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NASA NTRSDate not supplied

Metallic Environmentally Resistant Coating Rapid Innovation Initiative

Lightweight alloys such as aluminum (Al) and titanium (Ti) are often specified for space systems to minimize mass while maintaining structural integrity [1,2]. Such alloys however, have poor tribological response (high friction and wear), especially in extreme space environments, which becomes worse with the additional presence of lunar regolith. This leads to short lifetimes and premature failures that will ultimately limit long term operations on the lunar surface [2]. This project is addressing this technology gap by developing advanced wear- and radiation-resistant coatings for lightweight parts to extend the life-time and sustainability of both lunar and Martian assets. Ceramics were considered for their high wear resistance, but were rejected because of their low fracture toughness, which would be especially problematic for structural components. The novel and existing coating technologies and deposition methods are being tested in this project. The coating materials are Boron Nitride-Aluminum (BN-Al), Nickle Titanium (NiTi), Aluminum Oxide (AlO3), Ti64 with hBN at 2 and 10 vol percent (Ti-2vol%hBN and Ti-10vol%hBN), and the deposition techniques are high pressure cold-spray (CS) and ambient and vacuum plasma-spray (APS and VPS) [3,4,5]. BN-Al, NiTi, Ti-2vol%hBN, and Ti-10vol%hBN were applied with all three deposition techniques, and AlO3 was applied only using the APS deposition technique. A tungstenite (WS2) film was applied to the NiTi VPS coating. The coating and deposition technique configurations are being tested against several key end-use performance parameters. The parameters include the capabilities of the coatings under wear environments such as regolith simulant, thermal cycling from high (120°C) to cryogenic (-173°C), high vacuum (~10-7 torr), and pre- and post-exposure to ionizing particle radiation. Wear tests include pin on disk, three-body abrasion, and surface erosion by high velocity regolith impacts. The initial down selection is being performed using on virgin and environmental exposure samples using pin on disk and three body abrasion wear tests. From preliminary assessment of this testing, a few configurations were eliminated. Ti-10vol%hBN could not be applied using CS application and NiTi could not be applied using APS or CS application so these configurations did not get tested. Early pin on disk wear tests showed poor wear performance of BN-Al so this coating was eliminated early in the testing process. AlO3 on Al substrate did not survive thermal cycling, but wear testing is continuing for AlO3 on Ti substrate. A more detailed analysis is being con-ducted to further reduce the number of configuration for phase II and III. Phase II testing will include conventionally and additively manufactured substrates with surface erosion testing. In phase III, the coatings will be applied to three mechanism types: channel and slot, ball and socket, and a hinge joint. Each will demonstrate a different type of wear incidence. The mechanisms and their base materials are of direct interest to the end users and infusion points: the Human Landing System (HLS) and the Lunar Surface Innovation Initiative (sustained lunar surface operations). The technology development project is based out of Marshall Space Flight Center, has partnered with Florida International University (Miami, FL) and Plasma Processes (Huntsville, Al), and is supported by a group of NASA mentors from different centers.

dust mitigation↗

NASA NTRSDate not supplied

Splashdown Visualization of Spent Stages

The state of the art for many Earth-to-orbit trajectory analysis toolsets used at NASA is somewhat dated in terms of the languages they are written in and their user interfaces. Many of these programs are written in languages like Fortran or C that are no longer considered modern in the technology industry, and are command-line based without any means of interpreting the data outputs. This presentation is meant to demonstrate a specific use case for a newly developed web app that visualizes the output data for one of these tools. Specifically, one key usage is to investigate and validate launches for notional multi-stage vehicle concepts to various non-standard high-inclination orbits. Some NASA requirements dictate that trajectories be designed such that no surviving debris lands closer than 200 nautical miles (nm) from foreign landmasses or 27 nm from the continental United States, therefore validating re-entry locations of spent stages is an integral part of the launch planning process. In addition, at programmatic levels it can prove insightful and clarifying for the decision-making process to enhance the technical results of numerical simulations with visualizations. The intent with this tool is to provide the mission analyst and program level management with an intuitive and clear grasp of key information on possible mission scenarios either departing from or arriving at Earth, and in the future, the moon or Mars as well. The software tool was developed with an agile development approach and utilizes the latest frameworks and technologies. The front end uses the React JavaScript library for making a state of the art frontend and a backend based on the Django Python framework for handling data using Python’s powerful and free scientific libraries. In addition, the CesiumJS open-source library is key for visualizing these end-to-end trajectories on a high-resolution Earth model. The presentation will demonstrate the current capability and tested use cases.

