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NASA NTRSDate not supplied

Advancement of Metal Additive Manufacturing Processes and Alloys for Rocket Propulsion Applications

NASA has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the 2000’s. Several efforts have focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into development and flight applications. While many common aerospace alloys have been and continue to be a focus of ongoing development, the need for custom-alloy developments for high performance applications enabled by various AM processes has been realized. The applications being targeted are liquid rocket engines with high heat fluxes, high pressure, and that utilize propellants such as hydrogen, which can degrade the alloy. NASA has recently focused on the development and advancement of novel alloy advancement using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, and JBK-75. These alloys have been evaluated using powder bed fusion (PBF), directed energy deposition (DED), and solid-state AM processes. The results from these processes have demonstrated that AM can enable rapid development of new alloy systems that can yield higher performances across various metal AM processes. These alloys have undergone the fundamental metallurgical evaluations, heat treatment study, and microstructure characterization and mechanical testing campaign. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL). This presentation will provide a background and overview of various AM-enabled novel alloys, a comparison across the AM processes, and development including metallurgical and mechanical property studies. It will also cover the latest advancement in the parallel component development and testing and future developments. The goal of these alloy development and use of various AM processes is to allow for technology infusion into NASA and commercial spaceflight missions as well as to establish and sustain the needed commercial AM supply chain.

Additive Manufacturing↗

NASA NTRS1989

Data Acquisition Systems

Technology developed during a joint research program with Langley and Kinetic Systems Corporation led to Kinetic Systems' production of a high speed Computer Automated Measurement and Control (CAMAC) data acquisition system. The study, which involved the use of CAMAC equipment applied to flight simulation, significantly improved the company's technical capability and produced new applications. With Digital Equipment Corporation, Kinetic Systems is marketing the system to government and private companies for flight simulation, fusion research, turbine testing, steelmaking, etc.

Source record↗

NASA NTRS2014

Solar System Exploration Augmented by Lunar and Outer Planet Resource Utilization: Historical Perspectives and Future Possibilities

Establishing a lunar presence and creating an industrial capability on the Moon may lead to important new discoveries for all of human kind. Historical studies of lunar exploration, in-situ resource utilization (ISRU) and industrialization all point to the vast resources on the Moon and its links to future human and robotic exploration. In the historical work, a broad range of technological innovations are described and analyzed. These studies depict program planning for future human missions throughout the solar system, lunar launched nuclear rockets, and future human settlements on the Moon, respectively. Updated analyses based on the visions presented are presented. While advanced propulsion systems were proposed in these historical studies, further investigation of nuclear options using high power nuclear thermal propulsion, nuclear surface power, as well as advanced chemical propulsion can significantly enhance these scenarios. Robotic and human outer planet exploration options are described in many detailed and extensive studies. Nuclear propulsion options for fast trips to the outer planets are discussed. To refuel such vehicles, atmospheric mining in the outer solar system has also been investigated as a means of fuel production for high energy propulsion and power. Fusion fuels such as helium 3 (3He) and hydrogen (H2) can be wrested from the atmospheres of Uranus and Neptune and either returned to Earth or used in-situ for energy production. Helium 3 and H2 (deuterium, etc.) were the primary gases of interest with hydrogen being the primary propellant for nuclear thermal solid core and gas core rocket-based atmospheric flight. A series of analyses have investigated resource capturing aspects of atmospheric mining in the outer solar system. These analyses included the gas capturing rate, storage options, and different methods of direct use of the captured gases. While capturing 3He, large amounts of hydrogen and 4He are produced. With these two additional gases, the potential for fueling small and large fleets of additional exploration and exploitation vehicles exists.

