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NASA NTRSDate not supplied

Large-scale Additive Manufacturing for Exploration

Additive Manufacturing (AM) is emerging as a mainstream manufacturing technology, and demand for large part manufacturing is getting stronger. Direct Metal Deposition (DMD) is a DED technology based on laser and powder metal application using a closed-loop-feedback control system. This webinar focuses on additive manufacturing of NASA’s RS-25 engine nozzle liner using DMD technology. This liner (10ft in height and 8ft in diameter) is beyond the print capability of existing 3D printing processes. To print this part, significant advancements were made to the DMD technology by deploying two process heads in the machine and expanding the machine work envelop to allow manufacturing of such large parts in a safe and efficient environment. A successful demonstration of the AM of the RS25 engine nozzle liner marks a new era in 3D printing and elevates the current 3D printing technology to a new level for affordable manufacturing of large metal parts.

Additive Manufacturing↗

NASA NTRS2008

Distributed Aviation Concepts and Technologies

Aviation has experienced one hundred years of evolution, resulting in the current air transportation system dominated by commercial airliners in a hub and spoke infrastructure. While the first fifty years involved disruptive technologies that required frequent vehicle adaptation, the second fifty years produced a stable evolutionary optimization of decreasing costs with increasing safety. This optimization has resulted in traits favoring a centralized service model with high vehicle productivity and cost efficiency. However, it may also have resulted in a system that is not sufficiently robust to withstand significant system disturbances. Aviation is currently facing rapid change from issues such as environmental damage, terrorism threat, congestion and capacity limitations, and cost of energy. Currently, these issues are leading to a loss of service for weaker spoke markets. These catalysts and a lack of robustness could result in a loss of service for much larger portions of the aviation market. The impact of other competing transportation services may be equally important as casual factors of change. Highway system forecasts indicate a dramatic slow down as congestion reaches a point of non-linearly increasing delay. In the next twenty-five years, there is the potential for aviation to transform itself into a more robust, scalable, adaptive, secure, safe, affordable, convenient, efficient and environmentally friendly system. To achieve these characteristics, the new system will likely be based on a distributed model that enables more direct services. Short range travel is already demonstrating itself to be inefficient with a centralized model, providing opportunities for emergent distributed services through air-taxi models. Technologies from the on-demand revolution in computers and communications are now available as major drivers for aviation on-demand adaptation. Other technologies such as electric propulsion are currently transforming the automobile industry, and will also significantly alter the functionality of future distributed aviation concepts. Many hurdles exist, including technology, regulation, and perception. Aviation has an inherent governmental role not present in other recent on-demand transformations, which may pose a risk of curtailing aviation democratization .

Moore, Mark D.↗

NASA NTRS2019

Design of Experiment for the Measurement of Aerosol Droplet Size Distribution of Temperature-Controlled Thermally Atomized Printed Electronic Inks

In-Space Manufacturing (ISM) centers around NASA’s growing need and ability to produce space technologies on demand in space. As the future of long term presence in space and deep space exploration approach, fundamental questions of our dependence on earth resupply to Low Earth Orbit (LEO) remain unanswered. ISM is leading various effort to evaluate the feasibility of producing essential spares and redundant parts on demand to enable a sustainable space-based supply chain model for part resupply. Among the parts and systems being considered, Avionics form the neural network of modern day aircraft and space vehicles providing a wealth of information ranging from Guidance, Navigation, and Control (GN&C) systems to on board Environmental Control and Life Support (ECLS) systems. Recent advances in the use of Aerosol Jet Technology to print Avionics components ranging from electrical traces on a circuit board to complex transistors and sensors raise the possibility of using such technology to reproduce or recreate electronic parts on demand with the help of custom electronics 3D printers. The challenge herein lies within the ability of such printers to generate and deposit an aerosol of electronic material utilizing processes independent of or enhanced by gravity to ensure controllably identical or improved behavior of the aerosol in an International Space Station (ISS) laboratory and on the ground. The behavior as well as the hazards and properties associated with such aerosols in a microgravity environment must be understood well in order to merit a feasible approach to utilizing them for manufacturing in space. In this report, we outline the experimental setup of a modified conventional vaping device to be used as the ideal gravity independent thermal atomization mechanism to generate aerosol. Our objective is to identify the ideal mass, density, and volume of our aerosolized droplets of ink to conclude that there exist a threshold of aerosolized ink droplet sizes that are indeed independent of the effects of gravity and remain stable after atomization. We use a Malvern Spraytec® Spray Particle Size Analyzer to perform real-time laser diffraction measurement of our ink droplets during atomization. The droplet size between conductive ink, dielectric ink and vegetable glycerin have been measured and contrasted. Furthermore, the mechanism of thermal atomization versus traditional pneumatic and ultrasonic atomization for operation in microgravity have been explored.

