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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
NASA NTRS2000

Ignition Resistance of Polymeric Materials to Particle Impact in High-Pressure Oxygen

Particle impact ignition has been the primary cause of numerous fires in oxygen systems. This ignition phenomenon is known to occur where particles are present in high-velocity gas, and where impact occurs on a flammable material. The particle impact ignition behavior of many metals has been widely studied, but the particle impact ignition behavior of polymeric materials is relatively unknown. Particle impact ignition in polymeric materials is a concern as these materials are commonly used in component seat and seal applications, where high-velocity particle impacts can occur. This study evaluates several polymeric materials and compares the minimum temperature required for ignition (threshold temperature) of these materials: Kel-F 81 (CTFE), Teflon (PTFE), PEEK, Vespel SP-21, and Nylon 6/6. The materials were configured as targets in the White Sands Test Facility high-velocity particle impact test system. Gaseous oxygen was flowed at 4000 psi and sonic velocity, and the targets were impacted with 2000-micron aluminum 2017 particles. This paper discusses the results of these tests and ranks the materials according to their threshold temperatures at these conditions.

Forsyth, Elliot T.↗
NASA NTRS2001

Automated Fiber Placement of PEEK/IM7 Composites with Film Interleaf Layers

The incorporation of thin discrete layers of resin between plies (interleafing) has been shown to improve fatigue and impact properties of structural composite materials. Furthermore, interleafing could be used to increase the barrier properties of composites used as structural materials for cryogenic propellant storage. In this work, robotic heated-head tape placement of PEEK/IM7 composites containing a PEEK polymer film interleaf was investigated. These experiments were carried out at the NASA Langley Research Center automated fiber placement facility. Using the robotic equipment, an optimal fabrication process was developed for the composite without the interleaf. Preliminary interleaf processing trials indicated that a two-stage process was necessary; the film had to be tacked to the partially-placed laminate then fully melted in a separate operation. Screening experiments determined the relative influence of the various robotic process variables on the peel strength of the film-composite interface. Optimization studies were performed in which peel specimens were fabricated at various compaction loads and roller temperatures at each of three film melt processing rates. The resulting data were fitted with quadratic response surfaces. Additional specimens were fabricated at placement parameters predicted by the response surface models to yield high peel strength in an attempt to gage the accuracy of the predicted response and assess the repeatability of the process. The overall results indicate that quality PEEK/lM7 laminates having film interleaves can be successfully and repeatability fabricated by heated head automated fiber placement.

Hulcher, A. Bruce↗
NASA NTRS2002

Musing over Microbes in Microgravity: Microbial Physiology Flight Experiment

New York City, the most populated city in the United States, is home to over 8 million humans. This means over 26,000 people per square mile! Imagine, though, what the view would be if you peeked into the world of microscopic organisms. Scientists estimate that a gram of soil may contain up to 1 billion of these microbes, which is as much as the entire human population of China! Scientists also know that the world of microbes is incredibly diverse-possibly 10,000 different species in one gram of soil - more than all the different types of mammals in the world. Microbes fill every niche in the world - from 20 miles below the Earth's surface to 20 miles above, and at temperatures from less than -20 C to hotter than water's boiling point. These organisms are ubiquitous because they can adapt quickly to changing environments, an effective strategy for survival. Although we may not realize it, microbes impact every aspect of our lives. Bacteria and fungi help us break down the food in our bodies, and they help clean the air and water around us. They can also cause the dark, filmy buildup on the shower curtain as well as, more seriously, illness and disease. Since humans and microbes share space on Earth, we can benefit tremendously from a better understanding of the workings and physiology of the microbes. This insight can help prevent any harmful effects on humans, on Earth and in space, as well as reap the benefits they provide. Space flight is a unique environment to study how microbes adapt to changing environmental conditions. To advance ground-based research in the field of microbiology, this STS-107 experiment will investigate how microgravity affects bacteria and fungi. Of particular interest are the growth rates and how they respond to certain antimicrobial substances that will be tested; the same tests will be conducted on Earth at the same times. Comparing the results obtained in flight to those on Earth, we will be able to examine how microgravity induces physiological changes in the microbes.

Schweickart, Randolph↗
NASA NTRS2004

Automated Tow Placement Processing and Characterization of Composites

The project had one of the initial objectives as automated tow placement (ATP), in which a robot was used to place a collimated band of pre-impregnated ribbons or a wide preconsolidated tape onto a tool surface. It was proposed to utilize the Automated Tow Placement machine that was already available and to fabricate carbon fiber reinforced PEEK (polyether-ether-ketone) matrix composites. After initial experiments with the fabrication of flat plates, composite cylinders were to be fabricated. Specimens from the fabricated parts were to be tested for mechanical characterization. A second objective was to conduct various types of tests for characterizing composite specimens cured by different fabrication processes.