Palaszewski, Bryan↗

NASA NTRS2014

Solar System Exploration Augmented by Lunar and Outer Planet Resource Utilization: Historical Perspectives and Future Possibilities

Establishing a lunar presence and creating an industrial capability on the Moon may lead to important new discoveries for all of human kind. Historical studies of lunar exploration, in-situ resource utilization (ISRU) and industrialization all point to the vast resources on the Moon and its links to future human and robotic exploration. In the historical work, a broad range of technological innovations are described and analyzed. These studies depict program planning for future human missions throughout the solar system, lunar launched nuclear rockets, and future human settlements on the Moon, respectively. Updated analyses based on the visions presented are presented. While advanced propulsion systems were proposed in these historical studies, further investigation of nuclear options using high power nuclear thermal propulsion, nuclear surface power, as well as advanced chemical propulsion can significantly enhance these scenarios. Robotic and human outer planet exploration options are described in many detailed and extensive studies. Nuclear propulsion options for fast trips to the outer planets are discussed. To refuel such vehicles, atmospheric mining in the outer solar system has also been investigated as a means of fuel production for high energy propulsion and power. Fusion fuels such as Helium 3 (3He) and hydrogen can be wrested from the atmospheres of Uranus and Neptune and either returned to Earth or used in-situ for energy production. Helium 3 and hydrogen (deuterium, etc.) were the primary gases of interest with hydrogen being the primary propellant for nuclear thermal solid core and gas core rocket-based atmospheric flight. A series of analyses have investigated resource capturing aspects of atmospheric mining in the outer solar system. These analyses included the gas capturing rate, storage options, and different methods of direct use of the captured gases. While capturing 3He, large amounts of hydrogen and 4He are produced. With these two additional gases, the potential for fueling small and large fleets of additional exploration and exploitation vehicles exists.

Palaszewski, Bryan↗

NASA NTRS1981

A quantitative study of factors influencing lamellar eutectic morphology during solidification

The factors that influence the shape of the solid-liquid interface of a lamellar binary eutectic alloy are evaluated. Alloys of carbon tetrabromide and hexachloroethane which serve as a transparent analogue of lamellar metallic eutectics are used. The observed interface shapes are analyzed by computer-aided methods. The solid-liquid interfacial free energies of each of the individual phases comprising the eutectic system are measured as a function of composition using a 'grain boundary groove' technique. The solid-liquid interfacial free energy of the two phases are evaluated directly from the eutectic interface. The phase diagram for the system, the heat of fusion as a function of composition, and the density as a function of composition are measured. The shape of the eutectic interface is controlled mainly by the solid-liquid and solid-solid interfacial free energy relationships at the interface and by the temperature gradient present, rather than by interlamellar diffusion in the liquid at the interface, over the range of growth rates studied.

Kaukler, W. F. S.↗

NASA NTRS2013

Integration of Mirror Design with Suspension System using NASA's New Mirror Modeling Software

Advances in mirror fabrication is making very large space based telescopes possible. In the many applications, only monolithic mirrors meet the performance requirements. The existing and near-term planned heavy launch vehicles place a premium on lowest possible mass. Again, available and planned payload shroud size limits near term designs to 4 meter class mirror. Practical 8 meter and beyond designs could encourage planners to include larger shrouds if it can be proven that such mirrors can be manufactured. These two factors lower mass and larger mirrors, presents the classic optimization problem. There is a practical upper limit to how large a mirror can be supported by a purely kinematic mount system and be launched. This paper shows how the design of the suspension system and mirror blank needs to be designed simultaneously. We will also explore the concepts of auxiliary support systems, which act only during launch and disengage on orbit. We will define required characteristics of these systems and show how they can substantially reduce the mirror mass. The AMTD project is developing and maturing the processes for future replacements for HUBBLE, creating the design tools, validating the methods and techniques necessary to manufacture, test and launch extremely large optical missions. This paper will use the AMTD 4 meter "design point" as an illustration of the typical use of the modeler in generating the multiple models of mirror and suspension systems used during the conceptual design phase of most projects. The influence of Hexapod geometry, mirror depth, cell size and construction techniques (Exelsis Deep Core Low Temperature Fusion (c) versus Corning Frit Bonded (c) versus Schott Pocket Milled Zerodur (c) in this particular study) are being evaluated. Due to space and time consideration we will only be able to present snippets of the study in this paper. The advances in manufacturing techniques for lightweight mirrors, such as EXELSIS deep core low temperature fusion, Corning's continued improvements in the Frit bonding process and the ability to cast large complex designs, combined with water-jet and conventional diamond.

