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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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At least 631 records · Page 35
All sourcesNASA NTRSDOE OSTI
NASA NTRS1985

Dynamic verification of very large space structures

The dynamic verification of spacecraft relies heavily on ground-based tests. These tests usually simulate flight environments or validate analytical models used in establishing design loads and in designing control algorithms. They also provide security against failures resulting from unanticipated or unmodeled hardware behavior. Future orbital antennas, space stations, and solar power systems are likely to be of sizes difficult to test using current ground test technology. In addition to size, other factors such as low natural frequencies, lightweight construction, and the presence of many structural joints, cause significant sensitivity of the test process to the earth-gravity environment. Yet, accuracy requirements on the verification process will be more stringent because of modern flexible-structure control approaches. This paper describes some of the problems and discusses research on potential solutions. The importance of an integrated ground test, analysis, and flight test program is emphasized. An ongoing research program of this type focusing on a 60-meter, deployable, truss-beam test article is described.

Hanks, B. R.↗
NASA NTRS1974

Method of laminating structural members

A laminate is obtained by providing a lightweight core material, such as a honeycombed plastic or metal, within the cavity defined by an annular mold cavity frame. Face sheets, which are to be bonded to the core material, are provided on opposite sides of the frame and extend over the frame, thus sealing the core material in the cavity. An adhesive is provided between the core material and the face sheets and the combined thickness of the core material and adhesive is a close fit within the opposed face sheets. A gas tight seal, such as an O-ring gasket, is provided between the frame and the face sheet members to form a gas tight cavity between the face sheet members and the frame. External heat and pressure are used to bond the face sheets to the core material. Gas pressure is introduced into the sealed cavity to minimize out-gasing of the adhesive.

Heier, W. C.↗
NASA NTRS1980

Mechanical end joint for structural columns

Connector for tubular struts permits construction of lightweight frames without tools or assembly equipment. Two main components are node fitting and strut element. Components are aleaned approximately and pushed together. Design accommodates reasonable axial and rotational misalignment of nodes and struts. Also, individual columns can be inserted into receptacle and given slight push by operator, trigger pins release ratchet, allowing energy stored in springs to rotate screw into nut in receptacle.

Bush, H. G.↗
NASA NTRS2010

Concentric Nested Toroidal Inflatable Structures

Assemblies comprising multiple limited- height toroidal inflatable structures nested in a concentric arrangement have been invented to obtain more design flexibility than can be obtained in single taller, wider toroidal inflatable structures (see figure). Originally intended for use as containers for habitats for humans in outer space or on remote planets, these and related prior inflatable structures could also be useful on Earth as lightweight, compactly stowable, portable special-purpose buildings that could be transported to remote locations and there inflated to full size and shape. In the case of a single inflatable toroidal structure, one important source of lack of design flexibility is the fact that an increase in outer diameter (which is sometimes desired) is necessarily accompanied by an increase in height (which is sometimes undesired). Increases in diameter and height can also cause difficulty in utilization of the resulting larger volume, in that it can become necessary to partition the volume by means of walls and floors, and features (e.g., stairs or ladders) must be added to enable vertical movement between floors. Moreover, ascending and descending between floors in a gravitational environment could pose unacceptable difficulty for the inhabitants under some circumstances. Another source of lack of design flexibility in a single toroidal inflatable structure is that for a given inflation pressure, an increase in the outer diameter of the structure necessarily entails an increase in the maximum stress in the structure. Because it is necessary to keep the maximum stress within the load-bearing capability of the structural materials, consistent with other aspects of the design, this may translate to a limit on the outer diameter. In an assembly comprising concentric nested toroidal structures, an increase in outer diameter does not necessarily entail an increase in height or a maximum stress in excess of the load-bearing capability of the structural materials. The minor diameters of the nested toroid can be chosen to partition interior spaces optimally, without necessitating the addition of walls or floors. Inasmuch as the maximum stress in a nested inflatable toroidal structure is a function of its minor diameter and the minor diameter is typically small enough that the load-bearing capability of the structural materials is not exceeded, there is no longer a limit on the outer diameter of the assembly: instead, the assembly can be expanded, without limit, by simply adding concentric inflatable toroidal structures having suitable minor diameters and successively larger major diameters. The minor diameters need not be equal:

Johnson, Christopher J.↗
NASA NTRS1994

Load-limiting landing gear footpad energy absorption system

As a precursor to future manned missions to the moon, an inexpensive, unmanned vehicle that could carry small, scientific payloads to the lunar surface was studied by NASA. The vehicle, called the Common Lunar Lander, required extremely optimized structural systems to increase the potential payload mass. A lightweight energy-absorbing system (LAGFEAS), which also acts as a landing load-limiter was designed to help achieve this optimized structure. Since the versatile and easily tailored system is a load-limiter, it allowed for the structure to be designed independently of the ever-changing landing energy predictions. This paper describes the LAGFEAS system and preliminary verification testing performed at NASA's Johnson Space Center for the Common Lunar Lander program.

Hansen, Chris↗
NASA NTRS2017

Passive Earth Entry Vehicle Landing Test

Two full-scale passive Earth Entry Vehicles (EEV) with realistic structure, surrogate sample container, and surrogate Thermal Protection System (TPS) were built at NASA Langley Research Center (LaRC) and tested at the Utah Test and Training Range (UTTR). The main test objective was to demonstrate structural integrity and investigate possible impact response deviations of the realistic vehicle as compared to rigid penetrometer responses. With the exception of the surrogate TPS and minor structural differences in the back shell construction, the two test vehicles were identical in geometry and both utilized the Integrated Composite Stiffener Structure (ICoSS) structural concept in the forward shell. The ICoSS concept is a lightweight and highly adaptable composite concept developed at NASA LaRC specifically for entry vehicle TPS carrier structures. The instrumented test vehicles were released from a helicopter approximately 400 m above ground. The drop height was selected such that at least 98% of the vehicles terminal velocity would be achieved. While drop tests of spherical penetrometers and a low fidelity aerodynamic EEV model were conducted at UTTR in 1998 and 2000, this was the first time a passive EEV with flight-like structure, surrogate TPS, and sample container was tested at UTTR for the purpose of complete structural system validation. Test results showed that at a landing vertical speed of approximately 30 m/s, the test vehicle maintained structural integrity and enough rigidity to penetrate the sandy clay surface thus attenuating the landing load, as measured at the vehicle CG, to less than 600 g. This measured deceleration was found to be in family with rigid penetrometer test data from the 1998 and 2000 test campaigns. Design implications of vehicle structure/soil interaction with respect to sample container and sample survivability are briefly discussed.

Kellas, Sotiris↗
DOE OSTI2025

Curiosity driven exploration to optimize structure–property learning in microscopy

Rapidly determining structure–property correlations in materials is an important challenge in better understanding fundamental mechanisms and greatly assists in materials design. In microscopy, imaging data provides a direct measurement of the local structure, while spectroscopic measurements provide relevant functional property information. Deep kernel active learning approaches have been utilized to rapidly map local structure to functional properties in microscopy experiments, but are computationally expensive for multi-dimensional and correlated output spaces. Here, we present an alternative lightweight curiosity algorithm which actively samples regions with unexplored structure–property relations, utilizing a deep-learning based surrogate model for error prediction. We show that the algorithm outperforms random sampling for predicting properties from structures, and provides a convenient tool for efficient mapping of structure–property relationships in materials science.