Wu, Chih-Hao↗

NASA NTRS1992

Data management in NOAA

NOAA has 11 terabytes of digital data stored on 240,000 computer tapes. There are an additional 100 terabytes (TB) of geostationary satellite data stored in digital form on specially configured SONY U-Matic video tapes at the University of Wisconsin. There are over 90,000,000 non-digital form records in manuscript, film, printed, and chart form which are not easily accessible. The three NOAA Data Centers service 6,000 requests per year and publish 5,000 bulletins which are distributed to 40,000 subscribers. Seventeen CD-ROM's have been produced. Thirty thousand computer tapes containing polar satellite data are being copied to 12 inch WORM optical disks for research applications. The present annual data accumulation rate of 10 TB will grow to 30 TB in 1994 and to 100 TB by the year 2000. The present storage and distribution technologies with their attendant support systems will be overwhelmed by these increases if not improved. Increased user sophistication coupled with more precise measurement technologies will demand better quality control mechanisms, especially for those data maintained in an indefinite archive. There is optimism that the future will offer improved media technologies to accommodate the volumes of data. With the advanced technologies, storage and performance monitoring tools will be pivotal to the successful long-term management of data and information.

Callicott, William M.↗

NASA NTRSDate not supplied

Development of Aluminum/Air Battery as High-Capacity Primary Battery Energy Source for SUSAN Electrofan Project

High-capacity, high-performance, and safe battery technologies are demanded by the Subsonic Single Aft eNgine (SUSAN) Electrofan concept design project under National Aeronautics and Space Administration (NASA) electrified aircraft development program. These battery technologies, including both secondary (i.e., rechargeable) batteries for hybrid/electric propulsion and primary batteries (i.e. non-rechargeable or single-use) for backup/emergency use in case of turbine engine failure, are important and vital components in SUSAN concept design. This paper is focused on aluminum (Al)-air battery, which is considered to be the most promising candidate to meet the energy goal of primary batteries for SUSAN project. However, there are challenges for Al-air batteries, including aluminum self-corrosion with hydrogen (H2) gassing and sluggish kinetics of oxygen reduction reaction (ORR) in air-cathode. In this paper, the preliminary results on investigation of electrolytes and additives on controlling aluminum self-corrosion/H2 gassing suppression and the study of air-cathode design for ORR improvement are presented and discussed.

James Wu↗

NASA NTRSDate not supplied

Process Development for Printing Copper Conductible Ink on Flexible Substrates Using Aerosol Jet Technology

Rise in demand for wearable consumer electronics products has given an impetus to the development of flexible electronics technology encompassing flexible substrates and compatible circuitry. Also, additive manufacturing of flexible electronics is emerging rapidly via several techniques such as Inkjet and Aerosol Jet Printing (AJP). The basic component of all flexible circuits to be printed by these technologies is conductible ink, which is generally silver ink. Few studies exist on the printing of copper conductible ink and not many copper ink formulations are available in the market as that of silver inks. This study aims to develop a process development study for deposition of copper conductible lines on flexible substrates using the aerosol jet printing technology. The process development study includes investigation of photosintering parameters for obtaining desirable electrical resistance and shear load to failure values for the printed line. Different pre-drying techniques such as oven pre-drying and platen pre-drying have been used for improving the electrical and mechanical properties of the conductive traces. Techniques such as optical microscopy and white light interferometry have been used for the characterization of print quality of the conductible lines.

