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NASA NTRS2024

NIAC Phase I Final Report Lunar South Pole Oxygen Pipeline (LSPOP)

The Lunar South Pole Oxygen Pipeline (LSPOP) Phase I NIAC, is to analyze the feasibility of constructing a pipeline at the Moon’s South Pole for transporting gaseous oxygen from point of generation to point of use. A lunar pipeline has never been pursued and will revolutionize lunar surface operations for the Artemis program and reduce cost and risk. Our starting concept is for a 5 km pipeline to transport oxygen gas from an oxygen production source, for example from our molten regolith electrolysis (MRE, currently at TRL 5, see references[1],[2],[3],[4],[5],[6] for technical discussions of the MRE process) extraction site, or any other source, to an oxygen storage/liquification plant near a lunar base. The pipeline is designed to: 1) be constructed robotically from regolith-derived metals with minimal material transferred from Earth, 2) be repairable robotically, 3) have an oxygen flow rate of ~2 kg/hour, which is commensurate with the NASA initial projected need of 10,000 kg/year, 4) operate with minimal power over the lifetime of the pipeline, with a goal of high operational reliability and the ability to survive in the lunar environment for > 10 years. We compare this concept to a pipeline concept with pipe produced on Earth and then transported to and assembled on the Moon. Both approaches will use earth-based compressors, valves, and fittings which are integrated into the pipeline on the Moon.

NIAC Phase I↗

NASA NTRS1994

Protein Crystal Growth Results From the United States Microgravity Laboratory-1 Mission

Protein crystal growth experiments have been performed by this laboratory on 18 Space Shuttle missions since April, 1985. In addition, a number of microgravity experiments also have been performed and reported by other investigators. These Space Shuttle missions have been used to grow crystals of a variety of proteins using vapor diffusion, liquid diffusion, and temperature-induced crystallization techniques. The United States Microgravity Laboratory - 1 mission (USML-1, June 25 - July 9, 1992) was a Spacelab mission dedicated to experiments involved in materials processing. New protein crystal growth hardware was developed to allow in orbit examination of initial crystal growth results, the knowledge from which was used on subsequent days to prepare new crystal growth experiments. In addition, new seeding hardware and techniques were tested as well as techniques that would prepare crystals for analysis by x-ray diffraction, a capability projected for the planned Space Station. Hardware that was specifically developed for the USML-1 mission will be discussed along with the experimental results from this mission.

L J Delucas↗

NASA NTRS1967

Guidelines for Schlieren Systems at Langley Research Center

The original Langley Working Paper (LWP 448) published on July 27th, 1967, provided guidance to NASA Langley Research Center personnel on how to set up conventional path-integrated schlieren flow visualization systems and what pitfalls could be expected with such setups. The guidance and information contained in the document continues to be used for schlieren setups at NASA Langley Research Center to this day. The most commonly used method of flow visualization in supersonic wind tunnels is the schlieren method, or method of striae. At the Langley Research Center, this method is so commonly used that it has come to be regarded somewhat as merely another piece of instrumentation which is to be maintained by service people, and which is too mysteriously complicated to be touched by tunnel personnel. This should not be the case. High-quality results from a schlieren system can only be obtained by having personnel on the tunnel staff who are well-informed on the subject and who have the time and the interest to do a good job of adjustment. This paper is a discussion in practical terms, of some of the points to be considered and the pitfalls that may be encountered in designing, setting up and using a working schlieren system. It is directed specifically toward helping specify and install a Z-type mirror system. It is hoped that the material will be of assistance to facilities throughout the Center and NASA and that users of the schlieren method will be inspired to the point of training people in the adjustment of the systems in use at their facilities.

