum of the extraterrestrial material to help deliver itself to its destination is discussed. The purpose is neither to quantify nor justify the momentum exchange processes, but to stimulate collective imaginations with some intriguing possibilities which emerge when momentum as well as material is considered. A net and tether concept is the suggested means of asteroid capture, the basic momentum exchange process. The energy damping characteristics of the tether determines the velocity mismatch that can be tolerated, and hence the amount of momentum that can be harvested per capture. As the tether plays out of its reel, drag on the tether steadily accelerates the spacecraft and dilutes, in time, the would-be collision. A variety of concepts for riding and using asteroids after capture are introduced. The hitchhiker uses momentum transfer only. The beachcomber, the caveman, the swinger, the prospector, and the rock wrecker also take advantage of raw asteroid materials. The chemist and the hijacker go further, they process the asteroid into propellants. Or, an asteroid railway system could be constructed with each hijacked asteroid becoming a scheduled train. Travelers could board this space railway system assured that water, oxygen propellants, and shielding await them. Austere space travel could give way to comforts, with a speed and economy impossible without nature's gift of earth visiting asteroids.

Willoughby, Alan J.↗
NASA NTRS1992

A basis of settlement: Economic foundations of permanent pioneer communities

High transport costs will dominate the course of lunar development. During the earliest phases, when lunar facilities consist of a research and resource development complex with staff serving tours of a few months, transport costs will encourage local production of fuel, food, and building materials. Once these capabilities are in place and the number of personnel grows to a few hundred, staff rotation might well dominate transport budgets. At that point it would make economic sense to encourage some members of staff to become permanent residents. By analogy with early British settlement in Australia, a vigorous private sector economy could emerge if the lunar organization provided quasi-export earnings through its role as the community's major employer and as the major buyer of locally produced goods. By providing such a market for goods and services, the lunar organization would not only provide a means whereby permanent residents could support themselves, but could also accelerate the process of replacing imported goods with local manufacturers, thereby reducing the cost of operations. By analogy with recent Alaskan experience, if the resource development activity started making money from sales to orbital customers, export taxes and/or royalty payments could also provide means by which a lunar community could support itself.

Jones, Eric M.↗
NASA NTRS1993

Use of particle beams for lunar prospecting

A key issue in choosing the appropriate site for a manned lunar base is the availability of resources, particularly oxygen and hydrogen for the production of water, and ores for the production of fuels and building materials. NASA has proposed two Lunar Scout missions that would orbit the Moon and use, among other instruments, a hard X-ray spectrometer, a neutron spectrometer, and a Ge gamma ray spectrometer to map the lunar surface. This passive instrumentation will have low resolution (tens of kilometers) due to the low signal levels produced by natural radioactivity and the interaction of cosmic rays and the solar wind with the lunar surface. This paper presents the results of a concept definition effort for a neutral particle beam lunar mapper probe. The idea of using particle beam probes to survey asteroids was first proposed by Sagdeev et al., and an ion beam device was fielded on the 1988 Soviet probe to the Mars moon Phobos. During the past five years, significant advances in the technology of neutral particle beams (NPB) have led to a suborbital flight of a neutral hydrogen beam device in the SDIO-sponsored BEAR experiment. An orbital experiment, the Neutral Particle Beam Far Field Optics Experiment (NPB-FOX) is presently in the preliminary design phase. The development of NPB accelerators that are space-operable leads one to consider the utility of these devices for probing the surface of the Moon using gamma ray, X-ray, and optical/UV spectroscopy to locate various elements and compounds. We consider the utility of the NPB-FOX satellite containing a 5-MeV particle beam accelerator as a probe in lunar orbit. Irradiation of the lunar surface by the particle beam will induce secondary and back scattered radiation from the lunar surface to be detected by a sensor that may be co-orbital with or on the particle beam satellite platform, or may be in a separate orbit. The secondary radiation is characteristic of the make-up of the lunar surface. The size of the spot irradiated by the beam is less than 1 km wide along the ground track of the satellite, resulting in the potential for high resolution. The fact that the probe could be placed in polar orbit would result in global coverage of the lunar surface. The orbital particle beam probe could provide the basis for selection of sites for more detailed prospecting by surface rovers.

Toepfer, A. J.↗
NASA NTRS1926

Recent developments in the construction and operation of all-metal airplanes

Experiments on the effect of atmosphere and of sea water on the building materials employed by us have been carried on for years in the North Sea with the aid of the Hamburg Naval Observatory. Parallel experiments are being made at the Pisa Naval Observatory in the Mediterranean Sea. Metal sheets, sections, assemblies and experimental floats are being exposed to the action of the elements. Different construction techniques are discussed and a variety of specific airplanes are presented which incorporate some of the new thinking.

METAL AIRPLANE CONSTRUCTION - DORNIER (GER)↗
NASA NTRS1994

The origin and role of dust in the early solar system

Dust was the primary building material of the solar nebula planetesimals that accumulated to form minor planets, solid planets, and the cores of giant planets. Collected interplanetary dust particle (IDP) samples probably contain preserved samples of nebular dust that formed over a wide range of radial distance. There are two general source regions of IDP's, the asteroid belt and the short-period comets. The collected asteroid particles are likely to be rather representative samples of material that accreted into planetesimals in the 2.2 to 3.3 AU region. The comet samples are likely to be representative samples of grains that accreted in the Kuiper belt region between 20 AU and some hundreds of AU. Many of the solar system effects on grains should have been more pronounced or even restricted to the less than 5 AU region where the asteroids were formed. A major goal of IDP research is to try to identify typical asteroidal and cometary IDP's and to study their properties. If successful this will provide fundamental insight into both the initial solids in the solar nebula and materials modified by a variety of important nebular processes.

Brownlee, Don E.↗
NASA NTRS1998

Application of Rapid Prototyping Methods to High-Speed Wind Tunnel Testing

This study was undertaken in MSFC's 14-Inch Trisonic Wind Tunnel to determine if rapid prototyping methods could be used in the design and manufacturing of high speed wind tunnel models in direct testing applications, and if these methods would reduce model design/fabrication time and cost while providing models of high enough fidelity to provide adequate aerodynamic data, and of sufficient strength to survive the test environment. Rapid prototyping methods utilized to construct wind tunnel models in a wing-body-tail configuration were: fused deposition method using both ABS plastic and PEEK as building materials, stereolithography using the photopolymer SL-5170, selective laser sintering using glass reinforced nylon, and laminated object manufacturing using plastic reinforced with glass and 'paper'. This study revealed good agreement between the SLA model, the metal model with an FDM-ABS nose, an SLA nose, and the metal model for most operating conditions, while the FDM-ABS data diverged at higher loading conditions. Data from the initial SLS model showed poor agreement due to problems in post-processing, resulting in a different configuration. A second SLS model was tested and showed relatively good agreement. It can be concluded that rapid prototyping models show promise in preliminary aerodynamic development studies at subsonic, transonic, and supersonic speeds.

Springer, A. M.↗