Jack Agolli↗

NASA NTRS2012

Trajectory Software With Upper Atmosphere Model

The Trajectory Software Applications 6.0 for the Dec Alpha platform has an implementation of the Jacchia-Lineberry Upper Atmosphere Density Model used in the Mission Control Center for International Space Station support. Previous trajectory software required an upper atmosphere to support atmosphere drag calculations in the Mission Control Center. The Functional operation will differ depending on the end-use of the module. In general, the calling routine will use function-calling arguments to specify input to the processor. The atmosphere model will then compute and return atmospheric density at the time of interest.

Barrett, Charles↗

NASA NTRS1998

Challenging Pneumatic Requirements for Acoustic Testing of the Cryogenic Second Stage for the New Delta 3 Rocket

The paper describes the unique pneumatic test requirements for the acoustic and shock separation testing of the Second Stage for the new Delta III Rocket at the Goddard Space Flight Center in Greenbelt, Maryland. The testing was conducted in the 45,000 cu ft (25-feet wide by 30-feet deep by 50-foot high) Acoustic Facility. The acoustic testing required that the liquid oxygen (LOX) and liquid hydrogen (LH2) tanks be filled with enough liquid nitrogen (LN2) to simulate launch fuel masses during testing. The challenge for this test dealt with designing, procuring, and fabricating the pneumatic supply systems for quick assembly while maintaining the purity requirements and minimizing costs. The pneumatic systems were designed to fill and drain the both LOX and LH2 tanks as well as to operate the fill/drain and vent valves for each of the tanks. The test criteria for the pneumatic sub-systems consisted of function, cleanliness, availability, and cost. The first criteria, function, required the tanks to be filled and drained in an efficient manner while preventing them from seeing pressures greater than 9 psig which would add a pressure cycle to the tank. An LN2 tanker, borrowed from another NASA facility, served as the pre-cool and drain tanker. Pre-cooling the tanks allowed for more efficient and cost effective transfer from the LN2 delivery tankers. Helium gas, supplied from a high purity tube trailer, was used to pressurize the vapor space above the LN2 pushing it into the drain tanker. The tube trailer also supplied high pressure helium to the vehicle for valve control and component purges. Cleanliness was maintained by proper component selection, end-use particle filtration, and any on-site cleaning determined necessary by testing. In order to meet the availability/cost juggling act, products designed for LOX delivery systems were procured to ensure system compatibility while off the shelf valves and tubing designed for the semiconductor industry were procured for the gas systems.

Webb, Andrew T.↗

NASA NTRS2009

Nano-Particle Enhanced Polymer Materials for Space Flight Applications

Recent advances in materials technology both in polymer chemistry and nano-materials warrant development of enhanced structures for space flight applications. This work aims to develop spacecraft structures based on polymer matrix composites (PMCs) that utilize these advancements.. Multi-wall carbon nano-tubes (MWCNTs) are expected ·to increase mechanical performance, lower coefficient of thermal expansion (CTE), increase electrical conductivity (mitigate electrostatic charge), increase thermal conductivity, and reduce moisture absorption of the resultant space structures. In this work, blends of MWCNTs with PETI-330 were prepared and characterized. The nano-reinforced resins were then resin transfer molded (RTM) into composite panels using M55J carbon fabric and compared to baseline panels fabricated from a cyanate ester (RS-3) or a polyimide (PETI-330) resin containing no MWCNTs. In addition, methods of pre-loading the fabric with the MWCNTs were also investigated. The effects of the MWCNTs on the resin processing properties and on the composite end-use properties were also determined.