Langley Working Papers↗

NASA NTRS2026

Electromagnetic Melt Processing: A Pathway to New Additive Manufacturing Technologies for Functional High-Performance Thermoplastics

In this study, we apply the electromagnetic (EM) melt processing of thermoplastics on an innovative EM field-driven powder bed fusion additive manufacturing (AM) concept for high-performance functional parts: Selective Microwave Melting/Sintering (SMM/SMS). This technique leverages the EM susceptibility of carbon nanotube-coated polymer micro-pellets to achieve rapid, localized heating and powder fusion. Thus, selective microwave melting (SMM) was used to fabricate multilayer specimens made of recycled polyphenylene sulfide (rPPS) and carbon nanotubes (CNTs). The resulting SMM specimens exhibited very good interlayer integrity, localized fusion at pellet boundaries, and tolerable residual porosity, indicating effective fusion and acceptable consolidation. CNT-rich interphases were retained after irradiation, generating anisotropic electrically active network pathways and enabling conductivity enhancement at low filler content. At only 1.0 wt% CNT, the specimens exhibited electrical conductivity approximately three orders of magnitude higher than neat rPPS. Dynamic mechanical analysis showed improved viscoelastic response relative to neat rPPS, while tensile testing confirmed that the SMM-processed specimens retained practical mechanical integrity despite localized voids. These results demonstrate that SMM can effectively consolidate EM susceptible thermoplastic powder beds while preserving their segregated conductive networks. This may become a scalable route for producing multifunctional thermoplastic parts with low filler loadings, tunable anisotropy, and structured materials and parts. Overall, the findings suggest that EM field-based AM can help overcome key limitations of conventional thermoplastic processing by enabling scalable, energy-efficient fabrication of nanostructured composites and expanding AM to a broader range of resins, including high-performance thermoplastics with customized functional properties.

Powder bed fusion↗

NASA NTRS2026

Thermochemical Stability of Ca2Yb8(SiO4)6O2 Apatite in Presence of Molten Calcium-Magnesium-Aluminosilicate (CMAS)

Thermochemical stability of ytterbium silicon oxyapatite Ca 2 Yb 8 (SiO 4 ) 6 O 2 (CYbS) in the presence of molten calcium-magnesium aluminosilicate (CMAS) has been investigated at elevated temperatures for consideration as a thermal and environmental barrier coating (T/EBC) material. CYbS apatite powder was synthesized from the constituent oxides via a solid-state reaction method. Hot-pressed apatite substrates were exposed to molten CMAS at 1200, 1300, and 1400 °C for 1, 10, and 50 h. Development of phases in the interaction region of the heat-treated specimens was monitored using scanning electron microscopy, transmission electron microscopy, high-angle annular dark-field imaging, selected area electron diffraction, and energy dispersive x-ray spectroscopy. Monoclinic cyclosilicate Ca 3 Yb 2 (Si 3 O 9 ) 2 formed from interaction of CYbS apatite with CaO in the CMAS melt at the apatite-CMAS reaction front and continued to nucleate and grow within the residual CMAS in diffusion couples annealed for 1 to 50 h at 1200 °C as well as in those heat treated at 1300 °C for 1 h. Residual CMAS was depleted of Ca when cyclosilicate was present. Dendritic wollastonite (CaSiO3) was observed within the residual CMAS in couples annealed at 1200 and 1300 °C. Ingress of molten CMAS, because of its exponential decrease in viscosity, occurred through open pores and along the grain boundaries of the apatite substrates without any detectable chemical reaction at 1300 and 1400 °C. Results of this study indicate that Ca 2 Yb 8 (SiO 4 ) 6 O 2 apatite has the potential to mitigate the CMAS corrosion up to about 1200 °C but not at higher temperatures.

