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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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NASA NTRS1985

Remotely manipulated and autonomous robotic welding fabrication in space

The results of a NASA sponsored study, performed in order to establish the feasibility of remotely manipulated or unmanned welding fabrication systems for space construction, are presented. Possible space welding fabrication tasks and operational modes are classified and the capabilities and limitations of human operators and machines are outlined. Human performance in remote welding tasks was experimentally tested under the sensing and actuation constraints imposed by remote manipulation in outer space environments. Proposals for the development of space welding technology are made and necessary future R&D efforts are identified. The development of improved visual sensing strategies and computer encoding of the human welding engineering expertise are identified as essential, both for human operator assistance and for autonomous operation in all phases of welding fabrication. Novel uses of machine vision for the determination of the weld joint and bead geometry are proposed, and a prototype of a rule-based expert system is described for the interpretation of the visually detected weld features and defects.

Agapakis, J. E.↗

NASA NTRS1988

Fabrication of MgF2 and LiF windows for the Hubble Space Telescope Imaging Spectrograph

Two prototype test windows (MgF2 and LiF) to be used on the 75-mm UV MAMA detector tubes for the Hubble Space Telescope Imaging Spectrograph are described. The spatial and optical constraints of this instrument dictate that the thickness of the window materials be no greater than 2-3 mm to achieve a minimum 50-percent transmission at hydrogen Lyman alpha (121.6 nm), and that the window must be domed to minimize optical aberrations and provide structural strength. The detector window has an input diameter of about 100 mm with a radius-of-curvature of 70 mm. The manufacturing processes involved in the fabrication of these windows is discussed, as well as test programs (optical and structural) to be performed at Goddard Space Flight Center.

Gormley, Daphne↗

NASA NTRS2013

Fabrication Assembly and Test of the Mars Science Laboratory Descent Stage Propulsion System

The Descent Stage Propulsion System (DSPS) is the most challenging and complex propulsion system ever built at JPL. Performance requirements, such as the entry Reaction Control System (RCS) requirements, and the terminal descent requirements (3300 N maximum thrust and approximately 835,000 N-s total impulse in less than a minute), required a large amount of propellant and a large number of components for a spacecraft that had to fit in a 4.5 meter aeroshell. The size and shape of the aeroshell, along with the envelope of the stowed rover, limited the configuration options for the Descent Stage structure. The configuration and mass constraints of the Descent Stage structure, along with performance requirements, drove the configuration of the DSPS. This paper will examine some of the challenges encountered and solutions developed during the fabrication, assembly, and test of the DSPS.

Mars Science Laboratory (MSL)↗

NASA NTRS1979

An economic analysis of a commercial approach to the design and fabrication of a space power system

This paper discusses a commercial approach to the design and fabrication of an economical space power system. With the advent of the space shuttle, steps can be taken to back away from the presently used space qualified approach in order to reduce cost of space hardware by incorporating, where possible, commercial design, fabrication, and quality assurance methods. Cost reductions are projected through the conceptual design of a 2 kW space power system built with the capability for having serviceability. The approach to system costing that has been used takes into account both the constraints of operation in space and commercial production engineering approaches. The cost of this power system reflects a variety of cost/benefit tradeoffs that would reduce system cost as a function of system reliability requirements, complexity, and the impact of rigid specifications. A breakdown of the system design, documentation, fabrication and reliability and quality assurance cost estimates are detailed.

Putney, Z.↗

NASA NTRS2010

Documentation of Stainless Steel Lithium Circuit Test Section Design

The Early Flight Fission-Test Facilities (EFF-TF) team was tasked by Naval Reactors Prime Contract Team (NRPCT) to design, fabricate, and test an actively pumped lithium (Li) flow circuit. This Li circuit takes advantage of work in progress at the EFF TF on a stainless steel sodium/potassium (NaK) circuit. The effort involved modifying the original stainless steel NaK circuit such that it could be operated with Li in place of NaK. This new design considered freeze/thaw issues and required the addition of an expansion tank and expansion/extrusion volumes in the circuit plumbing. Instrumentation has been specified for Li and circuit heaters have been placed throughout the design to ensure adequate operational temperatures and no uncontrolled freezing of the Li. All major components have been designed and fabricated prior to circuit redesign for Li and were not modified. Basic circuit components include: reactor segment, Li to gas heat exchanger, electromagnetic liquid metal pump, load/drain reservoir, expansion reservoir, instrumentation, and trace heaters. The reactor segment, based on a Los Alamos National Laboratory 100-kW design study with 120 fuel pins, is the only prototypic component in the circuit. However, due to earlier funding constraints, a 37-pin partial-array of the core, including the central three rings of fuel pins (pin and flow path dimensions are the same as those in the full design), was selected for fabrication and test. This Technical Publication summarizes the design and integration of the pumped liquid metal Li flow circuit as of May 1, 2005.