printed electronics↗

NASA NTRS1979

Spinoff 1979

Technology is knowledge, the technical "know-how" employed by a society to produce things that improve the quality of human life. Like other forms of knowledge, it is transferable; once developed, technology can be applied to uses different-and often remote-from the original application. Thus, the technology that NASA has developed in more than two decades of space and aeronautical research constitutes a valuable national resource, a bank of knowledge available for secondary utilization, or "spinoff." NASA mainline programs, by their challenging nature, are particularly demanding of technological advance; meeting their goals has forced extraordinary advancements in virtually every scientific and technological discipline. For that reason, the wealth of aerospace-generated knowledge available for transfer is exceptionally diverse, and much of it is readily applicable to secondary use over a broad spectrum of public needs and conveniences. Through its Congressionally mandated Technology Utilization Program, NASA seeks to promote wider use of this technological resource. The program provides a link between the technology bank and those in either the private or public sectors who might be able to re-use the technology productively. Its aim is to accelerate the transfer process, to bring to the marketplace sooner those spinoffs which might eventually occur in the normal course of events, and to gain thereby more immediate economic benefit in terms of new products and new jobs. The program has been remarkably successful. Since its inception 17 years ago, thousands of spinoff products and processes have emerged. Some of these innovations bring only moderate increments of economic gain or lifestyle improvement, but many others amount to significant public benefits, with economic values often running to millions of dollars. Collectively, spinoffs provide a substantial bonus return on the funds invested in aerospace research. This publication is intended to increase public awareness of the resource that is NASA's technology bank and its potential for further public benefit. It is devoted primarily to the NASA technology transfer process, but in the interests of perspective it also describes related areas of NASA endeavor. Section 1 consists of a resume of NASA's current mainline programs. These programs are producing direct public benefit through direct application of technology; at the same time, they are contributing to indirect benefit-spinoff-by generating new technology which may find secondary application in the future. Section 2 is the focal point of this volume. It contains a representative sampling of spinoff products and processes employed in various avenues of everyday life, and it describes briefly the NASA technology from which these transfers derived. Section 3 details the mechanisms of the technology transfer process, including the means by which NASA seeks to stimulate technology utilization. Also described are NASA's activities in a related area of technology transfer: provision of assistance to agencies interested in exploiting the benefit potential of satellite remote sensing technology.

Haggerty, James J.↗

NASA NTRSDate not supplied

Progress of Aluminum/Air Battery Development for SUSAN Electrofan Project

Safe and high-performance battery technologies are demanded by the Subsonic Single Aft eNgine (SUSAN) Electrofan concept design project under National Aeronautics and Space Administration (NASA) electrified aircraft development program. Aluminum (Al)-air battery with very high theoretical specific energy density, is considered as promising battery chemistry which has the potential to meet the targeted specific energy goal of primary battery energy technology for the SUSAN project. In addition to having the exceptional electrochemical properties, aluminum is light weight, rich abundance, low cost, environmentally friendly, and has a good electrical conductivity and recyclability, which is among the key characteristics of SUSAN project on battery energy needs. A non-flammable aqueous electrolyte is used to prevent the fire and thermal runaway hazard for the safety of this battery chemistry. However, there are challenges for Al-air battery in practical application, mainly due to self-corrosion of Al and slow kinetics of oxygen reduction in air-cathode to impact the high-rate performance. Progress on addressing these challenges was made and some of the results were reported in our previous paper. In this paper, the focus is on the investigation of various factors, including electrolyte concentrations, temperature, and air-cathode loadings on ionic transport properties and discharge performance at different current densities. The results are discussed, and the progress is reported.

James J Wu↗

NASA NTRS1966

Science in and for space exploration

Relationships of scientific research and demands on technology for space exploration

SPACE SCIENCE↗

NASA NTRS1984

Spinoff, 1984

A pictorial resume that underlines the challenging nature of NASA programs and their extraordinary demands for technological input, is presented. Also, NASA's current mainline programs, which require development of new technology, are given. A representative sampling of spinoff products and processes resulting from technology utiliization, or secondary application, and the mechanisms NASA employs to stimulate technology utilization are provided. Contact sources for further information are presented.