Arnold, William↗

NASA NTRS2012

NASA-NIAC 2001 Phase I Research Grant on Aneutronic Fusion Spacecraft Architecture

This study was developed because the recognized need of defining of a new spacecraft architecture suitable for aneutronic fusion and featuring game-changing space travel capabilities. The core of this architecture is the definition of a new kind of fusion-based space propulsion system. This research is not about exploring a new fusion energy concept, it actually assumes the availability of an aneutronic fusion energy reactor. The focus is on providing the best (most efficient) utilization of fusion energy for propulsion purposes. The rationale is that without a proper architecture design even the utilization of a fusion reactor as a prime energy source for spacecraft propulsion is not going to provide the required performances for achieving a substantial change of current space travel capabilities.

aneutronic↗

NASA NTRS2014

Data Fusion Tool for Spiral Bevel Gear Condition Indicator Data

Tests were performed on two spiral bevel gear sets in the NASA Glenn Spiral Bevel Gear Fatigue Test Rig to simulate the fielded failures of spiral bevel gears installed in a helicopter. Gear sets were tested until damage initiated and progressed on two or more gear or pinion teeth. During testing, gear health monitoring data was collected with two different health monitoring systems. Operational parameters were measured with a third data acquisition system. Tooth damage progression was documented with photographs taken at inspection intervals throughout the test. A software tool was developed for fusing the operational data and the vibration based gear condition indicator (CI) data collected from the two health monitoring systems. Results of this study illustrate the benefits of combining the data from all three systems to indicate progression of damage for spiral bevel gears. The tool also enabled evaluation of the effectiveness of each CI with respect to operational conditions and fault mode.