Godfroy, T. J.↗

NASA NTRS2010

Documentation of Stainless Steel Lithium Circuit Test Section Design

Godfroy, Thomas J.↗

NASA NTRS1979

An economic analysis of a commercial approach to the design and fabrication of a space power system

A commercial approach to the design and fabrication of an economical space power system is presented. Cost reductions are projected through the conceptual design of a 2 kW space power system built with the capability for having serviceability. The approach to system costing that is used takes into account both the constraints of operation in space and commercial production engineering approaches. The cost of this power system reflects a variety of cost/benefit tradeoffs that would reduce system cost as a function of system reliability requirements, complexity, and the impact of rigid specifications. A breakdown of the system design, documentation, fabrication, and reliability and quality assurance cost estimates are detailed.

Putney, Z.↗

NASA NTRS2005

Net-Shape HIP Powder Metallurgy Components for Rocket Engines

True net shape consolidation of powder metal (PM) by hot isostatic pressing (HIP) provides opportunities for many cost, performance and life benefits over conventional fabrication processes for large rocket engine structures. Various forms of selectively net-shape PM have been around for thirty years or so. However, it is only recently that major applications have been pursued for rocket engine hardware fabricated in the United States. The method employs sacrificial metallic tooling (HIP capsule and shaped inserts), which is removed from the part after HIP consolidation of the powder, by selective acid dissolution. Full exploitation of net-shape PM requires innovative approaches in both component design and materials and processing details. The benefits include: uniform and homogeneous microstructure with no porosity, irrespective of component shape and size; elimination of welds and the associated quality and life limitations; removal of traditional producibility constraints on design freedom, such as forgeability and machinability, and scale-up to very large, monolithic parts, limited only by the size of existing HIP furnaces. Net-shape PM HIP also enables fabrication of complex configurations providing additional, unique functionalities. The progress made in these areas will be described. Then critical aspects of the technology that still require significant further development and maturation will be discussed from the perspective of an engine systems builder and end-user of the technology.

Bampton, Cliff↗

NASA NTRS2020

Evaluation of Packing_3D Code for Design of Variable-Depth, Bent-Chamber Acoustic Liners

Increases in the bypass ratio for commercial aircraft engines have caused the broadband fan noise component to become dominant. As a result, there is a need to develop improved acoustic liners suitable for absorption of this fan noise over a wide frequency range, preferably up to at least two octaves. Variable depth liners with bent chambers and three-dimensional geometries present one way to achieve this goal, however, they can be difficult and time-consuming to design due to their complexity and volume constraints. A packing code, called Packing3D, has been developed that automatically designs the chamber configurations of such liners once the chamber dimensions and volume constraints are known. The code uses a randomized trial and error approach to place each chamber in a representation of the liner sample, then returns a colored diagram and sufficient information for the liner sample to be fabricated. For evaluation, the code is used to design four liner samples of varying levels of complexity. These samples are tested with and without a mesh facesheet in the NASA Langley Normal Incidence Tube, and the results are compared to predictions computed in COMSOL. The results indicate that the packing code is able to quickly design samples that are predictable, achieve the desired absorption spectrum, fit the given constraints, and are able to be built. This code is flexible, lends itself to optimization, and allows samples to be designed quickly, accurately, and efficiently.

Marinova, Miroslava M.↗

NASA NTRS2016

Space to Space Advanced EMU Radio

The main task for this project was the development of a prototype for the Space to Space Advanced EMU Radio (SSAER). The SSAER is an updated version of the Space to Space EMU Radio (SSER), which is the current radio used by EMUs (Extravehicular Mobility Unit) for communication between suits and with the ISS. The SSER was developed in 1999, and it was desired to update the design used in the system. Importantly, besides replacing out-of-production parts it was necessary to decrease the size of the radio due to increased volume constraints with the updated Portable Life Support System (PLSS) 2.5, which will be attached on future space suits. In particular, it was desired to fabricate a PCB for the front-end of the prototype SSAER system. Once this board was manufactured and all parts assembled, it could then be tested for quality of operation as well as compliancy with the SSER required specifications. Upon arrival, a small outline of the target system was provided, and it was my responsibility to take that outline to a finished, testable board. This board would include several stages, including frequency mixing, amplification, modulation, demodulation, and handled both the transmit and receive lines of the radio. I developed a new design based on the old SSER system and the outline provided to me, and found parts to fit the tasks in my design. It was also important to consider the specifications of the SSER, which included the system noise figure, gain, and power consumption. Further, all parts needed to be impedance matched, and spurious signals needed to be avoided. In order to fulfill these two requirements, it was necessary to perform some calculations using a Smith Chart and excel analysis. Once all parts were selected, I drew the schematics for the system in Altium Designer. This included developing schematic symbols, as well as layout. Once the schematic was finished, it was then necessary to lay the parts out onto a PCB using Altium. Similar to the schematic design, in order to accomplish this it was necessary to develop component land patterns and add component 3D models. All of this was achieved, and the PCB is currently in review. After it is finished being reviewed, this board will be sent out for manufacture. All electronic components used in the PCB have been acquired, and once the board arrives they will be soldered onto the board using a machine in building 44. Finally, the board will be tested for performance on-site. This will likely be accomplished by the end of the internship.

