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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 NTRS1988

Advanced Porous Coating for Low-Density Ceramic Insulation Materials

The need for improved coatings on low-density reusable surface insulation (RSI) materials used on the space shuttle has stimulated research into developing tougher coatings. The processing of a new porous composite "coating" for RST called toughened unipiece fibrous insulation Is discussed. Characteristics including performance in a simulated high-speed atmospheric entry, morphological structure before and after this exposure, resistance to Impact, and thermal response to a typical heat pulse are described. It is shown that this coating has improved impact resistance while maintaining optical and thermal properties comparable to the previously available reaction-cured glass coating.

Leiser, Daniel B.↗
NASA NTRS1973

Cyclic arc plasma tests of RSI materials using a preheater

The results of a test program are reported in which a preheater was used with an arc plasma stream to study the thermal response of samples of candidate reusable surface insulation materials for the space shuttle. The preheater simulated the shuttle temperature history during the first and last portions of the test cycle, which could not be simulated by the air arc plasma flow. Pre- and post-test data taken for each of the materials included magnified views, optical properties, and chemical analyses. The test results indicate that the mullite base samples experience higher surface temperatures than the other materials at heating rates greater than 225 kw/sq m. The ceramic fibrous mullite and silica coatings show noncatalytic wall behavior. Internal temperature response data for the materials are compared and correlated with analytical predictions.

Stewart, D. A.↗
NASA NTRS2013

Dynamic Mechanical Analysis (DMA) to Help Characterize Vespel SP-211 Polyimide Material for Use as a 750 F Valve Seal on the Ares I Upper Stage J-2X Engine

DuPont (TM) Vespel (R) SP-211 polyimide was selected as the top candidate seal material for use in the Oxidizer Turbine Bypass Valve (OTBV) on NASA's Ares I Upper Stage J-2X engine. In the OTBV, the seal material would get exposed to temperatures up to 750degF for approx 10 minutes at a time. Although the J-2X engine is not reusable, the valve material could be exposed to multiple temperature cycles up to 750 F during engine operation. The Constellation Program that included the Ares I rocket was eventually cancelled, but the J-2X engine was chosen for continued use for development of NASA's Space Launch System (SLS). The SLS is a heavy-lift launch vehicle that will have capability of taking astronauts and hardware to the Moon, Mars and asteroids. Dynamic mechanical analysis (DMA) was one of several test techniques used to characterize Vespel SP-211 to help prove its worthiness for use on the OTBV of the J-2X engine.

Wingard, Doug↗
NASA NTRS2013

Dynamic Mechanical Analysis (DMA) to Help Characterize Vespel SP-211 Polyimide Material for Use as a 750 F Valve Seal on the Ares I Upper Stage J-2X Engine

DuPont(tm) Vespel(R) SP-211 polyimide was selected as the top candidate seal material for use in the Oxidizer Turbine Bypass Valve (OTBV) on NASA's Ares I Upper Stage J-2X engine. In the OTBV, the seal material would get exposed to temperatures up to 750degF for approx 10 minutes at a time. Although the J-2X engine is not reusable, the valve material could be exposed to multiple temperature cycles up to 750degF during engine operation. The Constellation Program that included the Ares I rocket was eventually cancelled, but the J-2X engine was chosen for continued use for development of NASA's Space Launch System (SLS). The SLS is a heavy-lift launch vehicle that will have capability of taking astronauts and hardware to the Moon, Mars and asteroids. Dynamic mechanical analysis (DMA) was one of several test techniques used to characterize Vespel SP-211 to help prove its worthiness for use on the OTBV of the J-2X engine.

Wingard, Doug↗
NASA NTRS2001

Thermal Protection Materials for Reentry and Planetary Applications

Thermal protection materials and systems (TPS) are used to protect spacecraft during reentry into Earth's atmosphere or entry into planetary atmospheres. As such, these materials are subject to severe environments with high heat fluxes and rapid heating. Catalytic effects can increase the temperatures substantially. These materials are also subject to impact damage from micrometeorites or other debris during ascent, orbit, and descent, and thus must be able to withstand damage and function following damage. Thermal protection materials and coatings used in reusable launch vehicles will be reviewed, including the needs and directions for new materials to enable new missions that require faster turnaround and much greater reusability. The role of ablative materials for use in high heat flux environments, especially for non-reusable applications and upcoming planetary missions, will be discussed. New thermal protection system materials may enable the use of sharp nose caps and leading edges on future reusable space transportation vehicles. Vehicles employing this new technology would have significant increases in maneuverability and out-of-orbit cross range compared to current vehicles, leading to increased mission safety in the event of the need to abort during ascent or from orbit. Ultrahigh temperature ceramics, a family of materials based on HfB2and ZrB2 with SiC, will be discussed. The development, mechanical and thermal properties, and uses of these materials will be reviewed.