Prabhakaran, R.↗
NASA NTRS1949

Landing Procedure in Model Ditching Tests of Bf 109

The purpose of the model tests is to clarify the motions in the alighting on water of a land plane. After discussion of the model laws, the test method and test procedure are described. The deceleration-time-diagrams of the landing of a model of the Bf 109 show a high deceleration peek of greater than 20g which can be lowered to 4 to 6g by radiator cowling and brake skid.

Sottorf, W.↗
NASA NTRS2013

Miga Aero Actuator and 2D Machined Mechanical Binary Latch

Shape memory alloy (SMA) actuators provide the highest force-to-weight ratio of any known actuator. They can be designed for a wide variety of form factors from flat, thin packages, to form-matching packages for existing actuators. SMA actuators can be operated many thousands of times, so that ground testing is possible. Actuation speed can be accurately controlled from milliseconds to position and hold, and even electronic velocity-profile control is possible. SMA actuators provide a high degree of operational flexibility, and are truly smart actuators capable of being accurately controlled by onboard microprocessors across a wide range of voltages. The Miga Aero actuator is a SMA actuator designed specifically for spaceflight applications. Providing 13 mm of stroke with either 20- or 40-N output force in two different models, the Aero actuator is made from low-outgassing PEEK (polyether ether ketone) plastic, stainless steel, and nickel-titanium SMA wires. The modular actuator weighs less than 28 grams. The dorsal output attachment allows the Aero to be used in either PUSH or PULL modes by inverting the mounting orientation. The SPA1 actuator utilizes commercially available SMA actuator wire to provide 3/8-in. (approx. =.1 cm) of stroke at a force of over 28 lb (approx. = .125 N). The force is provided by a unique packaging of the single SMA wire that provides the output force of four SMA wires mechanically in parallel. The output load is shared by allowing the SMA wire to slip around the output attachment end to adjust or balance the load, preventing any individual wire segment from experiencing high loads during actuation. A built-in end limit switch prevents overheating of the SMA element following actuation when used in conjunction with the Miga Analog Driver [a simple MOSFET (metal oxide semiconductor field-effect transistor) switching circuit]. A simple 2D machined mechanical binary latch has been developed to complement the capabilities of SMA wire actuators. SMA actuators typically perform ideally as latch-release devices, wherein a spring-loaded device is released when the SMA actuator actuates in one direction. But many applications require cycling between two latched states open and closed.

Gummin, Mark A.↗
NASA NTRSDate not supplied

Engineering Polymers as Structural Materials in Spacecraft Water Systems

The novel application of structural materials, surface treatments, and barrier coatings is desired to mitigate the rapid loss of ionic silver (Ag+) biocide observed with passive metal alloys, improve reliability, and reduce system mass. In this work, we provide an initial look at the potential replacement of these heritage alloys in spacecraft water systems with high-performance thermoplastic engineering polymers, including PEEK, PEI, and PVDF. Such materials have found increasing use as structural materials in a broad array of performance-critical applications, including in the aerospace, medical implant, and chemical processing fields. We selected a number of promising materials for investigation, compiled mechanical behavior data, and conducted theoretical performance analyses. We also identified and began to address numerous material suitability concerns as well as design requirements for pressurized components in human-rated spacecraft hardware. These include material flammability, offgassing, leaching, chemical resistance, radiation tolerance, prevention of fracture/yielding, and others. We find that there is significant potential for use of engineering polymers in spacecraft water systems, and suggest some directions for future research.

