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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 NTRSDate not supplied

Windform® XT 2.0 Use as 3U CubeSat Primary Structure

CubeSats provide a platform for small-scale space research and technology demonstration at reduced complexity, cost, and development time. These advantages drove the NASA Langley Research Center (LaRC) to develop and launch the GPX2 3U CubeSat to explore the viability of using Commercial Off-The-Shelf (COTS) differential GPS (dGPS) in low earth orbit. To reduce manufacturing costs and increase design flexibility, the project chose additive manufactured Windform® XT 2.0 as the primary bus material rather than traditional subtractive manufactured (milled) metal. The bus is a two-part, Selective Laser Sintered, 3D-print structure consisting of a single-piece, five-walled chassis and single-walled cover. The bus was specially designed to allow the project to accommodate the payload electronics stack as well as antennas, receivers, and deployable mechanisms. By using an additive manufactured solution, LaRC was able to design in features unrealizable through traditional milling, with a lead-time of roughly two weeks. In comparison, traditional subtractive manufacturing limits geometry options due to toolpath reach and bus construction would have required multiple components for each wall. This would have resulted in a more costly, longer lead-time article with more joints, fasteners, and complexity with a commensurate increase in overall mass. A number of lessons-learned were captured during the design, analysis, and testing of the GPX2 CubeSat covering thermal and structural analysis, vibration modeling, and geometric tolerancing. Additionally, a variety of material testing and verification were performed before and during spacecraft design and integration to assure the suitability of Windform® XT 2.0 for the launch and mission environments. This article provides the highlights of designing and testing the GPX2 bus.

CubeSat↗
NASA NTRS2003

Cardea: Providing Support for Dynamic Resource Access in a Distributed Computing Environment

The environment framing the modem authorization process span domains of administration, relies on many different authentication sources, and manages complex attributes as part of the authorization process. Cardea facilitates dynamic access control within this environment as a central function of an inter-operable authorization framework. The system departs from the traditional authorization model by separating the authentication and authorization processes, distributing the responsibility for authorization data and allowing collaborating domains to retain control over their implementation mechanisms. Critical features of the system architecture and its handling of the authorization process differentiate the system from existing authorization components by addressing common needs not adequately addressed by existing systems. Continuing system research seeks to enhance the implementation of the current authorization model employed in Cardea, increase the robustness of current features, further the framework for establishing trust and promote interoperability with existing security mechanisms.

Lepro, Rebekah↗
NASA NTRS1995

Micromechanical Machining Processes and their Application to Aerospace Structures, Devices and Systems

Micromechanical machining processes are those micro fabrication techniques which directly remove work piece material by either a physical cutting tool or an energy process. These processes are direct and therefore they can help reduce the cost and time for prototype development of micro mechanical components and systems. This is especially true for aerospace applications where size and weight are critical, and reliability and the operating environment are an integral part of the design and development process. The micromechanical machining processes are rapidly being recognized as a complementary set of tools to traditional lithographic processes (such as LIGA) for the fabrication of micromechanical components. Worldwide efforts in the U.S., Germany, and Japan are leading to results which sometimes rival lithography at a fraction of the time and cost. Efforts to develop processes and systems specific to aerospace applications are well underway.

Friedrich, Craig R.↗
NASA NTRS2016

An Assessment of Nondestructive Evaluation Capability for Complex Additive Manufacturing Aerospace Components

The primary focus of this work is to investigate some of the fundamental relationships between processing, mechanical testing, materials characterization, and NDE for additively manufactured (AM) components using the powder bed fusion direct melt laser sintered process. The goal is to understand the criticality of defects unique to the AM process and then how conventional nondestructive evaluation methods as well as some of the more non-traditional methods such as computed tomography, are effected by the AM material. Specific defects including cracking, porosity and partially/unfused powder will be addressed. Besides line-of-site NDE, as appropriate these inspection capabilities will be put into the context of complex AM geometries where hidden features obscure, or inhibit traditional NDE methods.