36 MATERIALS SCIENCE↗
NASA NTRS1994

NASA-UVA Light Aerospace Alloy and Structures Technology Program (LA2ST)

The NASA-UVA Light Aerospace Alloy and Structures Technology (LA2ST) Program was initiated in 1986 and continues with a high level of activity. Projects are being conducted by graduate students and faculty advisors in the Department of Materials Science and Engineering, as well as in the Department of Civil Engineering and Applied Mechanics, at the University of Virginia. This work is funded by the NASA-Langley Research Center under Grant NAG-1-745. Here, we report on progress achieved between January 1 and June 30, 1994. These results were presented at the Fifth Annual NASA LA2ST Grant Review Meeting held at the Langley Research Center in July of 1994. The objective of the LA2ST Program is to conduct interdisciplinary graduate student research on the performance of next generation, lightweight aerospace alloys, composites, and thermal gradient structures in collaboration with NASA-Langley researchers. Specific technical objectives are presented for each research project. We generally aim to produce relevant data and basic understanding of material mechanical response, environmental/corrosion behavior, and microstructure; new monolithic and composite alloys; advanced processing methods; new solid and fluid mechanics analyses; measurement and modeling advances; and a pool of educated graduate students for aerospace technologies.

Gangloff, Richard P.↗
NASA NTRS1998

Tooling Foam for Structural Composite Applications

Tooling technology applications for composite structures fabrication have been expanded at MSFC's Productivity Enhancement Complex (PEC). Engineers from NASA/MSFC and Lockheed Martin Corporation have developed a tooling foam for use in composite materials processing and manufacturing that exhibits superior thermal and mechanical properties in comparison with other tooling foam materials. This tooling foam is also compatible with most preimpregnated composite resins such as epoxy, bismaleimide, phenolic and their associated cure cycles. MARCORE tooling foam has excellent processability for applications requiring either integral or removable tooling. It can also be tailored to meet the requirements for composite processing of parts with unlimited cross sectional area. A shelf life of at least six months is easily maintained when components are stored between 50F - 70F. The MARCORE tooling foam system is a two component urethane-modified polyisocyanurate, high density rigid foam with zero ozone depletion potential. This readily machineable, lightweight tooling foam is ideal for composite structures fabrication and is dimensionally stable at temperatures up to 350F and pressures of 100 psi.

DeLay, Tom↗
NASA NTRS2008

Self-Deploying Trusses Containing Shape-Memory Polymers

Composite truss structures are being developed that can be compacted for stowage and later deploy themselves to full size and shape. In the target applications, these smart structures will precisely self-deploy and support a large, lightweight space-based antenna. Self-deploying trusses offer a simple, light, and affordable alternative to articulated mechanisms or inflatable structures. The trusses may also be useful in such terrestrial applications as variable-geometry aircraft components or shelters that can be compacted, transported, and deployed quickly in hostile environments. The truss technology uses high-performance shape-memory-polymer (SMP) thermoset resin reinforced with fibers to form a helical composite structure. At normal operating temperatures, the truss material has the structural properties of a conventional composite. This enables truss designs with required torsion, bending, and compression stiffness. However, when heated to its designed glass transition temperature (Tg), the SMP matrix acquires the flexibility of an elastomer. In this state, the truss can be compressed telescopically to a configuration encompassing a fraction of its original volume. When cooled below Tg, the SMP reverts to a rigid state and holds the truss in the stowed configuration without external constraint. Heating the materials above Tg activates truss deployment as the composite material releases strain energy, driving the truss to its original memorized configuration without the need for further actuation. Laboratory prototype trusses have demonstrated repeatable self-deployment cycles following linear compaction exceeding an 11:1 ratio (see figure).