Criss, Jim M., Jr.↗

NASA NTRS2001

Risk analysis simulation of rover operations for Mars surface exploration

Risk management advocates have long sought to directly influence the early stages of the systems engineering process through a more effective role in system design trade studies. The principal obstacle to this has been the lack of credible ways to represent and quantify mission risk—that is, a combination of the probability of mission success (“system safety”) and science value—for the project manager and the rest of the design team. If it were possible to quantify mission risk, then the effects of proposed mission and system design changes could be calculated, and along with life-cycle costs, could be used to explore the design space more extensively and select better designs. JPL has been working to build the capability to quantify the probability of mission success using a federation of diverse simulations and models, each of which contributes some vital piece of the puzzle. The initial institutional focus has been on Mars surface operations. This ensemble computing framework enables the diverse models and simulations to work together seamlessly. Recent work at JPL has demonstrated the capability to exercise this ensemble from end-to-end using an Oracle-based database to automatically move results from one model/simulation to the next stage in the analysis.

Shishko, Robert↗

NASA NTRS1972

Thermophysical characterization of composite materials under transient heating conditions

Thermophysical property measurements were made under transient heating conditions on several materials being considered for use in SCOUT rocket motors. The materials included were ATJ graphite, MX 2600 silica phenolic, FM 5272 cellulose phenolic, and two carbon-carbon composites: CARBITEX 700 and RPP-4. The ATJ was included as a reference or base line material to check performance of the transient tests as it was not expected to be sensitive to heating rate. Measurements included in the program were thermal conductivity, strength, compressive stress-strain (carbon-carbon only), thermal expansion and the effective thermal expansion under partially restrained conditions. Development of this latter measurement was a major part of the program. It consisted of partially restraining the expansion of a specimen as it was heated, measuring the load and strain which occurred (together with a simultaneous modulus determination by superimposing a small cyclic load) and using these quantities to calculate what the effective thermal expansion would have to be to produce the observed stress and deformation. For materials which are sensitive to heating rate, such as reinforced phenolics, it was believed that this would provide a more realistic determination of the thermal expansion as it more nearly simulates the conditions experienced in end use.

Roetling, J.↗

NASA NTRS1982

Polyimides: Tribological properties and their use as lubricants

Friction, wear, and wear mechanisms of several different polyimide films, solid bodies, composites, and bonded solid lubricant films are compared and discussed. In addition, the effect of such parameters as temperatures, type of atmosphere, contact stress, and specimen configuration are investigated. A friction and wear transition occurs in some polyimides at elevated temperatures and this transition is related to molecular relaxations that occur in polyimides. Friction and wear data from an accelerated test (pin-on-disk) are compared to similar data from an end use test device (plain spherical bearing), and to other polymers investigated in a similar geometry.

Fusaro, R. L.↗

NASA NTRS1984

Polyimides - Tribological properties and their use as lubricants

Fusaro, R. L.↗

NASA NTRS2002

Carbon Nanotubes Growth on Graphite Fibers

Carbon nanotubes (CNT) were synthesized on graphite fibers by thermal Chemical Vapor Deposition (CVD). On the fiber surface, iron nanoparticles are coated and act as catalysts for CNT growth. The growth temperature ranges from 550 to 1000 C at an ambient pressure. Methane and hydrogen gases with methane contents of 10% to 100% are used for the CNT synthesis. At high growth temperatures (greater than 800 C), the rapid inter-diffusion of the transition metal iron on the graphite surface results in a rough fiber surface with no CNT grown on the surface. When the growth temperature is relatively low (650 - 800 C), CNT are fabricated on the graphite surface with catalytic particles on the nanotube top ends. Using micro Raman spectroscopy in the breath mode region, single-walled or multi-walled CNT can be determined, depending on methane concentrations.