Haggerty, J. J.↗

NASA NTRS1993

US general aviation: The ingredients for a renaissance. A vision and technology strategy for US industry, NASA, FAA, universities

General aviation today is a vital component in the nation's air transportation system. It is threatened for survival but has enormous potential for expansion in utility and use. This potential for expansion is fueled by new satellite navigation and communication systems, small computers, flat panel displays, and advanced aerodynamics, materials and manufacturing methods, and propulsion technologies which create opportunities for new levels of environmental and economic acceptability. Expanded general aviation utility and use could have a large impact on the nation's jobs, commerce, industry, airspace capacity, trade balance, and quality of life. This paper presents, in viewgraph form, a general overview of U.S. general aviation. Topics covered include general aviation shipment and billings; airport and general aviation infrastructure; cockpit, airplane, and airspace technologies; market demand; air traffic operations and aviation accidents; fuel efficiency comparisons; and general aviation goals and strategy.

Holmes, Bruce↗

NASA NTRS1999

Propellant Feed System Leak Detection: Lessons Learned From the Linear Aerospike SR-71 Experiment (LASRE)

This paper presents pertinent results and assessment of propellant feed system leak detection as applied to the Linear Aerospike SR-71 Experiment (LASRE) program flown at the NASA Dryden Flight Research Center, Edwards, California. The LASRE was a flight test of an aerospike rocket engine using liquid oxygen and high-pressure gaseous hydrogen as propellants. The flight safety of the crew and the experiment demanded proven technologies and techniques that could detect leaks and assess the integrity of hazardous propellant feed systems. Point source detection and systematic detection were used. Point source detection was adequate for catching gross leakage from components of the propellant feed systems, but insufficient for clearing LASRE to levels of acceptability. Systematic detection, which used high-resolution instrumentation to evaluate the health of the system within a closed volume, provided a better means for assessing leak hazards. Oxygen sensors detected a leak rate of approximately 0.04 cubic inches per second of liquid oxygen. Pressure sensor data revealed speculated cryogenic boiloff through the fittings of the oxygen system, but location of the source(s) was indeterminable. Ultimately, LASRE was cancelled because leak detection techniques were unable to verify that oxygen levels could be maintained below flammability limits.

Hass, Neal↗

NASA NTRS1998

Recent Advancements in Propellant Densification

Next-generation launch vehicles demand several technological improvements to achieve lower cost and more reliable access to space. One technology area whose performance gains may far exceed others is densified propellants. The ideal rocket engine propellant is characterized by high specific impulse, high density, and low vapor pressure. A propellant combination of liquid hydrogen and liquid oxygen (LH2/LOX) is one of the highest performance propellants, but LH2 stored at standard conditions has a relatively low density and high vapor pressure. Propellant densification can significantly improve this propellant's properties relative to vehicle design and engine performance. Vehicle performance calculations based on an average of existing launch vehicles indicate that densified propellants may allow an increase in payload mass of up to 5 percent. Since the NASA Lewis Research Center became involved with the National Aerospace Plane program in the 1980's, it has been leading the way in making densified propellants a viable fuel for next-generation launch vehicles. Lewis researchers have been working to provide a method and critical data for continuous production of densified hydrogen and oxygen.