Walker, James↗
NASA NTRSDate not supplied

Novel Ceramic Dispersion Strengthened Refractory Metals for Improved Printability and Properties

Refractory metals and alloys are of major interest for nuclear fusion systems, space nuclear power and propulsion, and hypersonic applications due to their desirable properties at elevated temperatures (>1500°C). Limitations of refractory materials include their low ductility, poor oxidation resistance, and high manufacture cost using traditional techniques. Additive manufacturing (AM) can reduce material waste associated with manufacture, but AM fabrication is impacted by the brittleness of these refractory metals, resulting in excessive cracking during printing. Cracking reduces the effectiveness of hot isostatic pressing (HIP) which is commonly used to improve density and mechanical properties of AM components. The goal of this work is to improve refractory metal printability without majorly affecting the material properties which are the main reason these materials are used. Ceramic nanoparticles have been shown to help improve material properties after heat treatment. Results will be shown that demonstrate the effectiveness of adding nanoparticles to refractory metals. Additionally, there will be discussion regarding how these nanoparticles change the effect of heat treatments such as HIP compared with the AM pure metal samples.

Carly J. Romnes↗
NASA NTRSDate not supplied

Advanced Environmental Barrier Coating Testing and Development for Gas Turbine Engines

Environmental barrier coatings (EBCs) are an enabling technology for the use of SiC-based ceramic matrix composites (CMCs) in next generation gas turbine engines. SiC-based CMCs are lightweight and have higher temperature stability than traditional nickel based superalloys. However, SiC is susceptible to rapid oxidation and recession due to high temperature reactions with water vapor and other combustion species. Thus, EBCs were developed to protect these components and extend operating lifetime. In the extreme engine environment, EBCs must be able to withstand a variety of damage mechanisms and the synergies of degradation between them. This presentation will provide an overview of NASA Glenn Research Center, current aeronautics research, and an introduction to EBC failure modes and environmental durability test methods.

Jamesa L Stokes↗
NASA NTRS2010

Design of a Mechanical NaK Pump for Fission Space Power Systems

Alkali liquid metal cooled fission reactor concepts are under development for mid-range spaceflight power requirements. One such concept utilizes a sodium-potassium eutectic (NaK) as the primary loop working fluid. Traditionally, linear induction pumps have been used to provide the required flow and head conditions for liquid metal systems but can be limited in performance. This paper details the design, build, and check-out test of a mechanical NaK pump. The pump was designed to meet reactor cooling requirements using commercially available components modified for high temperature NaK service.

Mireles, Omar R.↗
NASA NTRS2020

Solar Contamination in Extreme-precision Radial-velocity Measurements: Deleterious Effects and Prospects for Mitigation

Solar contamination, due to moonlight and atmospheric scattering of sunlight, can cause systematic errors in stellar radial velocity (RV) measurements that significantly detract from the ~10 cm/s sensitivity required for the detection and characterization of terrestrial exoplanets in or near habitable zones of Sun-like stars. The addition of low-level spectral contamination at variable effective velocity offsets introduces systematic noise when measuring velocities using classical mask-based or template-based cross-correlation techniques. Here we present simulations estimating the range of RV measurement error induced by uncorrected scattered sunlight contamination. We explore potential correction techniques, using both simultaneous spectrometer sky fibers and broadband imaging via coherent fiber imaging bundles, that could reliably reduce this source of error to below the photon-noise limit of typical stellar observations. We discuss the limitations of these simulations, the underlying assumptions, and mitigation mechanisms. We also present and discuss the components designed and built into the NEID (NN-EXPLORE Exoplanet Investigations with Doppler spectroscopy) precision RV instrument for the WIYN 3.5m telescope, to serve as an ongoing resource for the community to explore and evaluate correction techniques. We emphasize that while “bright time” has been traditionally adequate for RV science, the goal of 10 cm/s precision on the most interesting exoplanetary systems may necessitate access to darker skies for these next generation instruments.