Narottam P Bansal↗

NASA NTRS1970

Adventures in Research: A History of Ames Research Center, 1940-1965

The present document, which I have called a history-though it certainly was not written for historians-was prepared for and at the request of the NASA Ames Research Center which, in sponsoring the project, acted with the encouragement of NASA Headquarters. It is an account of the establishment, evolutionary development, and activities of the Ames Research Center covering a period characterized by unprecedented scientific and technological revolution. The writing of this book about the Ames Research Center was undertaken with considerable pleasure by one who for many years was employed by the Center’s parent organization NASA and, before that, NACA; who had closely followed the Center’s growth from the beginning; and who was personally acquainted with, and who held in some affection, the members of its founding staff. These facts are given to alert readers to the presence of bias and the inaccuracies stemming therefrom. It should be emphasized that this work is a history only of the Ames Research Center. It is not a history of the U.S. Government, of NACA or NASA, of other research centers, of the military services, of industry, or of world events. Information on these peripheral subjects is introduced merely to provide the reader with a generalized feeling for the local and world environment in which the formation and subsequent activities of the Ames Research Center took place. The background material provided is notably incomplete and in some instances reveals the bias of the NACA/NASA community at the time the events took place. Frequently, also, it reflects the personalized viewpoint of the author who was a close observer of many of these events.

NASA Center History Series↗

NASA NTRS2025

Improving Adhesive Bondline Time of Flight Predictions During Autoclave Cure Utilizing Machine Learning

Composite materials are increasingly being used in aerospace applications due to their superior strength-to-weight ratio compared to commonly used metals. A current limitation to widespread adoption is the certification of adhesively bonded joints. One approach to improving adhesive bonding in composites is accurately measuring the thickness of adhesive bondlines in composite laminates. Precise bondline thickness control is essential for aerospace applications where adhesive layer thickness directly affects joint fracture properties and structural performance. This study focused on implementing machine learning techniques to determine the ultrasonic time of flight (directly correlated to thickness) in adhesive bondlines throughout autoclave cure cycles. A high-temperature (use up to 180°C) ultrasonic scanning system was deployed in an autoclave to provide time of flight data through composite panels. Three experiments were conducted on the curing of 305 mm × 305 mm unidirectional composite panels. In the first experiment, a piecewise function was fit for the temperature correction factor to account for changing autoclave temperatures. Due to deficiencies in the first calibration experiment, a second experiment was run, and the results were used to train a machine learning model. The revised experiment, in combination with the machine learning model, significantly increased the accuracy of the bondline time of flight predictions (~14% error reduced to <1%). Data was processed using the Regression Learner Application in MATLAB®, with a Support Vector Machine selected for the model. The result was a machine learning algorithm capable of reliably quantifying ultrasonic time of flight through adhesive bondlines. The third experiment provided independent test data for the machine learning model, demonstrating that the model produces accurate predictions from data beyond its training set.

Machine Learning↗

NASA NTRS1994

Review of European Microgravity Measurements

AA In a French/Russion cooperation, CNES developed a microgravity detection system for analyzing the Mir space station micro-g-environment for the first time. European efforts to characterize the microgravity (1/9) environment within a space laboratory began in the late seventies with the design of the First Spacelab Mission SL-1. Its Material Science Double Rack was the first payload element to carry its own tri-axial acceleration package. Even though incapable for any frequency analysis, the data provided a wealth of novel information for optimal experiment and hardware design and operations for missions to come. Theoretical investigations under ESA contract demonstrated the significance of the detailed knowledge of micro-g data for a thorough experiment analysis. They especially revealed the high sensitivity of numerous phenomena to low frequency acceleration. Accordingly, the payloads of the Spacelab missions D-1 and D-2 were furnished with state-of-the-art detection systems to ensure frequency analysis between 0.1 and 100 Hz. The Microgravity Measurement Assembly (MMA) of D-2 was a centralized system comprising fixed installed as well as mobile tri-axial packages showing real-time data processing and transmission to ground. ESA's free flyer EURECA carried a system for continuous measurement over the entire mission. All EURECA subsystems and experimental facilities had to meet tough requirements defining the upper acceleration limits. In a French/Russion cooperation, CNES developed a mi crogravity detection system for analyzing the Mir space station micro-g-environment for the first time. An approach to get access to low frequency acceleration between 0 and 0.02 Hz will be realized by QSAM (Quasi-steady Acceleration Measurement) on IML-2, complementary to the NASA system Spacelab Acceleration Measurement System SAMS. A second flight of QSAM is planned for the Russian free flyer FOTON.

