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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRS2015

Spin Forming Aluminum Crew Module (CM) Metallic Aft Pressure Vessel Bulkhead (APVBH) - Phase II

The principal focus of this project was to assist the Multi-Purpose Crew Vehicle (MPCV) Program in developing a spin forming fabrication process for manufacture of the Orion crew module (CM) aft pressure vessel bulkhead. The spin forming process will enable a single piece aluminum (Al) alloy 2219 aft bulkhead resulting in the elimination of the current multiple piece welded construction, simplify CM fabrication, and lead to an enhanced design. Phase I (NASA TM-2014-218163 (1)) of this assessment explored spin forming the single-piece CM forward pressure vessel bulkhead. The Orion MPCV Program and Lockheed Martin (LM) recently made two critical decisions relative to the NESC Phase I work scope: (1) LM selected the spin forming process to manufacture a single-piece aft bulkhead for the Orion CM, and (2) the aft bulkhead will be manufactured from Al 2219. Based on the Program's new emphasis related to the spin forming process, the NESC was asked to conduct a Phase II assessment to assist in the LM manufacture of the aft bulkhead and to conduct a feasibility study into spin forming the Orion CM cone. This activity was approved on June 19, 2013. Dr. Robert Piascik, NASA Technical Fellow for Materials at the Langley Research Center (LaRC), was selected to lead this assessment. The project plan was approved by the NASA Engineering and Safety Center (NESC) Review Board (NRB) on July 18, 2013. The primary stakeholders for this assessment were the NASA and LM MPCV Program offices. Additional benefactors are commercial launch providers developing CM concepts.

Hoffman, Eric K.↗
NASA NTRSDate not supplied

Advances in Integrally Formed Metallic Structures

NASA Langley Research Center (LaRC) is applying flow forming technology to aerospace aluminum alloys for the manufacture of integrally stiffened cylinders that meet aircraft fuselage or launch vehicle specifications. High-strength 2xxx series alloys, in various temper/product form conditions, are being compared with medium-strength, very formable AA 6061 as the benchmark. Screening of candidate materials traditionally relies on empirical forming trials, but more recently on metrics derived from constant nominal strain rate tensile testing. In this work, the established hierarchy of formability metrics is adopted as the baseline; tensile area reduction, work hardening exponent, and modulus of resilience. The suite of metrics can be expanded based on phenomenological and mechanistic considerations of plastic flow instabilities to incorporate anisotropy ratio, rate of work hardening, and dynamic strain aging effects. Separate research thrusts at LaRC are aimed at formulating a protocol for scalable production of fully formed, defect-free components: 1) quantifying the extended set of formability metrics from constant and jump strain rate tensile tests with digital image correlation (DIC); 2) using statistically designed experiments on a vertical spin/flow forming facility (WF VUD-600®) to isolate the effect of convenient process variables, such as axial feed rate and thickness reduction; and 3) predicting the effect of feed ratio (roller translation relative to mandrel rotation speeds) on material response via process modeling using the DEFORM® simulation software. Current results will be discussed in terms of correlating intrinsic material properties with the bulk workability characteristics to successfully fabricate cylinders with complex cross-sections.

Aluminum↗
NASA NTRS1962

Development of techniques for forming segments of a parabolic solar concentrator

This report covers a comprehensive research study of Androforming, explosive forming, and stretch forming as applied to shaping a parabolic reflector segment for use in a solar furnace. Development efforts were directed toward attaining accurate part contour, and assurance of process reproducibility. The three forming processes mentioned above were investigated by qualified contractors. Three test segments formed by each method along with a detailed analysis were submitted to MSFC. It was concluded that optimum results could be obtained with the stretch forming process. The three test segments of the solar concentrator tha.t were produced by this method, and evaluated optically, revealed a maximum contour deviation of O. 76 degrees.

P.H. Schuerer↗
NASA NTRS1972

Closed-form solutions for atomspheric flight with applications to shuttle guidance

Closed-form solutions for the motion of a rocket-powered vehicle during atmospheric ascent and closed-form solutions for unpowered atmospheric reentry are developed. These closed-form solutions are then used to develop a simplified guidance scheme and to develop a variation-of-parameters integration of more accurate equations of motion with the closed-form solutions as base solutions. The variation-of-parameters integration of the more accurate equations of motion also allows the transition partial derivative matrices associated with these equations to be easily developed. Then the partial derivative transition matrices are used to develop a guidance scheme based on the more accurate equations of motion instead of the less accurate closed-form solutions.