Johnson, Sylvia M.↗
NASA NTRS2001

Thermal Protection Materials for Reentry Applications

Thermal protection materials and systems (IRS) are used to protect spacecraft during reentry into Earth's atmosphere or entry into planetary atmospheres. As such, these materials are subject to severe environments with high heat fluxes and rapid heating. Catalytic effects can increase the temperatures substantially. These materials are also subject to impact damage from micrometeorites or other debris during ascent, orbit, and descent, and thus must be able to withstand damage and to function following damage. Thermal protection materials and coatings used in reusable launch vehicles will be reviewed, including the needs and directions for new materials to enable new missions that require faster turnaround and much greater reusability. The role of ablative materials for use in high heat flux environments, especially for non-reusable applications and upcoming planetary missions, will be discussed. New thermal protection system materials may enable the use of sharp nose caps and leading edges on future reusable space transportation vehicles. Vehicles employing this new technology would have significant increases in maneuverability and out-of-orbit cross range compared to current vehicles, leading to increased mission safety in the event of the need to abort during ascent or from orbit. Ultrahigh temperature ceramics, a family of materials based on HfB2 and ZrB2 with SiC, will be discussed. The development, mechanical and thermal properties, and uses of these materials will be reviewed.

Johnson, Sylvia M.↗
NASA NTRS1973

Silica RSI Morphology and Properties

The morphology of all silica materials studied has been noncrystalline and resistant to any phase transformations upon subsequent thermal testing representative of the shuttle environment envelope. The development of an extremely dependable reusable surface insulation material family offering the inherently superior characteristics of amorphous silica for the shuttle is described.

Beasley, R. M.↗
NASA NTRSDate not supplied

Autonomous In-space Construction, Maintenance, and Reconfiguration Using Programmable Meta-Material

NASA ARC's Coded Structures Laboratory (CSL) is developing autonomous construction, maintenance, and reconfiguration technologies to meet long-duration and deep space infrastructure needs, in accordance with long-term NASA goals of "in-space reliance" and "mass-less exploration." We seek to achieve these capabilities by utilizing a "programmable meta-material" approach that integrates emerging advances in materials (mechanical meta-materials), manufacturing (cooperative mobile robotics), and autonomy (multi-agent planning algorithms). Through the ARMADAS project, we have shown assembly of high-performance engineered cellular materials using multiple cooperating mobile robotic assemblers. In this paper, we describe how such a programmable meta-material architecture may shift the paradigm of how we design, build, manufacture, and operate future space infrastructure and assets. The core of a programmable meta-material architecture consists of 3 main technology sub-areas: the structure, the assembly agents, and the assembly algorithms. We co-design these systems to ensure an adaptable system that can create and reconfigure structures from a base set of building block components. From this core technology, we can branch out and expand the capability of the system through additional secondary component types and robotic agents to perform activities such as inspections, maintenance, repair, payload installation, or perform power and communications interconnect. As these technologies mature, future designers will be able to utilize the system to rapidly integrate and operate assets in space or on planetary surfaces from a set of well-tested part library, or create their own modules to integrate into the system. A core trait to the development of this system is the automation approach. Because of the modular and functional discrete (pixel-like) nature of the structural system, a diverse set of powerful algorithms for analysis, planning, and simulation can be adapted and leveraged to optimize construction, maintenance, and dynamic reorganization (as hardware with programmable form and function). With an ability to free the design space from launch vehicle constraints and fundamentally shift how a mission is designed and conducted, we discuss the influence of a programmable meta-material architecture on mission design, build, and operations. For the "design phase", we discuss project lifecycle effects, costs, time, and performance. For the "build phase", we discuss reusability, ISRU, manufacturing, material logistics, and scalability. And for "operations", we discuss autonomy, maintenance and upgrades, reliability, and reconfiguration. Autonomy and modularity are the primary enabling traits of this system. Engineering systems that utilize a modular and reconfiguration building block approach such as digital communication and computation systems, currently lead all other areas of technology in size and complexity scalability. NASA is extending the benefits and flexibility of digital systems to hardware systems, to optimize materials lifecycle management and expand our space exploration mission capabilities.