H Hamacher↗

NASA NTRS1977

A Survey of Lunar Rock Types and Comparison of the Crusts of Earth and Moon

The principal known types of lunar rocks are briefly reviewed, and their chemical relationships discussed. In the suite of low-KREEP highland rocks, Fe/(Fe + Mg) in the normative mafic minerals increases and the albite content of normative plagioclase decreases as the total amount of normative plagioclase increases, the opposite of the trend predicted by the Bowen reaction principle. Lunar highland samples analyzed are uniformly distributed in this sequence, in which normative plagioclase contents range from ~ 40 percent to ~ 100 percent. The distribution of compositions of rocks from terrestrial layered mafic intrusives is substantially different: here the analyses fall in several discrete clusters (anorthositic rocks, norites, granophyres and ferrogabbros, ultramafics), and the chemical trends noted above are not reproduced. It is suggested that the observed trends in lunar highland rocks could be produced by crystal fractionation in a deep global surface magma system if (1) plagioclase tended to float, upon crystallization, and (2) the magma was kept agitated and well mixed (probably by thermal convection) until crystallization was far advanced and relatively little residual liquid was left. When such a system was finally immobilized, the Fe-, Na-rich residual liquid would produce Fe-rich mafic minerals in the upper levels of the system, but could not much alter the composition of abundant calcic plagioclase. Conversely, the same liquid would produce sodic plagioclase deep in the sequence, but could not much alter the composition of abundant magnesian mafic minerals. After the crustal system solidified, but before extensive cooling had developed a thick, strong lithosphere, mantle convection was able to draw portions of the lunar anorthositic crust down into the mantle in a manner analogous to the present-day behavior of the terrestrial mantle and crust. At depth, the crustal material was heated; KREEP-rich norite was extracted by partial melting and erupted at the surface as a lava, analogous to terrestrial andesite eruptions.

John A Wood↗

NASA NTRS1993

Fuel injector design for high temperature aircraft engine

The objective of the Innovative High Temperature Aircraft Engine Fuel Nozzle Program was to design and evaluate a nozzle capable of operating at a combustor inlet air temperature of 1600 F (1144 K) and a fuel temperature of 350 F (450 K). The nozzle was designed to meet the same performance requirements and fit within the size envelope of a current production dual orifice fuel nozzle. The design approach was to use improved thermal protection and fuel passage geometry in combination with fuel passage surface treatment to minimize coking at these extreme fuel and air temperatures. Heat transfer models of several fuel injector concepts were used to optimize the thermal protection, while sample tube coking tests were run to evaluate the effect of surface finish, coatings and tube material on the coking rate. Based on heat transfer analysis, additional air gaps, reduced fuel passage flow area and use of ceramic tip components reduced local fuel wetted wall temperatures by more than 200 F (100 K) when compared to a current production fuel nozzle. Sample tube coking test results showed the importance of surface finish on the fuel coking rate. Therefore, a one micro-inch (0.025 micron) roughness was specified for all fuel passage surfaces. A novel flow divider valve in the tip was also employed to reduce weight, allow room for additional thermal protection, and provide back pressure to reduce the risk of fuel vaporization. The fuel nozzle was fabricated and evaluated in a series of high temperature coking tests. Initial results of these tests indicate that thermal protection and surface treatments were partially successful in preventing nozzle fouling, but additional refinement of the internal flowpath is needed to prevent buildup of coke particles that partially blocked the spin slots which meter the nozzle fuel flow.

