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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 NTRS1990

A comparison of forming technologies for ceramic gas-turbine engine components

For over ten years, injection molding and slip casting have been actively developed as forming techniques for ceramic gas turbine components. Co-development of these two processes has continued within the U.S. DOE-sponsored Advanced Turbine Technology Application Project (ATTAP). Progress within ATTAP with respect to these two techniques is summarized. A critique and comparison of the two processes are given. Critical aspects of both processes with respect to size, dimensional control, material properties, quality, cost, and potential for manufacturing scale-up are discussed.

Hengst, R. R.↗
NASA NTRS1991

Cartilage formation in the CELLS 'double bubble' hardware

The CELLS experiment scheduled to be flown on the first International Microgravity Laboratory is designed to study the effect of microgravity on the cartilage formation, by measuring parameters of growth in a differentiating cartilage cell culture. This paper investigates the conditions for this experiment by studying cartilage differentiation in the 'bubble exchange' hardware with the 'double bubble' design in which the bubbles are joined by a flange which also overlays the gasket. Four types of double bubbles (or double gas permeable membranes) were tested: injection-molded bubbles 0.01- and 0.005-in. thick, and compression molded bubbles 0.015- and 0.01-in. thick. It was found that double bubble membranes of 0.005- and 0.010-in. thickness supported cartilage differentiation, while the 0.015-in. bubbles did not. It was also found that nodule count, used in this study as a parameter, is not the best measure of the amount of cartilage differentiation.

Duke, P. J.↗
NASA NTRS1991

A multiple objective optimization approach to quality control

The use of product quality as the performance criteria for manufacturing system control is explored. The goal in manufacturing, for economic reasons, is to optimize product quality. The problem is that since quality is a rather nebulous product characteristic, there is seldom an analytic function that can be used as a measure. Therefore standard control approaches, such as optimal control, cannot readily be applied. A second problem with optimizing product quality is that it is typically measured along many dimensions: there are many apsects of quality which must be optimized simultaneously. Very often these different aspects are incommensurate and competing. The concept of optimality must now include accepting tradeoffs among the different quality characteristics. These problems are addressed using multiple objective optimization. It is shown that the quality control problem can be defined as a multiple objective optimization problem. A controller structure is defined using this as the basis. Then, an algorithm is presented which can be used by an operator to interactively find the best operating point. Essentially, the algorithm uses process data to provide the operator with two pieces of information: (1) if it is possible to simultaneously improve all quality criteria, then determine what changes to the process input or controller parameters should be made to do this; and (2) if it is not possible to improve all criteria, and the current operating point is not a desirable one, select a criteria in which a tradeoff should be made, and make input changes to improve all other criteria. The process is not operating at an optimal point in any sense if no tradeoff has to be made to move to a new operating point. This algorithm ensures that operating points are optimal in some sense and provides the operator with information about tradeoffs when seeking the best operating point. The multiobjective algorithm was implemented in two different injection molding scenarios: tuning of process controllers to meet specified performance objectives and tuning of process inputs to meet specified quality objectives. Five case studies are presented.

Seaman, Christopher Michael↗
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 NTRS1993

Novel cost controlled materials and processing for primary structures

Textile laminates, developed a number of years ago, have recently been shown to be applicable to primary aircraft structures for both small and large components. Such structures have the potential to reduce acquisition costs but require advanced automated processing to keep costs controlled while verifying product reliability and assuring structural integrity, durability and affordable life-cycle costs. Recently, resin systems and graphite-reinforced woven shapes have been developed that have the potential for improved RTM processes for aircraft structures. Ciba-Geigy, Brochier Division has registered an RTM prepreg reinforcement called 'Injectex' that has shown effectivity for aircraft components. Other novel approaches discussed are thermotropic resins producing components by injection molding and ceramic polymers for long-duration hot structures. The potential of such materials and processing will be reviewed along with initial information/data available to date.