Ingram, H. L.↗
NASA NTRS1975

Comments on 'Luenberger's canonical form revisited'

Results similar to those presented in the paper entitled 'Canonical forms for linear multivariable systems' by Luenberger (1967) have previously been developed for a slightly different version of Luenberger's canonical form. These results are summarized herein to provide an alternate canonical form that can be used for system identification. For certain applications, such as observer design, the canonical form presented is particularly well suited. Both canonical forms provide the same number of undefined parameters.

Denery, D. G.↗
NASA NTRS1977

Variational energy principle for compressible, baroclinic flow. 2: Free-energy form of Hamilton's principle

The first and second variations are calculated for the irreducible form of Hamilton's Principle that involves the minimum number of dependent variables necessary to describe the kinetmatics and thermodynamics of inviscid, compressible, baroclinic flow in a specified gravitational field. The form of the second variation shows that, in the neighborhood of a stationary point that corresponds to physically stable flow, the action integral is a complex saddle surface in parameter space. There exists a form of Hamilton's Principle for which a direct solution of a flow problem is possible. This second form is related to the first by a Friedrichs transformation of the thermodynamic variables. This introduces an extra dependent variable, but the first and second variations are shown to have direct physical significance, namely they are equal to the free energy of fluctuations about the equilibrium flow that satisfies the equations of motion. If this equilibrium flow is physically stable, and if a very weak second order integral constraint on the correlation between the fluctuations of otherwise independent variables is satisfied, then the second variation of the action integral for this free energy form of Hamilton's Principle is positive-definite, so the action integral is a minimum, and can serve as the basis for a direct trail and error solution. The second order integral constraint states that the unavailable energy must be maximum at equilibrium, i.e. the fluctuations must be so correlated as to produce a second order decrease in the total unavailable energy.

Schmid, L. A.↗
NASA NTRS1977

Method of forming metal hydride films

The substrate to be coated (which may be of metal, glass or the like) is cleaned, both chemically and by off-sputtering in a vacuum chamber. In an ultra-high vacuum system, vapor deposition by a sublimator or vaporizer coats a cooled shroud disposed around the substrate with a thin film of hydride forming metal which getters any contaminant gas molecules. A shutter is then opened to allow hydride forming metal to be deposited as a film or coating on the substrate. After the hydride forming metal coating is formed, deuterium or other hydrogen isotopes are bled into the vacuum system and diffused into the metal film or coating to form a hydride of metal film. Higher substrate temperatures and pressures may be used if various parameters are appropriately adjusted.

Steinberg, R.↗
NASA NTRS1989

Orthogonal canonical forms for second-order systems

The authors prove that a linear second-order system with arbitrary damping cannot be reduced to Hessenberg-triangular form by means of orthogonal transformations, while this reduction is always possible for the modal damping commonly assumed for models of flexible structures. The type of canonical form obtainable by means of orthogonal transformations acting on a second-order system is heavily dependent on the type of damping considered. If the damping matrix is merely positive semi-definite symmetric, it is generally not possible to obtain a reduction to Hessenberg-triangular form, while this reduction is trivial for zero or Rayleigh damping. If damping is modal, however, as is commonly assumed in structural models, the reduction exists and is nontrivial. Furthermore, reduction to triangular second-order Schur form is always possible for such damping: this canonical form appears likely to have applications to second-order system theory.

Williams, Trevor↗
NASA NTRS1989

Active star-forming galaxies in the X ray foreground

Star forming galaxies were discovered as a component of the X-ray background (XRB) in the Einstein deep surveys. Such star forming galaxies may be largely powered by superluminous Population 1 massive X-ray binaries (MXRB), formed in the wake of star formation in regions of low metallicity. The star forming galaxies with moderate numbers of MXRB may evolve into the infrared starburst galaxies found at low redshifts using IRAS (Infrared Astronomy Satellite), and may also be related to those galaxies identified with sub-mJy radio sources. A conservative contribution to the XRB of at least approximately 15 percent, without evolution is estimated. It is shown that moderate evolution leads to a contribution at least equalling that of quasars. Above 3 keV, star forming galaxies may dominate the XRB.

Griffiths, R. E.↗
NASA NTRS1991

Superplastic forming of Al-Li alloys for lightweight, low-cost structures

Superplastic forming of advanced aluminum alloys is being evaluated as an approach for fabricating low-cost, light-weight, cryogenic propellant tanks. Built-up structure concepts (with inherent reduced scrap rate) are under investigation to offset the additional raw material expenses incurred by using aluminum lithium alloys. This approach to fabrication offers the potential for significant improvements in both structural efficiency and overall manufacturing costs. Superplasticity is the ability of specially processed material to sustain very large forming strains without failure at elevated temperatures under controlled deformation conditions. It was demonstrated that superplastic forming technology can be used to fabricate complex structural components in a single operation and increase structural efficiency by as much as 60 percent compared to conventional configurations in skin-stiffened structures. Details involved in the application of this technology to commercial grade superplastic aluminum lithium material are presented. Included are identification of optimum forming parameters, development of forming procedures, and assessment of final part quality in terms of cavitation volume and thickness variation.