Arpita Roy↗
NASA NTRS2026

Understanding and Controlling Hybrid Electric Gas Turbine Engine Transient Dynamics

The electrification of the gas turbine engine is known to increase the flexibility of aircraft architectures by enabling the generation of electrical power to distribute to other electrically based, thrust producing subsystems. It also has potential for direct performance benefits in the gas turbine engine itself, both at steady state and dynamically. Although the design focus of the gas turbine engine performance is primarily at steady state, it is often the instabilities occurring during transients that cause disequilibrium and constrain performance improvements. Instabilities arise due to the disequilibrium of the energy storage mechanisms within the traditional engine system and likewise for the electrified engine system. The primary energy storage mechanisms in the traditional system are the rotational inertia, gas path volumes, the thermal masses that make up the mechanical structure, and now, the electrical power system will provide additional contributions. Understanding the effect each of these energy storage mechanisms has on the others and controlling them appropriately allows for the suppression of state changes within the turbomachinery components to the degree that the components remain near steady state, thus reducing the disequilibrium within the system. The ability to tightly regulate the state changes of turbomachinery components, such as the compressor, minimizes the excursion of the compressor operating point from the operating line (operability), allowing for higher performing, more efficient compressor designs by decreasing the amount of stall margin needed for safe engine power level changes. Preliminary studies with the electrification of the turbine engine have shown that this is possible, and this concept can lead to design trades benefitting engine performance, weight, and volume. This paper explores in detail the energy storage mechanisms and control approaches for coordinating their state changes, and ultimately proposes that a higher performing, more efficient compressor design can result.

transient dynamics↗
NASA NTRS1992

Automation of closed environments in space for human comfort and safety

This report culminates the work accomplished during a three year design project on the automation of an Environmental Control and Life Support System (ECLSS) suitable for space travel and colonization. The system would provide a comfortable living environment in space that is fully functional with limited human supervision. A completely automated ECLSS would increase astronaut productivity while contributing to their safety and comfort. The first section of this report, section 1.0, briefly explains the project, its goals, and the scheduling used by the team in meeting these goals. Section 2.0 presents an in-depth look at each of the component subsystems. Each subsection describes the mathematical modeling and computer simulation used to represent that portion of the system. The individual models have been integrated into a complete computer simulation of the CO2 removal process. In section 3.0, the two simulation control schemes are described. The classical control approach uses traditional methods to control the mechanical equipment. The expert control system uses fuzzy logic and artificial intelligence to control the system. By integrating the two control systems with the mathematical computer simulation, the effectiveness of the two schemes can be compared. The results are then used as proof of concept in considering new control schemes for the entire ECLSS. Section 4.0 covers the results and trends observed when the model was subjected to different test situations. These results provide insight into the operating procedures of the model and the different control schemes. The appendix, section 5.0, contains summaries of lectures presented during the past year, homework assignments, and the completed source code used for the computer simulation and control system.