R. W. Stickles↗

NASA NTRS1994

Resistance of Silicon Nitride Turbine Components to Erosion and Hot Corrosion/Oxidation Attack

Silicon nitride turbine components are under intensive development by AlliedSignal to enable a new generation of higher power density auxiliary power systems. In order to be viable in the intended applications, silicon nitride turbine airfoils must be designed for survival in aggressive oxidizing combustion gas environments. Erosive and corrosive damage to ceramic airfoils from ingested sand and sea salt must be avoided. Recent engine test experience demonstrated that NT154 silicon nitride turbine vanes have exceptional resistance to sand erosion, relative to superalloys used in production engines. Similarly, NT154 silicon nitride has excellent resistance to oxidation in the temperature range of interest - up to 1400 C. Hot corrosion attack of superalloy gas turbine components is well documented. While hot corrosion from ingested sea salt will attack silicon nitride substantially less than the superalloys being replaced in initial engine applications, this degradation has the potential to limit component lives in advanced engine applications. Hot corrosion adversely affects the strength of silicon nitride in the 850 to 1300 C range. Since unacceptable reductions in strength must be rapidly identified and avoided, AlliedSignal and the NASA Lewis Research Center have pioneered the development of an environmental life prediction model for silicon nitride turbine components. Strength retention in flexure specimens following 1 to 3300 hour exposures to high temperature oxidation and hot corrosion has been measured and used to calibrate the life prediction model. Predicted component life is dependent upon engine design (stress, temperature, pressure, fuel/air ratio, gas velocity, and inlet air filtration), mission usage (fuel sulfur content, location (salt in air), and times at duty cycle power points), and material parameters. Preliminary analyses indicate that the hot corrosion resistance of NT154 silicon nitride is adequate for AlliedSignal's initial engine applications. Protective coatings and/or inlet air filtration may be required to achieve required ceramic component lives in more aggressive environments.

Nitride↗

NASA NTRS2026

Performance Evaluation of Intravehicular Activity Spacesuit Without the Use of a Liquid Cooling Garment

The Orion Crew Survival Systems (OCSS) suit is equipped with safety technology that protects the crew during launch and re-entry and Intravehicular Activities (IVA). It was designed to be used with a Liquid Cooling Garment (LCG), an undergarment with tubes that circulate water to remove excess heat from a crew member. The objective of this study is to determine if the Modified Advanced Crew Escape Suit (MACES), which has very similar material, assembly, and pressure characteristics as the OCSS suit, can be used without the LCG to maintain the crew within their heat storage requirements where exceedances can lead to cognitive and physiological impairment. Testing was completed for both hot and cold environments where test subjects wore varying configurations of the MACES suit ensemble without the LCG. The tests were conducted in a temperature and humidity-controlled chamber with four test subjects ranging from extra small to large. Target metabolic rates were reached using an arm ergometer. To represent the different suit configurations seen in the concept of operations, the suit was tested with visor-down, visor-up, and without helmet and gloves. The test data was analyzed to determine how the environment, test subject size, metabolic rate, and suit configuration affected heat storage. Furthermore, the test data was used to correlate the METMAN model, a transient metabolic man program that simulates the heat transfer within a crew member’s body and from a crew member to the surrounding environment. The METMAN correlation showed good agreement between predicted heat storage and test data at the end of the test duration, with a coefficient of determination (R 2 ) value of 0.8999 for visor-down cases and R 2 of 0.8902 for visor-up and helmet off cases. A correlated METMAN model allows for the analysis and prediction of IVA suit performance without an LCG in additional scenarios.

Spacesuit↗

NASA NTRS2026

Performance Evaluation of Intravehicular Activity Spacesuit Without the Use of a Liquid Cooling Garment