in space assembly↗
NASA NTRS2011

Space Shuttle Propulsion Materials, Manufacturing, and Operational Challenges

Presentations in this session include: (1) External Tank (ET) Materials, Manufacturing, and Operational Challenges; (2) Space Shuttle Main Engine (SSME) Materials, Manufacturing, and Operational Challenges,(3) Reusable Solid Rocket Motor (RSRM) Materials, Manufacturing, and Operational Challenges and (4) Solid Rocket Booster (SRB) Materials, Manufacturing, and Operational Challenges.

Owen, James↗
NASA NTRS1973

Catalysis study for space shuttle vehicle thermal protection systems

Experimental results on the problem of reducing aerodynamic heating on space shuttle orbiter surfaces are presented. Data include: (1) development of a laboratory flow reactor technique for measuring gamma sub O and gamma sub N on candidate materials at surfaces, T sub w, in the nominal range 1000 to 2000, (2) measurements of gamma sub O and gamma sub N above 1000 K for both the glass coating of a reusable surface insulation material and the siliconized surface of a reinforced pyrolyzed plastic material, (3) measurement of the ablation behavior of the coated RPP material at T sub w is greater than or equal to 2150 K, (4) X-ray photoelectron spectral studies of the chemical constituents on these surfaces before and after dissociated gas exposure, (5) scanning electron micrograph examination of as-received and reacted specimens, and (6) development and exploitation of a method of predicting the aerodynamic heating consquences of these gamma sub O(T sub w) and gamma sub N(T sub w) measurements for critical locations on a radiation cooled orbiter vehicle.

Breen, J.↗
NASA NTRS1992

Reusable thermal protection system development: A prospective

The state of the art in passive reusable thermal protection system materials is described. Development of the Space Shuttle Orbiter, which was the first reusable vehicle, is discussed. The thermal protection materials and given concepts and some of the shuttle development and manufacturing problems are described. Evolution of a family of grid and flexible ceramic external insulation materials from the initial shuttle concept in the early 1970's to the present time is described. The important properties and their evolution are documented. Application of these materials to vehicles currently being developed and plans for research to meet the space programs future needs are summarized.

Goldstein, Howard↗
NASA NTRS1973

Evaluation of reusable surface insulation for space shuttle over a range of heat-transfer rate and surface temperature

Reusable surface insulation materials, which were developed as heat shields for the space shuttle, were tested over a range of conditions including heat-transfer rates between 160 and 620 kW/sq m. The lowest of these heating rates was in a range predicted for the space shuttle during reentry, and the highest was more than twice the predicted entry heating on shuttle areas where reusable surface insulation would be used. Individual specimens were tested repeatedly at increasingly severe conditions to determine the maximum heating rate and temperature capability. A silica-base material experienced only minimal degradation during repeated tests which included conditions twice as severe as predicted shuttle entry and withstood cumulative exposures three times longer than the best mullite material. Mullite-base materials cracked and experienced incipient melting at conditions within the range predicted for shuttle entry. Neither silica nor mullite materials consistently survived the test series with unbroken waterproof surfaces. Surface temperatures for a silica and a mullite material followed a trend expected for noncatalytic surfaces, whereas surface temperatures for a second mullite material appeared to follow a trend expected for a catalytic surface.