Source record↗
NASA NTRS1997

Determining the Composition of the Vela Pulsar's Jet

The pulsar jet is significant in explaining how the Vela pulsar's rotational energy is transported outward to the rest of the SNR, since direct radiation from the pulsar only accounts for a small percentage of the total power. Our previous ROSAT observations presented the first evidence that the pulsar is driving a narrow, collimated, and remarkably symmetrical jet into the SNR (Markwardt, C. and Oegelman, H., 1995, Nature, 375, p. 40) which we interpret to be from a 'cocoon' of hot gas surrounding the jet itself. We obtained an ASCA exposure of the jet in order to determine whether the spectrum is thermal or power-law continuum. The jet cocoon is detected with ASCA at approximately 2-3 x 10(exp -3) ct/s. The X-ray spectrum of the jet is remarkably similar to the surrounding supernova remnant spectrum and extends to X-ray energies of at least 7 keV, with a total flux of approximately 2 x 10(exp -13) erg/s sq cm sq arcmin. The only strong emission line is from He-like Neon at approx. 0.9 keV; otherwise the spectrum is quite smooth. The spectrum cannot be fit by any one standard plasma emission model, so we used models with two-components. The lower energy component is thermal and has a temperature of 0.29 +/- 0.03 keV; the higher energy portion can either be fit by a thermal component of temperature approx. 4 keV or a power law with photon index approx. 2.0. If the observed spectrum is of a 'traditional' jet cocoon, then we estimate the speed of the jet to be at least 800 km/s, depending on the angle of inclination of the jet axis to our line of sight. The mechanical power driving the jet is greater than or equal to 10(exp 36) erg/s which is comparable to the pulsar's spin-down luminosity of 7 x 10(exp 36) erg/s. and the mass flow rate at the head is greater than or equal to 10(exp -6) solar radius/yr. We conclude that the jet must be entraining material all along its length in order to generate such a large mass flow rate.

Ogelman, Hakki↗
NASA NTRS1996

New Antenna Deployment, Pointing and Supporting Mechanism

On ITALSAT Flight 2, the Italian telecommunications satellite, the two L-Ka antennas (Tx and Rx) use two large deployable reflectors (2000-mm diameter), whose deployment and fine pointing functions are accomplished by means of an innovative mechanism concept. The Antenna Deployment & Pointing Mechanism and Supporting Structure (ADPMSS) is based on a new configuration solution, where the reflector and mechanisms are conceived as an integrated, self-contained assembly. This approach is different from the traditional configuration solution. Typically, a rigid arm is used to deploy and then support the reflector in the operating position, and an Antenna Pointing Mechanism (APM) is normally interposed between the reflector and the arm for steering operation. The main characteristics of the ADPMSS are: combined implementation of deployment, pointing, and reflector support; optimum integration of active components and interface matching with the satellite platform; structural link distribution to avoid hyperstatic connections; very light weight and; high performance in terms of deployment torque margin and pointing range/accuracy. After having successfully been subjected to all component-level qualification and system-level acceptance tests, two flight ADPMSS mechanisms (one for each antenna) are now integrated on ITALSAT F2 and are ready for launch. This paper deals with the design concept, development, and testing program performed to qualify the ADPMSS mechanism.

Costabile, V.↗
NASA NTRS2008

Reliability and Confidence Interval Analysis of a CMC Turbine Stator Vane

High temperature ceramic matrix composites (CMC) are being explored as viable candidate materials for hot section gas turbine components. These advanced composites can potentially lead to reduced weight, enable higher operating temperatures requiring less cooling and thus leading to increased engine efficiencies. However, these materials are brittle and show degradation with time at high operating temperatures due to creep as well as cyclic mechanical and thermal loads. In addition, these materials are heterogeneous in their make-up and various factors affect their properties in a specific design environment. Most of these advanced composites involve two- and three-dimensional fiber architectures and require a complex multi-step high temperature processing. Since there are uncertainties associated with each of these in addition to the variability in the constituent material properties, the observed behavior of composite materials exhibits scatter. Traditional material failure analyses employing a deterministic approach, where failure is assumed to occur when some allowable stress level or equivalent stress is exceeded, are not adequate for brittle material component design. Such phenomenological failure theories are reasonably successful when applied to ductile materials such as metals. Analysis of failure in structural components is governed by the observed scatter in strength, stiffness and loading conditions. In such situations, statistical design approaches must be used. Accounting for these phenomena requires a change in philosophy on the design engineer s part that leads to a reduced focus on the use of safety factors in favor of reliability analyses. The reliability approach demands that the design engineer must tolerate a finite risk of unacceptable performance. This risk of unacceptable performance is identified as a component's probability of failure (or alternatively, component reliability). The primary concern of the engineer is minimizing this risk in an economical manner. The methods to accurately determine the service life of an engine component with associated variability have become increasingly difficult. This results, in part, from the complex missions which are now routinely considered during the design process. These missions include large variations of multi-axial stresses and temperatures experienced by critical engine parts. There is a need for a convenient design tool that can accommodate various loading conditions induced by engine operating environments, and material data with their associated uncertainties to estimate the minimum predicted life of a structural component. A probabilistic composite micromechanics technique in combination with woven composite micromechanics, structural analysis and Fast Probability Integration (FPI) techniques has been used to evaluate the maximum stress and its probabilistic distribution in a CMC turbine stator vane. Furthermore, input variables causing scatter are identified and ranked based upon their sensitivity magnitude. Since the measured data for the ceramic matrix composite properties is very limited, obtaining a probabilistic distribution with their corresponding parameters is difficult. In case of limited data, confidence bounds are essential to quantify the uncertainty associated with the distribution. Usually 90 and 95% confidence intervals are computed for material properties. Failure properties are then computed with the confidence bounds. Best estimates and the confidence bounds on the best estimate of the cumulative probability function for R-S (strength - stress) are plotted. The methodologies and the results from these analyses will be discussed in the presentation.