Hales, Stephen J.↗
NASA NTRS1992

TRASYS form factor matrix normalization

A method has been developed for adjusting a TRASYS enclosure form factor matrix to unity. This approach is not limited to closed geometries, and in fact, it is primarily intended for use with open geometries. The purpose of this approach is to prevent optimistic form factors to space. In this method, nodal form factor sums are calculated within 0.05 of unity using TRASYS, although deviations as large as 0.10 may be acceptable, and then, a process is employed to distribute the difference amongst the nodes. A specific example has been analyzed with this method, and a comparison was performed with a standard approach for calculating radiation conductors. In this comparison, hot and cold case temperatures were determined. Exterior nodes exhibited temperature differences as large as 7 C and 3 C for the hot and cold cases, respectively when compared with the standard approach, while interior nodes demonstrated temperature differences from 0 C to 5 C. These results indicate that temperature predictions can be artificially biased if the form factor computation error is lumped into the individual form factors to space.

Tsuyuki, Glenn T.↗
NASA NTRS1992

Formed platelet combustor liner construction feasibility, phase A

Environments generated in high pressure liquid rocket engines impose severe requirements on regeneratively cooled combustor liners. Liners fabricated for use in high chamber pressures using conventional processes suffer from limitations that can impair operational cycle life and can adversely affect wall compatibility. Chamber liners fabricated using formed platelet technology provide an alternative to conventional regeneratively cooled liners (an alternative that has many attractive benefits). A formed platelet liner is made from a stacked assembly of platelets with channel features. The assembly is diffusion bonded into a flat panel and then three-dimensionally formed into a section of a chamber. Platelet technology permits the liner to have very precisely controlled and thin hot gas walls and therefore increased heat transfer efficiency. Further cooling efficiencies can be obtained through enhanced design flexibility. These advantages translate into increased cycle life and enhanced wall compatibility. The increased heat transfer efficiency can alternately be used to increase engine performance or turbopump life as a result of pressure drop reductions within the regeneratively cooled liner. Other benefits can be obtained by varying the materials of construction within the platelet liner to enhance material compatibility with operating environment or with adjoining components. Manufacturing cost savings are an additional benefit of a formed platelet liner. This is because of reduced touch labor and reduced schedule when compared to conventional methods of manufacture. The formed platelet technology is not only compatible with current state-of-the art combustion chamber structural support and manifolding schemes, it is also an enabling technology that allows the use of other high performance and potentially low cost methods of construction for the entire combustion chamber assembly. The contract under which this report is submitted contains three phases: (1) phase A - feasibility study and technology development; (2) phase B - sub-scale fabrication feasibility; and (3) phase C - large scale fabrication validation. This report covers the Phase A activities, which began in December of 1988.

Hayes, W. A.↗
NASA NTRS1930

Drag and Cooling with Various Forms of Cowling for a "Whirlwind" Radial Air-Cooled Engine I

This report presents the results of an investigation undertaken in the 20-foot Propeller Research Tunnel at Langley Field on the cowling of radial air-cooled engines. A portion of the investigation has been completed, in which several forms and degrees of cowling were tested on Wright "Whirlwind" J-5 engine mounted in the nose of a cabin fuselage. The cowlings varied from the one extreme of an entirely exposed engine to the other in which the engine was entirely inclosed. Cooling tests were made and each cowling modified, if necessary, until the engine cooled approximately as satisfactorily as when it was entirely exposed. Drag tests were then made with each form of cowling, and the effect of the cowling on the propulsive efficiency determined with a metal propeller. The propulsive efficiency was found to be practically the same with all forms of cowling. The drag of the cabin fuselage with uncowled engine was found to be more than three times as great as the drag of the fuselage with engine removed and nose rounded. The conventional forms of cowling, in which at least the tops of the cylinder heads and valve gear are exposed, reduce the drag somewhat, but the cowling entirely covering the engine reduces it 2.6 times as much as the best conventional one. The decrease in drag due to the use of spinners proved to be almost negligible. The use of the cowling completely covering the engine seems entirely practical as regards both cooling and maintenance under service conditions. It must be carefully designed, however, to cool properly. With cabin fuselages its use should result in a substantial increase in high speed over that obtained with present forms of cowling on engines similar in contour to the J-5. (author)

Weick, Fred E↗
NASA NTRS1951

A summary of lateral-stability derivatives calculated for wing plan forms in supersonic flow

A compilation of theoretical values of the lateral-stability derivatives for wings at supersonic speeds is presented in the form of design charts. The wing plan forms for which this compilation has been prepared include a rectangular, two trapezoidal, two triangular, a fully-tapered swept-back, a sweptback hexagonal, an unswept hexagonal, and a notched triangular plan form. A full set of results, that is, values for all nine of the lateral-stability derivatives for wings, was available for the first six of these plan forms only. The reasons for the incompleteness of the results available for other plan forms are discussed.