Schueler, Robert M.↗
DOE OSTI2025

Lightweight Metal Stamping Optimization Enabled by Artificial Intelligence

Successfully manufacturing an automotive body structure made via the sheet metal stamping process depends upon simultaneous consideration of component design, tooling design, stamping process control, and material properties. In many cases, introducing lightweight sheet materials (e.g., aluminum alloys, magnesium alloys, advanced high strength steels) holds the potential to significantly reduce vehicle weight, but challenges the stamping process by introducing materials with inherently less ductility. Successful and repeatable applications require co-developing the stamping process controls with the varying material properties, including formability. During the stamping process, as soon as the forming limit of the sheet is exceeded, the material shows localized necking which quickly leads to splits. Controlling process variability to avoid these material splits will enable deployment of less formable, lighter, and stronger materials for stamped automotive components. A typical optimization procedure for manufacturing requires an iterative process involving parameter setting, execution of computational simulations, and modifying the parameters. The entire process demands substantial computational time, making it impractical for real-time feedback towards rapid corrective actions required for in-line control for running production processes. To overcome this challenge, artificial intelligence (AI) can be leveraged to determine optimal manufacturing parameters within a single manufacturing cycle time. This research proposes an in-line optimization framework incorporating a trained AI model to predict kidney-shaped die forming. Preliminary results indicate that the AI framework can accurately predict draw-in values based on a given parameter set, a process referred to as forward prediction. Furthermore, the AI framework can also predict the optimal parameter set that leads to the desired draw-in values, referred to as inverse optimization (or backward prediction). This research has been performed in collaborations with USCAR (US Council for Automotive Research) and AutoForm. The members of USCAR are Ford, GM, and Stellantis.

36 MATERIALS SCIENCE↗
NASA NTRS2004

Lightweight, Rack-Mountable Composite Cold Plate/Shelves

Rack-mountable composite-material structural components that would serve as both shelves and cold plates for removing heat from electronic or other equipment mounted on the shelves have been proposed as lightweight alternatives to all-metal cold plate/shelves now in use. A proposed cold plate/shelf would include a highly thermally conductive face sheet containing oriented graphite fibers bonded to an aluminum honeycomb core, plus an extruded stainless-steel substructure containing optimized flow passages for a cooling fluid, and an inlet and outlet that could be connected to standard manifold sections. To maximize heat-transfer efficiency, the extruded stainless-steel substructure would be connected directly to the face sheet. On the basis of a tentative design, the proposed composite cold plate/shelf would weigh about 38 percent less than does an all-aluminum cold plate in use or planned for use in some spacecraft and possibly aircraft. Although weight is a primary consideration, the tentative design offers the additional benefit of reduction of thickness to half that of the all-aluminum version.

Hurlbert, Kathryn M.↗
NASA NTRS2002

Finite Element Modeling of Deployment, and Foam Rigidization of Struts and Quarter Scale Shooting Star Experiment

Inflated cylindrical struts constructed of kapton polyimide film and rigidized with foam have considerable practical application and potential for use as components of inflatable concentrator assemblies, antenna structures and space power systems, Because of their importance, it is of great interest to characterize the dynamic behavior of these components and structures both experimentally and analytically. It is very helpful to take a building-block approach to modeling and understanding inflatable assemblies by first investigating in detail the behavior of the components such as the struts. The foam material used for rigidization of such cylinders has varying modulus, which is a function of different factors, such as density of the foam. Thus, the primary motivation of the tests and analytical modeling efforts was to determine and understand the response of foam-rigidized cylinders for different densities, sizes, and construction methods. In recent years, inflatable structures have been the subject of renewed interest for space applications such as communications antennae, solar thermal propulsion, and space solar power. A major advantage of using inflatable structures in space is that they are extremely lightweight. This makes inflatables a perfect match for solar thermal propulsion because of the low thrust levels available. An obvious second advantage is on-orbit deployability and subsequent space savings in launch configuration. It can be seen that inflatable cylindrical struts and torus are critical components of structural assemblies. In view of this importance, structural dynamic and static behaviors of typical rigidized polyimide struts are investigated in this paper. The paper will focus on the finite element models that were used to model the behavior of the complete solar collector structure, and the results that they provided, as compared to test data.