Zhu, Shen↗

NASA NTRS1999

Performance of a 2.5 THz Receiver Front-End for Spaceborne Applications

The OH radical plays a significant role in a great many of the known ozone destruction cycles, and has become the focus of an important radiometer development effort for NASA's Earth Observing System Chem I satellite, which will monitor and study many tropospheric and stratospheric gases and is scheduled for launch in 2002. Here we describe the design, fabrication, and testing of a receiver front end used to detect the OH signals at 2.5 THz. This is to be the first Terahertz heterodyne receiver to be flown in space. The challenges of producing the necessary high-performance mixers are numerous, but for this application, there is the added challenge of designing a robust receiver which can withstand the environmental extremes of a rocket launch and five years in space. The receiver front-end consists of the following components: a four-port dual-polarization diplexer, off-axis elliptical feed mirrors, mixers for horizontal and vertical polarization, support structures allowing simple and rugged alignment, low noise IF amplification from 7.7 to 21.1 GHz, and mixer DC bias circuitry. The front-end design, alignment, and operation will be covered in depth, followed by a discussion of the most recent results in receiver noise and dual-mode horn beam patterns. JPL MOMED mixers are employed, and have resulted in receiver noise temperatures of 14,500 K, DSB with LO frequency 2.522 GHz and IF of 12.8 GHz. Horn beam patterns correspond well with theory, with no significant sidelobes above the -25 dB level. Considering the high-quality beam of this receiver, these results are competitive with the best reported in the literature.

Gaidis, Michael C.↗

NASA NTRS2009

Improvements in Production of Single-Walled Carbon Nanotubes

A continuing program of research and development has been directed toward improvement of a prior batch process in which single-walled carbon nanotubes are formed by catalytic disproportionation of carbon monoxide in a fluidized-bed reactor. The overall effect of the improvements has been to make progress toward converting the process from a batch mode to a continuous mode and to scaling of production to larger quantities. Efforts have also been made to optimize associated purification and dispersion post processes to make them effective at large scales and to investigate means of incorporating the purified products into composite materials. The ultimate purpose of the program is to enable the production of high-quality single-walled carbon nanotubes in quantities large enough and at costs low enough to foster the further development of practical applications. The fluidized bed used in this process contains mixed-metal catalyst particles. The choice of the catalyst and the operating conditions is such that the yield of single-walled carbon nanotubes, relative to all forms of carbon (including carbon fibers, multi-walled carbon nanotubes, and graphite) produced in the disproportionation reaction is more than 90 weight percent. After the reaction, the nanotubes are dispersed in various solvents in preparation for end use, which typically involves blending into a plastic, ceramic, or other matrix to form a composite material. Notwithstanding the batch nature of the unmodified prior fluidized-bed process, the fluidized-bed reactor operates in a continuous mode during the process. The operation is almost entirely automated, utilizing mass flow controllers, a control computer running software specific to the process, and other equipment. Moreover, an important inherent advantage of fluidized- bed reactors in general is that solid particles can be added to and removed from fluidized beds during operation. For these reasons, the process and equipment were amenable to modification for conversion from batch to continuous production.

Balzano, Leandro↗

NASA NTRS2004

Spaceflight Operations Services Grid (SOSG)