Chapman, A. J.↗
NASA NTRS2011

Thermal Protection Materials

Thermal protection materials and systems (TPS) are required to protect a vehicle returning from space or entering an atmosphere. The selection of the material depends on the heat flux, heat load, pressure, and shear and other mechanical loads imposed on the material, which are in turn determined by the vehicle configuration and size, location on the vehicle, speed, a trajectory, and the atmosphere. In all cases the goal is to use a material that is both reliable and efficient for the application. Reliable materials are well understood and have sufficient test data under the appropriate conditions to provide confidence in their performance. Efficiency relates to the behavior of a material under the specific conditions that it encounters TPS that performs very well at high heat fluxes may not be efficient at lower heat fluxes. Mass of the TPS is a critical element of efficiency. This talk will review the major classes of TPS, reusable or insulating materials and ablators. Ultra high temperature ceramics for sharp leading edges will also be reviewed. The talk will focus on the properties and behavior of these materials.

Johnson, Sylvia M.↗
NASA NTRS2000

Solid Freeform Fabrication of Continuous Fiber Reinforced Composites for Propulsion Applications

For propulsion related applications, materials must be able to demonstrate excellent ablation and oxidation resistance at temperature approaching 3500'C, adequate load bearing capabilities, non-catastrophic failure modes, and ability to withstand transient thermal shock. A potential list of propulsion-material property requirements includes, low density, high elastic modulus, low thermal-expansion coefficient, high thermal conductivity, excellent erosion and oxidation/corrosion resistance, and flaw-insensitivity. In many cases, they will also need to be able to be joined, survive thermal cycling and multi-axial stress states, and for reusable applications, the materials must maintain the above attributes after prolonged exposure to extremely harsh chemical environments. The final and possibly most important attribute for these materials are the need to be lower cost and readily available in large quantities. Recently, Advanced Ceramics Research, Inc. (ACR) has developed low cost, flexible- manufacturing processes for Zr & Hf-based carbon fiber reinforced composites, materials with good oxidation and ablation resistance up to 3500 C. This process, called Continuous Composite Co-extrusion (C(sup 3)), incorporates carbon fibers to fabricate 'in-situ' carbide and boride-matrix/carbon fiber composites. This is a variation of ACR's manufacturing process for low-cost structural ceramic materials called Fibrous Monoliths With carbon fiber reinforcements. Fibrous Monolithic materials have a distinct fibrous texture, consist of intertwined cells of a primary phase, separated by cell boundaries of a tailored secondary phase and show very high fracture energies, damage tolerance, and graceful failure. Since they are monolithic powder based composites-, they can be manufactured by conventional powder processing techniques using inexpensive raw materials. This combination of high performance and low cost is a breakthrough that could enable wider application of ceramics in high temperature applications. Typical volume fractions of the two phases are 80 to 95% for the cell phase and 5 to 20% for the interpenetrating cell boundary phase. ACR is currently developing an innovative solid freeform form fabrication (SFF) approach to produce Hf and Zr based ceramic composite components reinforced with continuous carbon fiber tows for critical structural components such as tubes and blisks. The process is simple, robust and will be widely applicable to a number of material systems. This technique was originally developed at the University of Delaware Center for Composite Materials (UD-CCM) for rapid fabrication of polymer matrix composites by a technique called automated tow placement or ATP. The current process is being developed in collaboration with UD-CCM. The paper will detail the freeform fabrication process to create low-cost ceramic fiber reinforced composites for high-temperature applications. The results of mechanical properties and microstructural characterization will be presented, together with examples of complex shapes and parts. It is believed that the process will be able to create complex shaped parts for propulsion applications at an order of magnitude lower cost than current CVI and PIP process.

Vaidyanathan, R.↗
NASA NTRS2001

Solid Free-Form Fabrication of Continuous Fiber Reinforced Composites for Propulsion Application