Dastin, S. J.↗
NASA NTRS1995

Advancing MEMS Technology Usage through the MUMPS (Multi-User MEMS Processes) Program

In order to help provide access to advanced micro-electro-mechanical systems (MEMS) technologies and lower the barriers for both industry and academia, the Microelectronic Center of North Carolina (MCNC) and ARPA have developed a program which provides users with access to both MEMS processes and advanced electronic integration techniques. The four distinct aspects of this program, the multi-user MEMS processes (MUMP's), the consolidated micro-mechanical element library, smart MEMS, and the MEMS technology network are described in this paper. MUMP's is an ARPA-supported program created to provide inexpensive access to MEMS technology in a multi-user environment. It is both a proof-of-concept and educational tool that aids in the development of MEMS in the domestic community. MUMP's technologies currently include a 3-layer poly-silicon surface micromachining process and LIGA (lithography, electroforming, and injection molding) processes that provide reasonable design flexibility within set guidelines. The consolidated micromechanical element library (CaMEL) is a library of active and passive MEMS structures that can be downloaded by the MEMS community via the internet. Smart MEMS is the development of advanced electronics integration techniques for MEMS through the application of flip chip technology. The MEMS technology network (TechNet) is a menu of standard substrates and MEMS fabrication processes that can be purchased and combined to create unique process flows. TechNet provides the MEMS community greater flexibility and enhanced technology accessibility.

Koester, D. A.↗
NASA NTRS1999

Developments in Nano-Satellite Structural Subsystem Design at NASA-GSFC

The NASA-GSFC Nano-satellite Technology Development Program will enable flying constellations of tens to hundreds of nano-satellites for future NASA Space and Earth Science missions. Advanced technology components must be developed to make these future spacecraft compact, lightweight, low-power, low-cost, and survivable to a radiation environment over a two-year mission lifetime. This paper describes the efforts underway to develop lightweight, low cost, and multi-functional structures, serviceable designs, and robust mechanisms. As designs shrink, the integration of various subsystems becomes a vital necessity. This paper also addresses structurally integrated electrical power, attitude control, and thermal systems. These innovations bring associated fabrication, integration, and test challenges. Candidate structural materials and processes are examined and the merits of each are discussed. Design and fabrication processes include flat stock composite construction, cast aluminum-beryllium alloy, and an injection molded fiber-reinforced plastic. A viable constellation deployment scenario is described as well as a Phase-A Nano-satellite Pathfinder study.

Rossoni, Peter↗
NASA NTRS2002

Studies on Stress-Strain Relationships of Polymeric Materials Used in Space Applications

A two-year research plan was undertaken in association with Polymers Branch, NASA Glenn Research Center, to carry out experimental and modeling work relating stress and strain behavior of polymeric materials, especially elastomers and vulcanized rubber. An experimental system based on MTS (Mechanical Testing and Simulation) A/T-4 test facility environment has been developed for a broader range of polymeric materials in addition to a design of laser compatible temperature control chamber for online measurements of various strains. Necessary material processing has been accomplished including rubber compounding and thermoplastic elastomer processing via injection molding. A broad suite of testing methodologies has been identified to reveal the complex non-linear mechanical behaviors of rubbery materials when subjected to complex modes of deformation. This suite of tests required the conceptualization, design and development of new specimen geometries, test fixtures, and test systems including development of a new laser based technique to measure large multi-axial deformations. Test data has been generated for some of these new fixtures and has revealed some complex coupling effects generated during multi-axial deformations. In addition, fundamental research has been conducted concerning the foundation principles of rubber thermodynamics and resulting theories of rubber elasticity. Studies have been completed on morphological properties of several thermoplastic elastomers. Finally, a series of steps have been identified to further advance the goals of NASA's ongoing effort.

Jana, Sadhan C.↗
NASA NTRS1996

Heat Pipes

Heat Pipes were originally developed by NASA and the Los Alamos Scientific Laboratory during the 1960s to dissipate excessive heat build- up in critical areas of spacecraft and maintain even temperatures of satellites. Heat pipes are tubular devices where a working fluid alternately evaporates and condenses, transferring heat from one region of the tube to another. KONA Corporation refined and applied the same technology to solve complex heating requirements of hot runner systems in injection molds. KONA Hot Runner Systems are used throughout the plastics industry for products ranging in size from tiny medical devices to large single cavity automobile bumpers and instrument panels.

Source record↗
NASA NTRS1981

Heat Pipe Technology

The heat pipe, a sealed chamber whose walls are lined with a "wick," a thin capillary network containing a working fluid in liquid form was developed for a heat distribution system for non-rotating satellites. Use of the heat pipe provides a continuous heat transfer mechanism. "Heat tubes" that improve temperature control in plastics manufacturing equipment incorporated the heat pipe technology. James M. Stewart, an independent consultant, patented the heat tubes he developed and granted a license to Kona Corporation. The Kona Nozzle for heaterless injection molding gets heat for its operation from an external source and has no internal heating bands, reducing machine maintenance and also eliminating electrical hazards associated with heater bands. The nozzles are used by Eastman Kodak, Bic Pen Corporation, Polaroid, Tupperware, Ford Motor Company, RCA, and Western Electric in the molding of their products.