Human Thermal Modeling↗

NASA NTRS2026

Tracing the Source of Carbon Oxides on the Large Moons of Uranus

The Uranian moons Ariel, Umbriel, Titania, and Oberon are enriched in CO 2 mixed with CO, but the origin(s) of these carbon oxides, be they primarily native or radiolytic, remain(s) uncertain. Using data collected by NIRSpec on the James Webb Space Telescope (JWST), we measured the spectral signature of CO 2 and other carbon oxides to help disentangle these hypotheses. Through comparison to laboratory data, we find that many of the detected spectral features are consistent with CO 2 ice, including 12 CO2 scattering peaks (4.15–4.26 μm), multilobe 13 CO 2 bands (4.35–4.43 μm), and CO 2 biphonon and triphonon modes (4.80–5.25 μm). Our measurements show that CO 2 and CO are concentrated on the trailing hemispheres of the inner moons Ariel and Umbriel, potentially supporting a radiolytic production hypothesis, consistent with prior ground-based results. However, many of the identified spectral features are only observed in thick crystalline ice deposits measured in the laboratory, which may be difficult to form via radiolysis of carbon-bearing material mixed in icy regoliths. Similarly, the data exhibit weak 4.02 and 4.40 μm bands, hinting at the presence of carbonate minerals and 13 CO 2 clathrates, respectively, possibly formed in the interiors of these moons. Furthermore, JWST has revealed that CO 2 is widespread at Uranus, present in its system of rings, ring moons, and irregular satellites, consistent with its largest moons accreting CO 2 and other carbon oxides from the Uranian subnebula. We conclude that exposed carbon oxides are potentially native, with their surface distributions shaped by charged particle irradiation and seasonal sublimation–condensation cycles.

Ice spectroscopy↗

NASA NTRS2026

In-Flight Calibration of ESA Hera’s Hyperscout-H Imager

ESA’s Hera space mission is on its way to the mission target, the binary asteroid (65803) Didymos. HyperScout-H, one of the instruments onboard Hera, is a hyperspectral imager operating in the visible and near-infrared regions between 0.65 and 0.95 μm. HyperScout-H will enable a detailed assessment of the composition of both objects, Didymos and its satellite Dimorphos, the characterization of space weathering effects, and the possible presence of exogenous material on their surfaces. To monitor instrument functionality, calibration exposures are acquired regularly. This article describes the in-flight calibrations carried out for HyperScout-H during the commissioning and cruise phases. Bias and dark exposures, as well as stellar field observations, were acquired several times after launch. We update the calibration data and monitor instrument performance in the space environment. In addition, images of Earth and Moon were acquired from distances of 1.5 × 10 6 to 2.0 × 10 6 km, and Mars and its satellite were imaged during the flyby. In five images, the surface of Mars fills the entire field of view, enabling cross-validation of HyperScout-H results with those reported by other Mars missions. We characterize the detector under in-flight operational conditions. The calibration data indicate that the bias pattern is stable, the dark current remains negligible for short exposures, and the detector response is highly linear. We quantify the field-of-view alignment and geometric distortion, and evaluate the point spread function based on the stellar field observations. Stellar observations and Mars swing-by data provide updated radiometric calibration constants, suggesting that in-flight conditions have slightly modified the detector’s spectral response. In-flight calibrations are essential to ensure data quality and reliability.

Image Processing↗

NASA NTRS1992

On the isotopic signature of recent solar-wind nitrogen

One of the most intriguing discoveries yielded by the Apollo samples was evidence pointing towards a significant long-term change in the composition of the sun. Such a change, of the size inferred from the lunar sample data, is inconsistent with present theories of solar evolution. Consequently, there is much interest in exploring this phenomenon as closely as possible, to determine exactly what compositional changes have taken place and whether those changes really did take place in the sun, or whether the cause lies elsewhere. The reason why we can use the moon to analyze the elements in the sun is that the sun emits a stream of ions, known as the solar wind, whose composition, on average, is believed to be the same as that in the surface regions of the sun. When the solar-wind ions hit the surface of the moon, many of them penetrate a short distance into the dust grains lying on the lunar surface. Thus, after a grain has sat on the lunar surface for a while, it has a rim of material that is partly lunar and partly solar in composition. For most chemical elements, the difference between lunar and solar composition is so sufficiently small that the solar elements cannot be detected, but for a handful of elements that are missing from the moon, their solar 'signature' can be observed in samples of lunar soil brought back by the astronauts. Among those elements is nitrogen, the most common element in the air we breathe, but very rare indeed on the moon. Our analytical techniques are not sophisticated enough yet to enable us to analyze individual lunar soil grains for nitrogen, much less to zero in on just the nitrogen in the surface of such a grain. Consequently we are forced to analyze samples consisting of many different grains, each of which could have experienced its own individual history. This makes it difficult to identify the nitrogen implanted in grain surfaces, and also to define the age of a sample.