Larry Leigh, Jr.↗
NASA NTRS1986

Thermal stability of lightweight graphite glass sandwich reflectors for far infrared astronomy

Graphite fiber-reinforced glass matrix composites are being developed for a variety of structural applications requiring excellent thermomechanical stability. These materials are ideally suited for lightweight, high strength, thermally stable infrared mirrors because of their low density, low thermal expansion, high strength and stiffness, and their ability to be machined, replicated and figured using standard polishing techniques. These properties are particularly promising for applications such as a 3-meter balloon-borne far-infrared and submillimeter telescope mirror which must be both very lightweight and able to retain its figure accuracy when cycled between room temperature and its operating temperature of -50 C. This paper presents the results of a set of low temperature optical tests conducted to determine the figure stability of a 30-cm diameter, frit-bonded graphite/glass mirror in the +20 to -60 C temperature range using a 10.6 micron laser interferometer. The results indicate that the residual change in figure was less than 0.3 microns, rms.

Bluege, J. H.↗
NASA NTRS2015

Electron Beam Irradiated Intercalated CNT Yarns For Aerospace Applications

Multi-walled CNT yarns have been experimentally and commercially created to yield lightweight, high conductivity fibers with good tensile properties for application as electrical wiring and multifunctional tendons. Multifunctional tendons are needed as the cable structures in tensegrity robots for use in planetary exploration. These lightweight robust tendons can provide mechanical strength for movement of the robot in addition to power distribution and data transmission. In aerospace vehicles, such as Orion, electrical wiring and harnessing mass can approach half of the avionics mass. Use of CNT yarns as electrical power and data cables could reduce mass of the wiring by thirty to seventy percent. These fibers have been intercalated with mixed halogens to increase their specific electrical conductivity to that near copper. This conductivity, combined with the superior strength and fatigue resistance makes it an attractive alternative to copper for wiring and multifunctional tendon applications. Electron beam irradiation has been shown to increase mechanical strength in pristine CNT fibers through increased cross-linking. Both pristine and intercalated CNT yarns have been irradiated using a 5-megavolt electron beam for various durations and the conductivities and tensile properties will be discussed. Structural information obtained using a field emission scanning electron microscope, energy dispersive X-ray spectroscopy (EDS), and Raman spectroscopy will correlate microstructural details with bulk properties.

electrical wiring↗
NASA NTRS1984

Advanced passive radiator for spaceborne cryogenic cooling

A novel design to improve the cooling capability of spaceborne cryogenic passive radiators is described. The design is based on the use of lightweight angled radiation shields, low-conductance structural supports, and a separate detachable launch-support system to reduce the parasitic heat leaks from the warm spacecraft to the cold radiator. The effectiveness of this design is demonstrated by thermal-vacuum-chamber experiments which indicate that the angled-radiation-shield assembly has an effective emittance that is an order of magnitude lower than that of the best multilayer insulation used in flight. Performance predictions based on the experiments and analytical model indicate that an advanced passive-radiator design based on this technology would be between 10 and 57% of the size and 10 and 36% of the mass of the best state-of-the-art passive radiators and would make lower temperatures (< 60 K) and larger heat loads practical. The cooling requirements of many new spaceborne instruments could be accommodated by application of this new passive-radiator design.

Steven Bard↗
NASA NTRS1989

Conceptual design of a self-deployable, high performance parabolic concentrator for advanced solar-dynamic power systems

A summary is presented of the concentrator conceptual design work performed under a NASA-funded project. The design study centers around two basic efforts: conceptual design of a self-deploying, high-performance parabolic concentrator; and materials selection for a lightweight, shape-stable concentrator. The primary structural material selected for the concentrator is PEEK/carbon fiber composite. The deployment concept utilizes rigid gore-shaped reflective panels. The assembled concentrator takes a circular shape with a void in the center. The deployable solar concentrator concept is applicable to a range of solar dynamic power systems of 25 kWe to more than 75 kWe.

Dehne, Hans Joachim↗