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NASA NTRS1981

Copying Machine Improvement

Manufacturer of the Model 2210 copying machine was looking for a plastic valve bushing material that could be produced by a low-cost injection molding process to replace the unsuitable valve bushing they were using. NERAC conducted a computer search of the NASA database and was able to supply Nashua Corporation with several technical reports in their area of interest. Information aided the company's development of a urethane valve bushing which solved the problem and created a dramatic reduction in unit cost.

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NASA NTRS1976

Coating Plastic Lenses

Bell & Howell Company (at their own expense) arranged to work with an Ames Research Center scientist to learn NASA's technique of plasma polymerization. Plastic is easily formed into aspherical surfaces and compound lenses are made from plastics of different refractive indexes. Plastic lenses are injection molded at a tenth the cost of making glass lenses and are lighter than glass and cannot shatter. Scratches scatter light reducing light transmission. This technique is used for coating plastic lenses of film projectors and other optical equipment.

Source record↗
NASA NTRS2005

GRCop-84: A High Temperature Copper-based Alloy For High Heat Flux Applications

While designed for rocket engine main combustion chamber liners, GRCop-84 (Cu-8 at.% Cr-4 at.% Nb) offers potential for high heat flux applications in industrial applications requiring a temperature capability up to approximately 700 C (1292 F). GRCop-84 is a copper-based alloy with excellent elevated temperature strength, good creep resistance, long LCF lives and enhanced oxidation resistance. It also has a lower thermal expansion than copper and many other low alloy copper-based alloys. GRCop-84 can be manufactured into a variety of shapes such as tubing, bar, plate and sheet using standard production techniques and requires no special production techniques. GRCop-84 forms well, so conventional fabrication methods including stamping and bending can be used. GRCop-84 has demonstrated an ability to be friction stir welded, brazed, inertia welded, diffusion bonded and electron beam welded for joining to itself and other materials. Potential applications include plastic injection molds, resistance welding electrodes and holders, permanent metal casting molds, vacuum plasma spray nozzles and high temperature heat exchanger applications.

Ellis, David L.↗
NASA NTRS2007

Strengthening Aluminum Alloys for High Temperature Applications Using Nanoparticles of Al203 and Al3-X Compounds (X= Ti, V, Zr)

In this paper the effect of nanoparticles A12O3 and A13-X compounds (X= Ti, V, Zr) on the improvement of mechanical properties of aluminum alloys for elevated temperature applications is presented. These nanoparticles were selected based on their chemical stability and low diffusions rates in aluminum matrix at high temperatures. The strengthening mechanism for aluminum alloy is based on the mechanical blocking of dislocation movements by these nanoparticles. Samples were prepared from A12O3 nanoparticle preforms, which were produced using ceramic injection molding process and pressure infiltrated by molten aluminum. A12O3 nanoparticles can also be homogeneously mixed with aluminum powder and consolidated into samples through hot pressing and sintering. On the other hand, the Al3-X nanoparticles are produced as precipitates via in situ reactions with molten aluminum alloys using conventional casting techniques. The degree of alloy strengthening using nanoparticles will depend on the materials, particle size, shape, volume fraction, and mean inter-particle spacing.