McNelis, Nancy B.↗

NASA NTRS2007

The MSFC Systems Engineering Guide: An Overview and Plan

As systems and subsystems requirements become more complex in the pursuit of the exploration of space, advanced technology will demand and require an integrated approach to the design and development of safe and successful space vehicles and there products. System engineers play a vital and key role in transforming mission needs into vehicle requirements that can be verified and validated. This will result in a safe and cost effective design that will satisfy the mission schedule. A key to successful vehicle design within systems engineering is communication. Communication, through a systems engineering infrastructure, will not only ensure that customers and stakeholders are satisfied but will also assist in identifying vehicle requirements; i.e. identification, integration and management. This vehicle design will produce a system that is verifiable, traceable, and effectively satisfies cost, schedule, performance, and risk throughout the life-cycle of the product. A communication infrastructure will bring about the integration of different engineering disciplines within vehicle design. A system utilizing these aspects will enhance system engineering performance and improve upon required activities such as Development of Requirements, Requirements Management, Functional Analysis, Test, Synthesis, Trade Studies, Documentation, and Lessons Learned to produce a successful final product. This paper will describe the guiding vision, progress to date and the plan forward for development of the Marshall Space Flight Center (MSFC) Systems Engineering Guide (SEG), a virtual systems engineering handbook and archive that will describe the system engineering processes that are used by MSFC in the development of complex systems such as the Ares launch vehicle. It is the intent of this website to be a "One Stop Shop" for our systems engineers that will provide tutorial information, an overview of processes and procedures and links to assist system engineering with guidance and references, and provide an archive of systems engineering artifacts produced by the many NASA projects developed and managed by MSFC over the years.

Shelby, Jerry A.↗

NASA NTRS2024

Investigation of Carbon-Reinforced Acrylonitrile Butadiene Styrene 3D-Printed Honeycomb Composites

The expansive utility of polymeric 3D printing technologies and demand for high-performance lightweight structures has prompted the emergence of various carbon-reinforced polymer composite filaments. However, detailed characterization of the processing-microstructure-property relationships of these materials is still required to realize their full potential. In this study, acrylonitrile butadiene styrene (ABS) and carbon reinforced ABS variants, both carbon nanotubes (CNT) and 5 wt.% chopped carbon fiber (CF), are fabricated in a honeycomb geometry and investigated across a range of layer thicknesses and hex sizes. Microscopy of material cross-sections is conducted to evaluate the relationship between print parameters and porosity. Additionally, mechanical properties are evaluated through compression testing, demonstrating the potential of honeycomb ABS, ABS-CNT, and ABS-5wt.% CF polymer composites for novel 3D printed structures.

ABS (Acrylonitrile Butadiene Styrene)↗

NASA NTRSDate not supplied

Investigation of Carbon-Reinforced Acrylonitrile Butadiene Styrene 3D-Printed Honeycomb Composites

ABS (Acrylonitrile Butadiene Styrene)↗

NASA NTRS2018

CLAS-ACT: Conformal, Lightweight Antennas for Aeronautical Communications Technology

The growing demand for Unmanned Aerial Vehicles (UAVs) and operating them beyond the line of sight (BLOS) has resulted in an increased interest in using existing satellite communication capabilities for command, control, and telemetry (CC&T). As the user base in this allocated portion of the spectrum expands, there is an increased potential for interference with existing terrestrial fixed-point communication systems. As secondary users, UAVs must seek out new solutions to avoid interfering with these existing ground sites while maintaining good links with satellite constellations. In this presentation, a novel lightweight conformal phased array antenna currently under development is presented that can use null steering and/or beam shaping to avoid ground interference while simultaneously providing strong satellite microwave links for communications. The reduced weight of this design and ability to integrate into the fuselage of smaller UAV platforms will also be discussed as a potential solution to provide BLOS operation via spectrum sharing for an expanding user base.

Meador, Mary Ann↗

NASA NTRS1995

Optical Computers and Space Technology

The rapidly increasing demand for greater speed and efficiency on the information superhighway requires significant improvements over conventional electronic logic circuits. Optical interconnections and optical integrated circuits are strong candidates to provide the way out of the extreme limitations imposed on the growth of speed and complexity of nowadays computations by the conventional electronic logic circuits. The new optical technology has increased the demand for high quality optical materials. NASA's recent involvement in processing optical materials in space has demonstrated that a new and unique class of high quality optical materials are processible in a microgravity environment. Microgravity processing can induce improved orders in these materials and could have a significant impact on the development of optical computers. We will discuss NASA's role in processing these materials and report on some of the associated nonlinear optical properties which are quite useful for optical computers technology.

Abdeldayem, Hossin A.↗