For propulsion related applications, materials must be able to demonstrate excellent ablation and oxidation resistance at temperature approaching 3500 C, adequate load bearing capabilities, non-catastrophic failure modes, and ability to withstand transient thermal shock. A potential list of propulsion-material property requirements includes, low density, high elastic modulus, low thermal-expansion coefficient, high thermal conductivity, excellent erosion and oxidation/corrosion resistance, and flaw-insensitivity. In many cases, they will also need to be able to be joined, survive thermal cycling and multi-axial stress states, and for reusable applications, the materials must maintain the above attributes after prolonged exposure to extremely harsh chemical environments. The final and possibly most important attribute for these materials are the need to be lower cost and readily available in large quantities. Recently, Advanced Ceramics Research, Inc. (ACR) has developed low cost, flexible-manufacturing processes for Zr & Hf-based carbon fiber reinforced composites, materials with good oxidation and ablation resistance up to 3500 C. This process, called Continuous Composite Co-extrusion (C(sup 3)), incorporates carbon fibers to fabricate 'in-situ' carbide and boride-matrix/carbon fiber composites. M is a variation of ACR's manufacturing process for low-cost structural ceramic materials called Fibrous Monoliths with carbon fiber reinforcements. Fibrous Monolithic materials have a distinct fibrous texture, consist of intertwined cells of a primary phase, separated by cell boundaries of a tailored secondary phase and show very high fracture energies, damage tolerance, and graceful failure. Since they are monolithic powder based composites; they can be manufactured by conventional powder processing techniques using inexpensive raw materials. This combination of high performance and low cost is a breakthrough that could enable wider application of ceramics in high temperature applications. Typical volume fractions of the two phases are 80 to 95% for the cell phase and 5 to 20% for the interpenetrating cell boundary phase. ACR is currently developing an innovative solid freeform form fabrication (SFF) approach to produce Hf and Zr based ceramic composite components reinforced with continuous carbon fiber tows for critical structural components such as tubes and blisks. The process is simple, robust and will be widely applicable to a number of material systems. This technique was originally developed at the University of Delaware Center for Composite Materials (UD-CCM) for rapid fabrication of polymer matrix composites by a technique called automated tow placement or ATP. The current process is being developed in collaboration with UD-CCM. The paper will detail the freeform fabrication process to create low-cost ceramic fiber reinforced composites for high-temperature applications. The results of mechanical properties and microstructural characterization will be presented, together with examples of complex shapes and parts. It is believed that the process will be able to create complex shaped parts for propulsion applications at an order of magnitude lower cost than current CVI and PIP processes.

Vaidyanathan, R.↗
NASA NTRS2001

Solid Freeform Fabrication of Continuous Fiber Reinforced Composites for Propulsion Applications

Monolithic ceramics lack the fracture toughness necessary to be considered for propulsion related applications. To be used for such applications, materials must possess low density, high elastic modulus, a low thermal expansion coefficient, high thermal conductivity, excellent erosion and oxidation/corrosion resistance, and flaw-insensitivity. They will in many cases also be required to possess the ability to be joined, to survive thermal cycling and multi-axial stress states, and for reusable applications the materials must maintain the above attributes after prolonged exposure to extremely harsh chemical environments. The final and possibly most important attributes for these materials are the need to be of low cost and readily available in large quantities.

Vaidyanathan, R.↗
NASA NTRS1981

Developments in Fibrous Refractory Composite Insulation

A family of high strength per unit density fibrous insulation materials has undergone preliminary development for heat-shielding advanced, reusable entry vehicles. These materials have a range of temperature capabilities dependent on composition. They have an unusually high thermal-shock resistance, an unusually high strain-to- failure, low thermal conductivity, and good morphological stability. One composition within the family, 22% aluminoborosilicate fiber (0.19 g/cc), has been successfully produced in a pilot plant and scaled up to full production. This fiber's additional strength makes it a desirable composition; it will be used on the third and fourth Space Shuttle vehicles. Another composition, 15% aluminoborosilicate fiber (0.14 g/cc) , has been adopted for use on limited parts of the third vehicle and as a replacement for the 0.14 g/cc density, rigid silica RSI on the fourth.

Leiser, Daniel B.↗
NASA NTRS2012

Thermal Protection Materials: Development, Characterization and Evaluation

Thermal protection materials and systems (TPS) are used to protect space vehicles from the heat experienced during entry into an atmosphere. The application for these materials is very specialized as are the materials. They must have specific properties to withstand conditions during specific entries. There is no one-size-fits-all TPS as the conditions experienced by a material are very dependent upon the atmosphere, the entry speed, the size and shape of the vehicle, and the location on the vehicle. However, all TPS must be reliable and efficient to ensure mission safety, that is to protect the vehicle while ensuring that payload is maximized. Types of TPS will be reviewed in relation to types of missions and applications. Both reusable and ablative materials will be discussed. Approaches to characterizing and evaluating these materials will be presented. The role of heritage versus new materials will be described.

Johnson, Silvia M.↗