In an effort to adapt existing space flight operations services to new emerging Grid technologies we are developing a Grid-based prototype space flight operations Grid. This prototype is based on the operational services being provided to the International Space Station's Payload operations located at the Marshall Space Flight Center, Alabama. The prototype services will be Grid or Web enabled and provided to four user communities through portal technology. Users will have the opportunity to assess the value and feasibility of Grid technologies to their specific areas or disciplines. In this presentation descriptions of the prototype development, User-based services, Grid-based services and status of the project will be presented. Expected benefits, findings and observations (if any) to date will also be discussed. The focus of the presentation will be on the project in general, status to date and future plans. The End-use services to be included in the prototype are voice, video, telemetry, commanding, collaboration tools and visualization among others. Security is addressed throughout the project and is being designed into the Grid technologies and standards development. The project is divided into three phases. Phase One establishes the baseline User-based services required for space flight operations listed above. Phase Two involves applying Gridlweb technologies to the User-based services and development of portals for access by users. Phase Three will allow NASA and end users to evaluate the services and determine the future of the technology as applied to space flight operational services. Although, Phase One, which includes the development of the quasi-operational User-based services of the prototype, development will be completed by March 2004, the application of Grid technologies to these services will have just begun. We will provide status of the Grid technologies to the individual User-based services. This effort will result in an extensible environment that incorporates existing and new spaceflight services into a standards-based framework providing current and future NASA programs with cost savings and new and evolvable methods to conduct science. This project will demonstrate how the use of new programming paradigms such as web and grid services can provide three significant benefits to the cost-effective delivery of spaceflight services. They will enable applications to operate more efficiently by being able to utilize pooled resources. They will also permit the reuse of common services to rapidly construct new and more powerful applications. Finally they will permit easy and secure access to services via a combination of grid and portal technology by a distributed user community consisting of NASA operations centers, scientists, the educational community and even the general population as outreach. The approach will be to deploy existing mission support applications such as the Telescience Resource Kit (TReK) and new applications under development, such as the Grid Video Distribution System (GViDS), together with existing grid applications and services such as high-performance computing and visualization services provided by NASA s Information Power Grid (IPG) in the MSFC s Payload Operations Integration Center (POIC) HOSC Annex. Once the initial applications have been moved to the grid, a process will begin to apply the new programming paradigms to integrate them where possible. For example, with GViDS, instead of viewing the Distribution service as an application that must run on a single node, the new approach is to build it such that it can be dispatched across a pool of resources in response to dynamic loads. To make this a reality, reusable services will be critical, such as a brokering service to locate appropriate resource within the pool. This brokering service can then be used by other applications such as the TReK. To expand further, if the GViDS application is constructed using a services-based mel, then other applications such as the Video Auditorium can then use GViDS as a service to easily incorporate these video streams into a collaborative conference. Finally, as these applications are re-factored into this new services-based paradigm, the construction of portals to integrate them will be a simple process. As a result, portals can be tailored to meet the requirements of specific user communities.

Bradford, Robert N.↗

NASA NTRS2015

Thermally-Resilient, Broadband Optical Absorber from UV-to-IR Derived from Carbon Nanostructures and Method of Making the Same

A monolithic optical absorber and methods of making same. The monolithic optical absorber uses an array of mutually aligned carbon nanotubes that are grown using a PECVD growth process and a structure that includes a conductive substrate, a refractory template layer and a nucleation layer. Monolithic optical absorbers made according to the described structure and method exhibit high absorptivity, high site densities (greater than 10.sup.9 nanotubes/cm.sup.2), very low reflectivity (below 1%), and high thermal stability in air (up to at least 400.degree. C.). The PECVD process allows the application of such absorbers in a wide variety of end uses.

Kaul, Anupama B.↗

NASA NTRS1994

Holographic testing of composite propfans for a cruise missile wind tunnel model

Each of the approximately 90 composite propfan blades constructed for a 55 percent scale cruise missile wind tunnel model were holographically tested to obtain natural frequencies and mode shapes. These data were used not only for quality assurance, but also to select sets of similar blades for each blade row. Presented along with the natural frequency data is a description of a computer-based image processing system developed to supplement the photographic based system for holographic image analysis and storage. The new system is quicker and cheaper, the holograms are indexed better, and several engineers can access the data simultaneously. The only negative effect is a slight reduction in image resolution, which does not influence the end use.