Murthy, Pappu L. N.↗
NASA NTRSDate not supplied

Ab-Initio Study of Stacking Fault Segregation Behavior in Ni-based Superalloys at High Temperatures

Ni-based superalloys demonstrate extraordinary creep properties compared to traditional metallic systems due to the formation of L12 (γ’) precipitates. Despite experimental evidence of alloying element segregation to the stacking faults, prior ab-initio efforts indicated repulsion of Nb from superlattice intrinsic stacking faults (SISFs) . Due to the importance of this element in key strengthening mechanisms, we developed a new technique to account for multi-component segregation behavior at temperature combining ab-initio molecular dynamics (AIMD) and Monte-Carlo (MC) simulations. Using this technique, we replicated experimentally observed segregation behavior of Nb, Co, and Ti to the SISF in L12 (Figure 1). Furthermore, we investigated the co-segregation behaviors of individual pairs of alloying elements to determine the interaction effects which lead to this segregation behavior in the full alloy system. By simulating the reduced-chemistry models using our approach, we reconciled previous ab-initio calculations demonstrating repulsion of Nb from the SISF and the experimentally observed segregation behavior.

Molecular Dynamics↗
NASA NTRS2005

Effects of Control Mode and R-Ratio on the Fatigue Behavior of a Metal Matrix Composite

Composite Because of their high specific stiffness and strength at elevated temperatures, continuously reinforced metal matrix composites (MMC's) are under consideration for a future generation of aeropropulsion systems. Since components in aeropropulsion systems experience substantial cyclic thermal and mechanical loads, the fatigue behavior of MMC's is of great interest. Almost without exception, previous investigations of the fatigue behavior of MMC's have been conducted in a tension-tension, load-controlled mode. This has been due to the fact that available material is typically less than 2.5-mm thick and, therefore, unable to withstand high compressive loads without buckling. Since one possible use of MMC's is in aircraft skins, this type of testing mode may be appropriate. However, unlike aircraft skins, most engine components are thick. In addition, the transient thermal gradients experienced in an aircraft engine will impose tension-compression loading on engine components, requiring designers to understand how the MMC will behave under fully reversed loading conditions. The increased thickness of the MMC may also affect the fatigue life. Traditionally, low-cycle fatigue (LCF) tests on MMC's have been performed in load control. For monolithic alloys, low-cycle fatigue tests are more typically performed in strain control. Two reasons justify this choice: (1) the critical volume from which cracks initiate and grow is generally small and elastically constrained by the larger surrounding volume of material, and (2) load-controlled, low-cycle fatigue tests of monolithics invariably lead to unconstrained ratcheting and localized necking--an undesired material response because the failure mechanism is far more severe than, and unrelated to, the fatigue mechanism being studied. It is unknown if this is the proper approach to composite testing. However, there is a lack of strain-controlled data on which to base any decisions. Consequently, this study addresses the isothermal, LCF behavior of a [0]_32 MMC tested under strain- and load-controlled conditions for both zero-tension and tension-compression loading conditions. These tests were run at 427 C on thick specimens of SiC-reinforced Ti-15-3. For the fully-reversed tests, no difference was observed in the lives between the load- and strain-controlled tests. However, for the zero-tension tests, the strain-controlled tests had longer lives by a factor of 3 in comparison to the load-controlled tests. This was due to the fact that under strain-control the specimens cyclically softened, reducing the cracking potential. In contrast, the load-controlled tests ratcheted toward larger tensile strains leading to an eventual overload of the fibers. Fatigue tests revealed that specimens tested under fully-reversed conditions had lives approximately an order of magnitude longer than for those specimens tested under zero tension. When examined on a strain-range basis, the fully reversed specimens had similar, but still shorter lives than those of the unreinforced matrix material. However, the composite had a strain limitation at short lives because of the limited strain capacity of the brittle ceramic fiber. The composite also suffered at very high lives because of the lack of an apparent fatigue limit in comparison to the unreinforced matrix. The value of adding fibers to the matrix is apparent when the fatigue lives are plotted as a function of stress range. Here, the composite is far superior to the unreinforced matrix because of the additional load-carrying capacity of the fibers.