health monitoring↗

NASA NTRS1999

Molecular Mechanisms Regulating Muscle Fiber Composition Under Microgravity

The overall goal of this project is to reveal the molecular mechanisms underlying the selective and debilitating atrophy of specific skeletal muscle fiber types that accompanies sustained conditions of microgravity. Since little is currently known about the regulation of fiber-specific gene expression programs in mammalian muscle, elucidation of the basic mechanisms of fiber diversification is a necessary prerequisite to the generation of therapeutic strategies for attenuation of muscle atrophy on earth or in space. Vertebrate skeletal muscle development involves the fusion of undifferentiated mononucleated myoblasts to form multinucleated myofibers, with a concomitant activation of muscle-specific genes encoding proteins that form the force-generating contractile apparatus. The regulatory circuitry controlling skeletal muscle gene expression has been well studied in a number of vertebrate animal systems. The goal of this project has been to achieve a similar level of understanding of the mechanisms underlying the further specification of muscles into different fiber types, and the role played by innervation and physical activity in the maintenance and adaptation of different fiber phenotypes into adulthood. Our recent research on the genetic basis of fiber specificity has focused on the emergence of mature fiber types and have implicated a group of transcriptional regulatory proteins, known as E proteins, in the control of fiber specificity. The restriction of E proteins to selected muscle fiber types is an attractive hypothetical mechanism for the generation of muscle fiber-specific patterns of gene expression. To date our results support a model wherein different E proteins are selectively expressed in muscle cells to determine fiber-restricted gene expression. These studies are a first step to define the molecular mechanisms responsible for the shifts in fiber type under conditions of microgravity, and to determine the potential importance of E proteins as upstream targets for the effects of weightlessness. In the past year we have determined that the expression of E Proteins is restricted to specific fiber types by post-transcriptional mechanisms. By far, the most prevalent mechanism of cellular control for achieving post-transcriptional regulation of gene expression is selective proteolysis -through the ubiquitin -proteasome pathway. Steady-state levels of HEB message are similar in all fast and slow skeletal muscle fiber types, yet the protein is restricted to Type IIX fibers. HEB appears to be a nodal point for regulating fiber-specific transcription, as expression of the transcription factor is regulated at the post-transcriptional level. It is not clear at present whether the regulation is at the level of protein synthesis or degradation. We are now poised to evaluate the biological role of ubiquitination in fiber specific-gene expression by controlling the post-transcriptional expression of E Proteins. The use of metabolic labelling and pharmacological inhibitors of the ubiquitin pathway will be used to identify the mode of regulation of the Type IIX expression pattern. The potential role of specific kinases in effecting the restriction of HEB expression will be examined by using both inhibitors and activators. The results of these studies will provide the necessary information to evaluate the biological role of E proteins in controlling fiber type transitions, and in potentially attenuating the atrophic effects of microgravity conditions. We have also recently shown that ectopic expression of the HEB protein transactivates the Type IIX-specific skeletal a-actin reporter. The 218 bp skeletal a-actin promoter drives transgene expression solely in mature Type IIX fibers. A mouse also carrying the transgene MLCI/HEB (which ectopically expresses the E Protein HEB in Type IIB fibers) forces expression of the skeletal a-actin reporter gene in Type IIB fibers. We can now dissect the composition of this fiber-specific cis-element. The skeletal a-actin promoter is quite compact and has been extensively characterized in vitro for activity and binding factors. The single E box may act as a binding target of myogenic factor/HEB heterodimer to allow for IIX expression. The HEB transcription factor may recognize either the precise flanking sequences of the E Box, or perhaps interacting with other proteins bound nearby, and activating expression in Type IIX fibers. This E box will be both ablated, and alternatively, as ablation may well destroy any muscle-specific transcriptional activity, flanking sequences substituted with those surrounding the E box (El) of the myogenin promoter. Modification of fiber-specific transgene expression will be tested in transgenic mice. The results of these studies will provide basic information on the regulatory circuitry underlying fiber specificity, and will form the basis for building appropriate transgenic regulatory cassettes to effect fiber transitions in subsequent experimental manipulations on unweighted muscles.

Rosenthal, Nadia A.↗

NASA NTRSDate not supplied

Advancement of Novel Additively Manufactured Alloys for Space Applications

NASA has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts have focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into development and flight applications. While many common aerospace alloys have been and continue to be a focus of ongoing development, the need for custom-alloy developments for high performance applications enabled by AM processes has been realized. The applications being targeted are liquid rocket engines with high heat fluxes, high pressure, and that utilize propellants such as hydrogen, which can degrade the alloy. NASA has recently focused on the development and advancement of novel alloy advancement using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, and JBK-75. These alloys have been evaluated using the laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. The results from these processes have demonstrated that AM can enable rapid development of new alloy systems that can yield higher performances. These alloys have undergone the fundamental metallurgical evaluations, heat treatment study, and microstructure characterization and mechanical testing campaign. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL). This presentation will provide a background and overview of these AM-enabled novel alloys, AM processing development including metallurgical and mechanical property studies. It will also cover the latest advancement in the parallel component development and testing and future developments. The goal of these alloy development is to allow for technology infusion into NASA and commercial spaceflight missions as well as to establish and sustain the needed commercial AM supply chain.

Additive Manufacturing↗

NASA NTRSDate not supplied

Introduction to Additive Manufacturing for Propulsion and Energy Systems

Explore the source record for details and available documents.