Jones, Arthur L↗
NASA NTRS1994

Near-net-shape manufacturing: Spray-formed metal matrix composites and tooling

Spray forming is a materials processing technology in which a bulk liquid metal is converted to a spray of fine droplets and deposited onto a substrate or pattern to form a near-net-shape solid. The technology offers unique opportunities for simplifying materials processing without sacrificing, and oftentimes substantially improving, product quality. Spray forming can be performed with a wide range of metals and nonmetals, and offers property improvements resulting from rapid solidification (e.g. refined microstructures, extended solid solubilities and reduced segregation). Economic benefits result from process simplification and the elimination of unit operations. The Idaho National Engineering Laboratory is developing a unique spray-forming method, the Controlled Aspiration Process (CAP), to produce near-net-shape solids and coatings of metals, polymers, and composite materials. Results from two spray-accompanying technical and economic benefits. These programs involved spray forming aluminum strip reinforced with SiC particulate, and the production of tooling, such as injection molds and dies, using low-melting-point metals.

Mchugh, Kevin M.↗
NASA NTRS1994

Advanced method and processing technology for complicated shape airframe part forming

Slow deformation modes of forming give considerably higher residual fatigue life of the airframe part. It has experimentally proven that fatigue life of complicated shape integral airframe panels made of high strength aluminum alloys is significantly increased after creep deformation process. To implement the slow deformation mode forming methods, universal automated equipment was developed. Multichannel forming systems provide high accuracy of airframe part shape eliminating residual stresses and spring effect. Forming process multizone control technology was developed and experimentally proved that static/fatigue properties of formed airframe parts are increased.

Miodushevsky, P. V.↗
NASA NTRS1995

Method for Fabricating Composite Structures Including Continuous Press Forming and Pultrusion Processing

A method for fabricating composite structures at a low-cost, moderate-to-high production rate is disclosed. A first embodiment of the method includes employing a continuous press forming fabrication process. A second embodiment of the method includes employing a pultrusion process for obtaining composite structures. The methods include coating yarns with matrix material, weaving the yarn into fabric to produce a continuous fabric supply, and feeding multiple layers of net-shaped fabrics having optimally oriented fibers into a debulking tool to form an undebulked preform. The continuous press forming fabrication process includes partially debulking the preform, cutting the partially debulked preform, and debulking the partially debulked preform to form a netshape. An electron-beam or similar technique then cures the structure. The pultrusion fabric process includes feeding the undebulked preform into a heated die and gradually debulking the undebulked preform. The undebulked preform in the heated die changes dimension until a desired cross-sectional dimension is achieved. This process further includes obtaining a net-shaped infiltrated uncured preform, cutting the uncured preform to a desired length, and electron-beam curing (or similar technique) the uncured preform. These fabrication methods produce superior structures formed at higher production rates, resulting in lower cost and high structural performance.

Farley, Gary L.↗
NASA NTRS1997

Method for Fabricating Composite Structures Using Continuous Press Forming

A method for fabricating composite structures at a low-cost. moderate-to-high production rate. A first embodiment of the method includes employing a continuous press forming fabrication process. A second embodiment of the method includes employing a pultrusion process for obtaining composite structures. The methods include coating yarns with matrix material, weaving the yarn into fabric to produce a continuous fabric supply and feeding multiple layers of net-shaped fabrics having optimally oriented fibers into a debulking tool to form an undebulked preform. The continuous press forming fabrication process includes partially debulking the preform, cutting the partially debulked preform and debulking the partially debulked preform to form a net-shape. An electron-beam or similar technique then cures the structure. The pultrusion fabric process includes feeding the undebulked preform into a heated die and gradually debulking the undebulked preform. The undebulked preform in the heated die changes dimension until a desired cross-sectional dimension is achieved. This process further includes obtaining a net-shaped infiltrated uncured preform, cutting the uncured preform to a desired length and electron-beam curing (or similar technique) the uncured preform. These fabrication methods produce superior structures formed at higher production rates. resulting in lower cost and high structural performance.

Farley, Gary L.↗