Source record↗
NASA NTRS2019

Refractive Index of Polyaryletherketone (PEEK) at X- and W-Band

This report details refractive index measurements of polyaryletherketone (PEEK) thermoplastic between X-band (8 to 12 GHz) and W-band (75 to 110 GHz) frequencies. Scattering-parameter data are collected using both traditional waveguide and modified free-space techniques. The complex-valued refractive index is calculated using the standard Nicolson-Ross-Weir method. Results indicate that PEEK’s refractive index is n = 1.783 – 0.001i across X-band and n = 1.792 – 0.007i across W-band. Therefore, PEEK exhibits a moderate real refractive index component and low transmission loss. Coupled with its favorable mechanical and thermal properties, this makes PEEK an ideal material to inspect using NASA’s submillimeter radiofrequency-based technology.

Polyaryletherketone↗
NASA NTRS1990

A figure-of-merit approach to extraterrestrial resource utilization

A concept is developed for interrelated optimizations in space missions that utilize extraterrestrial resources. It is shown that isolated (component) optimizations may not result in the best mission. It is shown that substantial benefits can be had through less than the best propellants, propellant combinations, propulsion hardware, and actually, some waste in the traditional sense. One ready example is the possibility of discarding hydrogen produced extraterrestrially by water splitting and using only the oxygen to burn storable fuels. The gains in refrigeration and leak-proof equipment mass (elimination) outweigh the loss in specific impulse. After a brief discussion of this concept, the synthesis of the four major components of any future space mission is developed. The four components are: orbital mechanics of the transportation; performance of the rocket motor; support systems that include power; thermal and process controls, and instruments; and in situ resource utilization plant equipment. This paper's main aim is to develop the concept of a figure-of-merit for the mission. The Mars Sample Return Mission is used to illustrate the new concept. At this time, a popular spreadsheet is used to quantitatively indicate the interdependent nature of the mission optimization. Future prospects are outlined that promise great economy through extraterrestrial resource utilization and a technique for quickly evaluating the same.

Ramohalli, K.↗
NASA NTRS2013

Thermo-Mechanical Methodology for Stabilizing Shape Memory Alloy Response

This innovation is capable of significantly reducing the amount of time required to stabilize the strain-temperature response of a shape memory alloy (SMA). Unlike traditional stabilization processes that take days to weeks to achieve stabilized response, this innovation accomplishes stabilization in a matter of minutes, thus making it highly useful for the successful and practical implementation of SMA-based technologies in real-world applications. The innovation can also be applied to complex geometry components, not just simple geometries like wires or rods.

Padula, Santo↗