Lee, Jonathan A.↗
NASA NTRS2009

Chemochromic Hydrogen Leak Detectors

At NASA, hydrogen safety is a key concern for space shuttle processing. Leaks of any level must be quickly recognized and addressed due to hydrogen s lower explosion limit. Chemo - chromic devices have been developed to detect hydrogen gas in several embodiments. Because hydrogen is odorless and colorless and poses an explosion hazard, there is an emerging need for sensors to quickly and accurately detect low levels of leaking hydrogen in fuel cells and other advanced energy- generating systems in which hydrogen is used as fuel. The device incorporates a chemo - chromic pigment into a base polymer. The article can reversibly or irreversibly change color upon exposure to hydrogen. The irreversible pigment changes color from a light beige to a dark gray. The sensitivity of the pigment can be tailored to its application by altering its exposure to gas through the incorporation of one or more additives or polymer matrix. Furthermore, through the incorporation of insulating additives, the chemochromic sensor can operate at cryogenic temperatures as low as 78 K. A chemochromic detector of this type can be manufactured into any feasible polymer part including injection molded plastic parts, fiber-spun textiles, or extruded tapes. The detectors are simple, inexpensive, portable, and do not require an external power source. The chemochromic detectors were installed and removed easily at the KSC launch pad without need for special expertise. These detectors may require an external monitor such as the human eye, camera, or electronic detector; however, they could be left in place, unmonitored, and examined later for color change to determine whether there had been exposure to hydrogen. In one type of envisioned application, chemochromic detectors would be fabricated as outer layers (e.g., casings or coatings) on high-pressure hydrogen storage tanks and other components of hydrogen-handling systems to provide visible indications of hydrogen leaks caused by fatigue failures or other failures in those systems. In another type of envisioned application, chemochromic detectors of this type could be optoelectronically instrumented for monitoring to provide measured digital indications of color changes indicative of the presence of hydrogen.

Roberson, Luke↗
NASA NTRS2009

Cast Aluminum Alloys for High Temperature Applications Using Nanoparticles Al2O3 and Al3-X Compounds (X = Ti, V, Zr)

In this paper, the effect of nanoparticles Al2O3 and Al3-X compounds (X = Ti, V, Zr) on the improvement of mechanical properties of aluminum alloys for elevated temperature applications is presented. These nanoparticles were selected based on their low cost, chemical stability and low diffusions rates in aluminum at high temperatures. The strengthening mechanism at high temperature for aluminum alloy is based on the mechanical blocking of dislocation movements by these nanoparticles. For Al2O3 nanoparticles, the test samples were prepared from special Al2O3 preforms, which were produced using ceramic injection molding process and then pressure infiltrated by molten aluminum. In another method, Al2O3 nanoparticles can also be homogeneously mixed with fine aluminum powder and consolidated into test samples through hot pressing and sintering. With the Al3-X nanoparticles, the test samples are produced as precipitates from in-situ reactions with molten aluminum using conventional permanent mold or die casting techniques. It is found that cast aluminum alloy using nanoparticles Al3-X is the most cost effective method to produce high strength aluminum alloys for high temperature applications in comparison to nanoparticles Al2O3. Furthermore, significant mechanical properties retention in high temperature environment could be achieved with Al3-X nanoparticles, resulting in tensile strength of nearly 3 times higher than most 300- series conventional cast aluminum alloys tested at 600 F.

Lee, Jonathan A.↗
NASA NTRS2003

Miniature Gas-Turbine Power Generator

A proposed microelectromechanical system (MEMS) containing a closed- Brayton-cycle turbine would serve as a prototype of electric-power generators for special applications in which high energy densities are required and in which, heretofore, batteries have been used. The system would have a volume of about 6 cm3 and would operate with a thermal efficiency >30 percent, generating up to 50 W of electrical power. The energy density of the proposed system would be about 10 times that of the best battery-based systems now available, and, as such, would be comparable to that of a fuel cell. The working gas for the turbine would be Xe containing small quantities of CO2, O2, and H2O as gaseous lubricants. The gas would be contained in an enclosed circulation system, within which the pressure would typically range between 5 and 50 atm (between 0.5 and 5 MPa). The heat for the Brayton cycle could be supplied by any of a number of sources, including a solar concentrator or a combustor burning a hydrocarbon or other fuel. The system would include novel heat-transfer and heat-management components. The turbine would be connected to an electric power generator/starter motor. The system would include a main rotor shaft with gas bearings; the bearing surfaces would be made of a ceramic material coated with nanocrystalline diamond. The shaft could withstand speed of 400,000 rpm or perhaps more, with bearing-wear rates less than 10(exp -)4 those of silicon bearings and 0.05 to 0.1 those of SiC bearings, and with a coefficient of friction about 0.1 that of Si or SiC bearings. The components of the system would be fabricated by a combination of (1) three-dimensional xray lithography and (2) highly precise injection molding of diamond-compatible metals and ceramic materials. The materials and fabrication techniques would be suitable for mass production. The disadvantages of the proposed system are that unlike a battery-based system, it could generate a perceptible amount of sound, and, if it were to burn fuel, then it would also generate exhaust, similarly to other combustion-based power sources.

Wiberg, Dean↗