Additive Manufacturing↗

NASA NTRS1992

Geographic information system for fusion and analysis of high-resolution remote sensing and ground truth data

We seek to combine high-resolution remotely sensed data with models and ground truth measurements, in the context of a Geographical Information System, integrated with specialized image processing software. We will use this integrated system to analyze the data from two Case Studies, one at a bore Al forest site, the other a tropical forest site. We will assess the information content of the different components of the data, determine the optimum data combinations to study biogeophysical changes in the forest, assess the best way to visualize the results, and validate the models for the forest response to different radar wavelengths/polarizations. During the 1990's, unprecedented amounts of high-resolution images from space of the Earth's surface will become available to the applications scientist from the LANDSAT/TM series, European and Japanese ERS-1 satellites, RADARSAT and SIR-C missions. When the Earth Observation Systems (EOS) program is operational, the amount of data available for a particular site can only increase. The interdisciplinary scientist, seeking to use data from various sensors to study his site of interest, may be faced with massive difficulties in manipulating such large data sets, assessing their information content, determining the optimum combinations of data to study a particular parameter, visualizing his results and validating his model of the surface. The techniques to deal with these problems are also needed to support the analysis of data from NASA's current program of Multi-sensor Airborne Campaigns, which will also generate large volumes of data. In the Case Studies outlined in this proposal, we will have somewhat unique data sets. For the Bonanza Creek Experimental Forest (Case I) calibrated DC-8 SAR data and extensive ground truth measurement are already at our disposal. The data set shows documented evidence to temporal change. The Belize Forest Experiment (Case II) will produce calibrated DC-8 SAR and AVIRIS data, together with extensive measurements on the tropical rain forest itself. The extreme range of these sites, one an Arctic forest, the other a tropical rain forest, has been deliberately chosen to find common problems which can lead to generalized observations and unique problems with data which raise issues for the EOS System.

Freeman, Anthony↗

NASA NTRS1993

Geographic information system for fusion and analysis of high-resolution remote sensing and ground data

We seek to combine high-resolution remotely sensed data with models and ground truth measurements, in the context of a Geographical Information System (GIS), integrated with specialized image processing software. We will use this integrated system to analyze the data from two Case Studies, one at a boreal forest site, the other a tropical forest site. We will assess the information content of the different components of the data, determine the optimum data combinations to study biogeophysical changes in the forest, assess the best way to visualize the results, and validate the models for the forest response to different radar wavelengths/polarizations. During the 1990's, unprecedented amounts of high-resolution images from space of the Earth's surface will become available to the applications scientist from the LANDSAT/TM series, European and Japanese ERS-1 satellites, RADARSAT and SIR-C missions. When the Earth Observation Systems (EOS) program is operational, the amount of data available for a particular site can only increase. The interdisciplinary scientist, seeking to use data from various sensors to study his site of interest, may be faced with massive difficulties in manipulating such large data sets, assessing their information content, determining the optimum combinations of data to study a particular parameter, visualizing his results and validating his model of the surface. The techniques to deal with these problems are also needed to support the analysis of data from NASA's current program of Multi-sensor Airborne Campaigns, which will also generate large volumes of data. In the Case Studies outlined in this proposal, we will have somewhat unique data sets. For the Bonanza Creek Experimental Forest (Case 1) calibrated DC-8 SAR (Synthetic Aperture Radar) data and extensive ground truth measurement are already at our disposal. The data set shows documented evidence to temporal change. The Belize Forest Experiment (Case 2) will produce calibrated DC-8 SAR and AVIRIS data, together with extensive measurements on the tropical rain forest itself. The extreme range of these sites, one an Arctic forest, the other a tropical rain forest, has been deliberately chosen to find common problems which can lead to generalized observations and unique problems with data which raise issues for the EOS System.

Freeman, Anthony↗

NASA NTRS2002

Overexpression of neurofilament H disrupts normal cell structure and function

Studying exogenously expressed tagged proteins in live cells has become a standard technique for evaluating protein distribution and function. Typically, expression levels of experimentally introduced proteins are not regulated, and high levels are often preferred to facilitate detection. However, overexpression of many proteins leads to mislocalization and pathologies. Therefore, for normative studies, moderate levels of expression may be more suitable. To understand better the dynamics of intermediate filament formation, transport, and stability in a healthy, living cell, we inserted neurofilament heavy chain (NFH)-green fluorescent protein (GFP) fusion constructs in adenoviral vectors with tetracycline (tet)-regulated promoters. This system allows for turning on or off the synthesis of NFH-GFP at a selected time, for a defined period, in a dose-dependent manner. We used this inducible system for live cell imaging of changes in filament structure and cell shape, motility, and transport associated with increasing NFH-GFP expression. Cells with low to intermediate levels of NFH-GFP were structurally and functionally similar to neighboring, nonexpressing cells. In contrast, overexpression led to pathological alterations in both filament organization and cell function. Copyright 2002 Wiley-Liss, Inc.