Maicke, Andrew↗

NASA NTRS1995

Sample acquisition and instrument deployment

Progress is reported in developing the Sample Acquisition and Instrument Deployment (SAID) system, a robotic system for deploying science instruments and acquiring samples for analysis. The system is a conventional four degree of freedom manipulator 2 meters in length. A baseline design has been achieved through analysis and trade studies. The design considers environmental operating conditions on the surface of Mars, as well as volume constraints on proposed Mars landers. Control issues have also been studied, and simulations of joint and tip movements have been performed. The systems have been fabricated and tested in environmental chambers, as well as soil testing and robotic control testing.

Boyd, Robert C.↗

NASA NTRS1970

Hypersonic research engine project. Phase 2: Structures and cooling development

The flightweight components were adapted to form the basic engine assembly. The water cooled test adapters for use in wind tunnel tests were fabricated. Commercially available valves were selected for the coolant control system. The simplification of the temperature control concept and of the absence of weight and volume constraints made it possible to use these valves. Various calibration tests are also discussed.

Jilly, L. F.↗

NASA NTRS1976

Space-to-earth power transmission system

A preliminary analysis was conducted to establish the requirements of a space-to-earth microwave power transmission system. The need for accurate phase control on the transmitter was established and methods for assessing the impact of power density and thermal constraints on system performance were demonstrated. Potential radio frequency interference was considered. The sensitivity of transmission system scale to variations in power source, transportation and orbital fabrication and assembly costs was also determined.

Stevens, G. H.↗

NASA NTRS2005

Thin Films and Inflatable Applications in Exploration Habitat Structures

NASA's vision to return to the Moon and then extend human exploration to Mars will benefit from human habitat technology development using new and creative applications of polymer materials and concepts. Thin Film and Inflatable (TFVI) materials are particularly interesting for exploration applications due to their light weight and low volume. Whereas TF/I materials can be launched and carried from Earth to multiple and distant exploration sites without the constraints of upmass limitations, eventually, with recycling and reclamation efforts, these materials may be developed using in-situ resources. These materials can be useful for fabricating, patching and repairing vehicles, replacement parts and even habitat structures, as well as for developing stand-alone habitat structure technologies and for nested and integrated applications. TF/Is can also be ideal environmental containment vessels within lunar or Martian regolith walls or as liners inside caves or raw regolith exterior structures for the provisions of atmosphere containment, debris protection and cleanliness. Further, TFOs can be specialized and matured for various and diverse applications. The desired range of applications will require materials specification for such properties as transparency, elasticity, thermal conductivity, mechanical strength, heat capacity, chemical resistance, and permeability. This paper will discuss Marshall Space Flight Center's plans to analyze and prioritize TF/I materials properties and classifications and to develop applications for these highly desirable materials in human habitat construction projects on the Moon and Mars.

Frazier, Donald O.↗

NASA NTRS2015

Design Process of Flight Vehicle Structures for a Common Bulkhead and an MPCV Spacecraft Adapter

Design and manufacturing space flight vehicle structures is a skillset that has grown considerably at NASA during that last several years. Beginning with the Ares program and followed by the Space Launch System (SLS); in‐house designs were produced for both the Upper Stage and the SLS Multipurpose crew vehicle (MPCV) spacecraft adapter. Specifically, critical design review (CDR) level analysis and flight production drawing were produced for the above mentioned hardware. In particular, the experience of this in‐house design work led to increased manufacturing infrastructure for both Marshal Space Flight Center (MSFC) and Michoud Assembly Facility (MAF), improved skillsets in both analysis and design, and hands on experience in building and testing (MSA) full scale hardware. The hardware design and development processes from initiation to CDR and finally flight; resulted in many challenges and experiences that produced valuable lessons. This paper builds on these experiences of NASA in recent years on designing and fabricating flight hardware and examines the design/development processes used, as well as the challenges and lessons learned, i.e. from the initial design, loads estimation and mass constraints to structural optimization/affordability to release of production drawing to hardware manufacturing. While there are many documented design processes which a design engineer can follow, these unique experiences can offer insight into designing hardware in current program environments and present solutions to many of the challenges experienced by the engineering team.