Kim, Y.↗

NASA NTRS1994

Bipolar Ag-Zn battery

The silver-zinc (AgZn) battery system has been unique in its ability to safely satisfy high power demand applications with low mass and volume. However, a new generation of defense, aerospace, and commercial applications will impose even higher power demands. These new power demands can be satisfied by the development of a bipolar battery design. In this configuration the power consuming, interelectrode current conductors are eliminated while the current is then conducted via the large cross-section electrode substrate. Negative and positive active materials are applied to opposite sides of a solid silver foil substrate. In addition to reducing the weight and volume required for a specified power level, the output voltage performance is also improved as follows. Reduced weight through: elimination of the plastic cell container; elimination of plate leads and intercell connector; and elimination of internal plate current collector. Increased voltage through: elimination of resistance of current collector; elimination of resistance of plate lead; and elimination of resistance of intercell connector. EPI worked previously on development of a secondary bipolar silver zinc battery. This development demonstrated the electrical capability of the system and manufacturing techniques. One difficulty with this development was mechanical problems with the seals. However, recent improvements in plastics and adhesives should eliminate the major problem of maintaining a seal around the periphery of the bipolar module. The seal problem is not as significant for a primary battery application or for a requirement for only a few discharge cycles. A second difficulty encountered was with activation (introducing electrolyte into the cell) and with venting gas from the cell without loss of electrolyte. During previous work, the following projections for energy density were made from test data for a high power system which demonstrated in excess of 50 discharge/charge cycles. Projected system power = 100 kilowatts; discharge time = 30 seconds; discharge current density = 1.75 amps/sq in.; system weight = 86 lbs (9.7 WH/lb); and system volume = 1071 cu. in. (.78 WH/cu. in.). EPI is currently working on a development program to produce a bipolar silver-zinc battery design for NASA. The potential application would be to power electromechanical actuators for space launch vehicles.

Giltner, L. John↗

NASA NTRS2025

Mechanics of Preloaded Bolt Tensile Loading With Focus on Load Introduction Factor

The bolt tensile and joint separation loads are directly influenced by the locations at which the external loads enter the clamped members of a preloaded bolted joint (PBJ) and the associated load-paths through the joint. This physical load introduction mechanism affecting the bolt tensile loading is typically represented in the bolt tensile load equation, in part, by a load introduction factor (LIF), which was shown by H.M. Lee of Marshall Spaceflight Center to be a natural product of the bolt tensile load equation using a linear spring stiffness model. This LIF, being a function of load-path stiffness, has subsequently been denoted as the stiffness-based LIF (SBLIF), providing a framework to calculate the LIF using whatever load-path stiffness approximations are appropriate. Expanding upon the work of Lee, it is shown that the SBLIF and the joint stiffness factor are functions of the stiffnesses of the same load-paths and regions within a PBJ, and thus they should not be treated as independent variables. Mathematical expressions for the SBLIF are presented. Comparisons are shown between the analytically calculated SBLIF, the analytically calculated geometric LIF (GLIF), which is a simple clamped-member thickness ratio, the experimentally derived LIF, and the LIF determined by finite element analysis (FEA). Using experiment and FEA as a benchmark, the SBLIF, using traditional load-path stiffness approximations, enables a more accurate prediction of bolt tensile loading than the GLIF, although it can be unconservative near joint separation. The GLIF generally attributes more of the externally applied tensile load to the bolt than does the SBLIF, potentially resulting in heavier and/or more costly bolted joints. Mathematical relationships between the SBLIF and the GLIF are developed. Supplemental material is provided in the appendixes where the historical practice of using the joint compressive stiffness in place of the joint tensile stiffness is evaluated. The appendixes include step-by-step examples demonstrating the calculation of the SBLIF using traditional stiffness approximations and conclude with the development of the joint diagram in terms of the SBLIF, culminating into formulas for the key features of a joint diagram, which is useful for programming.

Load Path↗