Non-NASA Center↗

NASA NTRSDate not supplied

Microstructural Characterization of Laser Powder Bed Fusion (L-PBF) Additively Manufactured Inconel 718 for Aerospace Application

Alloy 718 (Inconel 718) is used for aerospace applications because of its excellent corrosion resistance and mechanical properties. This alloy is particularly applicable in manufacturing components subjected to high temperatures in rocket engines, aero-engines, and gas turbines. Properties for this alloy when processing on systems from similar and different Laser Powder Bed Fusion (L-PBF) machines provide subtle differences due to process parameters, feedstock, and machine configurations. A series of sixteen L-PBF AM Inconel 718 geometric feature build plates have been evaluated for microstructure using optical microscopy. This study presents the details of the microstructure analysis concerning geometry and different machine platforms. Microstructural investigations of these samples included average grain width measurement for all the X-Y and Y-Z build layers and are accompanied by process parameters and powder characterization. The present work concludes with a discussion on the importance of captured differences among builds to understand the practical limitations among AM platforms.

Additive Manufacturing↗

NASA NTRS1982

Chemical systematics among the moldavite tektites

The compositional variations that occur among the moldavite tektites are caused principally by incomplete mixing of two components during fusion. With the possible exception of silica, there is no evidence for significant losses of volatile species by fractional vaporization. Chemical constraints have been calculated for the two source-materials that contributed to the moldavites. If these tektites were formed by impact fusion, as is commonly believed, then the compositional systematics preserved within the moldavites suggest that hypersonic flow and ejection of impact melts are orderly processes. Insights gained from the study of tektites should prove useful in interpreting the chemistries of impact glasses from other bodies in the solar system.

Delano, J. W.↗

NASA NTRSDate not supplied

Metal Additive Manufacturing Developments for Propulsion Applications

Additive Manufacturing↗

NASA NTRS1989

Techniques for studying the effects of microgravity on model particle/cell systems

In an effort to learn more about the effects of a simulated low gravity environment on skeletal muscle, skeletal muscle cell cultures were grown within the lumen of XM-80 hollow fibers (i.d. = 0.5 mm) in a Clinostat rotating at 100 rpm. Cells were isolated from the thigh muscle tissue of 12 day embryos and were cultured for up to 14 days in the hollow fiber environment. Cells proliferated to confluency within several days, and fusion into multinucleated myotubes was then apparent. Fibers were stretched by a built-in spring mechanism to hold the fiber tightly at the center of rotation, and sections of the fiber were removed at 3, 7 and 14 days for electron microscopic analysis. When the Clinostat is rotated in the horizontal position, the gravity vector approaches zero and the cells are in an environment that simulates microgravity. Control experiments consist of one fiber rotated in the vertical position in the clinostat and another fiber that is held in a horizontal configuration in a comparable sized tube that is not rotated at all. Examination of skeletal muscle cells by electron microscopy revealed that myoblast fusion and myofibril accumulation were extensive. Two general conclusions were apparent. First, muscle cells undergo the normal progression of proliferation, fusion, and myofibril assembly in the presence of simulated microgravity for the first week in culture. After 14 days, however, many muscle fibers undergo degeneration such that myofibrillar structures are not extensive or well organized. Second, although no major abnormalities in myofibril assembly were detected in Clinostat-rotated cultures in comparison to controls that were not rotated in a Clinostat, the myofibrils in non-rotated controls tend to be more highly organized than those in either horizontally or vertically rotated Clinostat samples.

Young, Ronald B.↗