Miller, Christopher J.↗

NASA NTRS2015

Layered Thermal Insulation Systems for Industrial and Commercial Applications

From the high performance arena of cryogenic equipment, several different layered thermal insulation systems have been developed for industrial and commercial applications. In addition to the proven areas in cold-work applications for piping and tanks, the new Layered Composite Insulation for Extreme Environments (LCX) has potential for broader industrial use as well as for commercial applications. The LCX technology provides a unique combination of thermal, mechanical, and weathering performance capability that is both cost-effective and enabling. Industry applications may include, for example, liquid nitrogen (LN2) systems for food processing, liquefied natural gas (LNG) systems for transportation or power, and chilled water cooling facilities. Example commercial applications may include commercial residential building construction, hot water piping, HVAC systems, refrigerated trucks, cold chain shipping containers, and a various consumer products. The LCX system is highly tailorable to the end-use application and can be pre-fabricated or field assembled as needed. Product forms of LCX include rigid sheets, semi-flexible sheets, cylindrical clam-shells, removable covers, or flexible strips for wrapping. With increasing system control and reliability requirements as well as demands for higher energy efficiencies, thermal insulation in harsh environments is a growing challenge. The LCX technology grew out of solving problems in the insulation of mechanically complex cryogenic systems that must operate in outdoor, humid conditions. Insulation for cold work includes equipment for everything from liquid helium to chilled water. And in the middle are systems for LNG, LN2, liquid oxygen (LO2), liquid hydrogen (LH2) that must operate in the ambient environment. Different LCX systems have been demonstrated for sub-ambient conditions but are capable of moderately high temperature applications as well.

thermal conductivity↗

NASA NTRS1991

Hydrocarbon-fuel/combustion-chamber-liner materials compatibility

The results of dynamic tests using methane and NASA-Z copper test specimen under conditions that simulate those expected in the cooling channels of a regeneratively cooled LOX/hydrocarbon booster engine operating at chamber pressures up to 3000 psi are presented. Methane with less than 0.5 ppm sulfur contamination has little or no effect on cooling channel performance. At higher sulfur concentrations, severe corrosion of the NASA-Z copper alloy occurs and the cuprous sulfide Cu2S, thus formed impedes mass flow rate and heat transfer efficiency. Therefore, it is recommended that the methane specification for this end use set the allowable sulfur content at 0.5 ppm (max). Bulk high purity liquid methane that meets this low sulfur requirement is currently available from only one producer. Pricing, availability, and quality assurance are discussed in detail. Additionally, it was found that dilute sodium cyanide solutions effectively refurbish sulfur corroded cooling channels in only 2 to 5 minutes by completely dissolving all the Cu2S. Sulfur corroded/sodium cyanide refurbished channels are highly roughened and the increased surface roughness leads to significant improvements in heat transfer efficiency with an attendant loss in mass flow rate. Both the sulfur corrosion and refurbishment effects are discussed in detail.

Homer, G. David↗

NASA NTRS2018

Large Scale Cryogenic Storage with Active Refrigeration

Storage and transfer of cryogenic liquefied gases on volume scales from under 10 liters for lab use, up to hundreds of millions of liters for industrial applications is of paramount importance across a vast range of industries. Traditionally, these commodities have been stored at or near the normal boiling point due to relative ease of operation and safety-related considerations; however, this also means that some percentage will always be lost due to environmental heat leaking into the vessel and causing boil-off. These losses become more concerning as scales increase, and are of particular importance for high-cost commodities such helium and hydrogen. Additionally, the normal boiling point marks the highest liquid density achievable; which becomes a strong driver of end-use system designs such as space launch vehicles. Recent development and testing of an Integrated Refrigeration and Storage (IRAS) system for liquid hydrogen has proven that next generation cryogenic storage operations such as zero boil-off and densification are feasible on a large scale. This IRAS system married an 850 Watt at 20 Kelvin reverse-Brayton cycle commercial cryogenic refrigerator with a 125,000 liter LH2 storage tank via and internal tubular heat exchanger. This allowed heat to be removed directly from the hydrogen, and by extension, provided a means to control the bulk thermodynamic state. Zero boil-off, in-situ liquefaction, and densification down to the triple point was performed during testing, and data such as fluid temperature profiles and tank pressure were gathered. Details regarding the design, setup, and testing of the IRAS system are discussed herein, and the data used to anchor various physics models created to predict the behavior of the system during transient and steady state operation. It is hoped that these efforts will provide a useful basis for the design and implementation of future large scale IRAS systems across numerous industries.

Swanger, Adam M.↗