Aggarwal, Pravin↗

NASA NTRS2015

Adjustable Grazing-Incidence X-Ray Optics

With its unique subarcsecond imaging performance, NASA's Chandra X-ray Observatory illustrates the importance of fine angular resolution for x-ray astronomy. Indeed, the future of x-ray astronomy relies upon x-ray telescopes with comparable angular resolution but larger aperture areas. Combined with the special requirements of nested grazing-incidence optics, mass, and envelope constraints of space-borne telescopes render such advances technologically and programmatically challenging. The goal of this technology research is to enable the cost-effective fabrication of large-area, lightweight grazing-incidence x-ray optics with subarcsecond resolution. Toward this end, the project is developing active x-ray optics using slumped-glass mirrors with thin-film piezoelectric arrays for correction of intrinsic or mount-induced distortions.

O'Dell, Stephen L.↗

NASA NTRS2016

Toward Large-Area Sub-Arcsecond X-Ray Telescopes II

In order to advance significantly scientific objectives, future x-ray astronomy missions will likely call for x-ray telescopes with large aperture areas (approx. = 3 sq m) and fine angular resolution (approx. = 1"). Achieving such performance is programmatically and technologically challenging due to the mass and envelope constraints of space-borne telescopes and to the need for densely nested grazing-incidence optics. Such an x-ray telescope will require precision fabrication, alignment, mounting, and assembly of large areas (approx. = 600 sq m) of lightweight (approx. = 2 kg/sq m areal density) high-quality mirrors, at an acceptable cost (approx. = 1 M$/sq m of mirror surface area). This paper reviews relevant programmatic and technological issues, as well as possible approaches for addressing these issues-including direct fabrication of monocrystalline silicon mirrors, active (in-space adjustable) figure correction of replicated mirrors, static post-fabrication correction using ion implantation, differential erosion or deposition, and coating-stress manipulation of thin substrates.

Shi Ye↗

NASA NTRS2010

Propulsion Design With Freeform Fabrication (PDFF)

The nation is challenged to decrease the cost and schedule to develop new space transportation propulsion systems for commercial, scientific, and military purposes. Better design criteria and manufacturing techniques for small thrusters are needed to meet current applications in missile defense, space, and satellite propulsion. The requirements of these systems present size, performance, and environmental demands on these thrusters that have posed significant challenges to the current designers and manufacturers. Designers are limited by manufacturing processes, which are complex, costly, and time consuming, and ultimately limited in their capabilities. The PDFF innovation vastly extends the design opportunities of rocket engine components and systems by making use of the unique manufacturing freedom of solid freeform rapid prototype manufacturing technology combined with the benefits of ceramic materials. The unique features of PDFF are developing and implementing a design methodology that uses solid freeform fabrication (SFF) techniques to make propulsion components with significantly improved performance, thermal management, power density, and stability, while reducing development and production costs. PDFF extends the design process envelope beyond conventional constraints by leveraging the key feature of the SFF technique with the capability to form objects with nearly any geometric complexity without the need for elaborate machine setup. The marriage of SFF technology to propulsion components allows an evolution of design practice to harmonize material properties with functional design efficiency. Reduced density of materials when coupled with the capability to honeycomb structure used in the injector will have significant impact on overall mass reduction. Typical thrusters in use for attitude control have 60 90 percent of its mass in the valve and injector, which is typically made from titanium. The combination of material and structure envisioned for use in an SFF thruster design could reduce thruster weight by a factor of two or more. The thrust-to-weight ratios for such designs can achieve 1,000:1 or more, depending on chamber pressure. The potential exists for continued development in materials, size, speed, accuracy of SFF techniques, which can lead to speculative developments of PDFF processes such as fabrication of custom human interface devices like masks, chairs, and clothing, and advanced biomedical application to human organ reconstruction. Other potential applications are: higher fidelity lower cost test fixtures for probes and inspection, disposable thrusters, and ISRU (in situ resource utilization) for component production in space or on Lunar and Martian missions, and application for embedding MEMS (microelectromechanical systems) during construction process of form changing aerostructure/dynamic structures.

Barnes, Daudi↗