Lance Dean Delzeit↗
NASA NTRSDate not supplied

Unlocking the Mysteries of the Moon’s Shadowed Regions

The Moon poles host large quantities of water-ice deposits in the permanently shadowed regions (PSRs), which are vital for enabling sustainable human space exploration, making these regions high-priority targets for upcoming Artemis missions [1]. Unfortunately, today, the best available orbital lunar imagery [2, 3] lacks the meter-scale resolution and signal needed to understand the geomorphology and trafficability of PSRs, complicating the planning and execution of future missions seeking to explore PSRs. We have developed an image enhancement tool called HORUS (Hyper-effective nOise Removal Unet Software) [4, 5], designed to enhance LRO Narrow-Angle Camera (NAC) optical low-light imagery of permanently shadowed regions by effectively removing the CCD-related, photon, and other residual noises that corrupt the images. The tool is composed of two deep learning neural networks trained on environmental metadata and real and synthetic imagery, the latter generated by a physical noise model (LROC). We demonstrated that HORUS effectively produces low-noise, high-resolution images (~1.5m/px), achieving a 5 to 10x improvement over existing long-exposure images of PSRs. HORUS allows scientists and engineers to identify geomorphic features (e.g., craters and boulders) in shadowed regions as small as 3 meters across as well as to peek inside of small shadowed regions, for the first time. The tool was deployed and thoroughly validated for NASA's VIPER mission [6], where it was applied to 20 candidate target regions across the lunar South Pole. Additionally, we conducted different approaches to validate the resulting HORUS-processed images. With HORUS denoised images, VIPER scientists can increase their confidence on what surface features (previously unseen) exist in the shadowed regions, helping them plan rover traverses more safely and efficiently (e.g., Fig. 1) In this manuscript, we will describe how VIPER scientists are utilizing HORUS denoised images to extract new information from the terrain and increase their confidence in what surface features exist in the shadowed regions. In combination with other high-resolution images and digital elevation maps, HORUS images are helping the team analyze potential lading and science sites, as well as planning traverses more safely and efficiently (e.g., Fig. 1). Additionally, we will describe how HORUS tool unlocks a broad range of scientific and exploration applications to other Artemis and CPLS missions to the lunar poles, including (but not limited to) geomorphic analysis, change detection, surface hazard detection, and terrain relative navigation.

artificial intelligence↗
NASA NTRSDate not supplied

Study of the Thermal Physical Properties of Insulating Materials in A Titan Environment

Dragonfly is a planned rotorcraft mission that NASA/APL will be sending to Saturn’s moon Titan to study its chemistry. The Dragonfly Mass Spectrometer (DraMS) is a mass spectrometer that is being developed to identify different kinds of organic material that comprises Titan’s surface. The Cryogenic engineering team on DraMS is developing and interface between the room temperature rotorcraft body and the near-cryogenic temperatures of an onboard sample chamber, while minimizing the thermal leak to the Titan environment. As part of design process, the Cryogenic team has built a conductivity test rig for testing the thermophysical properties of candidate insulators, which includes Rohacell 31HF and hollowed 3D printed PEEK structures, at simulated Titan environmental conditions.

Thermal Conductivity↗
NASA NTRSDate not supplied

Laser Angle of Incidence Effects on in-Situ Consolidation of Automated Fiber Placement of Polyaryletherketone Composites

NASA and Electroimpact, Inc. ®†† in conjunction with other U.S. industry partners are performing research as a part of the NASA High-rate Composites for Aircraft Manufacturing (HiCAM) Project to fabricate thermoplastic panels using automated fiber placement (AFP) to increase manufacturing rates of aircraft structural composites. This work focuses on evaluating the in-situ consolidation AFP of thermoplastics (ICAT) process. Previous studies of the ICAT process using semi-crystalline, polyaryletherketone (PAEK) slit-tape have resulted in an adequate degree of intimate contact between plies; however, the resulting interlaminar strength have been less than laminates fabricated in an autoclave. To improve these properties, the effect of reducing the laser angle of incidence (AoI) during placement to increase the degree of auto-hesion was evaluated. The AoI of the laser assisted AFP head was varied between 12° and 16° to fabricate multiple quasi- isotropic and unidirectional test panels. Physics-based thermal models developed at the NASA Langley Research Center were utilized to predict the temperature profile. Laminate processing temperature was measured experimentally, and panel quality was evaluated by both non- destructive evaluation (NDE) as well as destructively by photo-microscopy. The effect on interlaminar strength was determined by short beam strength testing. Test results of carbon fiber laminates fabricated by ICAT using polyetheretherketone (PEEK), polyetherketoneketone (PEKK), and low-melt polyaryletherketone (LM-PAEK) at various laser angles of incidence, placement temperatures and placement speeds are presented.

Laser↗
NASA NTRSDate not supplied

Composites From in-Situ Consolidation Automated Fiber Placement of Thermoplastics for High-Rate Aircraft Manufacturing

The National Aeronautics and Space Administration (NASA) project Hi-Rate Composites Aircraft Manufacturing (HiCAM) aims to significantly increase commercial aircraft composite structures manufacturing rate. Thermoplastic composites offer attractive solutions to rapid manufacturing due to their ability to be formed and consolidated quickly. NASA has a particular interest in assessing composite structure manufacturing utilizing an in-situ consolidation automated fiber placement (AFP) of thermoplastics (ICAT) process employing current state-of-the-art laser heating systems. Three semi-crystalline polyaryletherketone (PAEK) thermoplastic tape materials were characterized to ascertain the ICAT process parameters. The required laser power settings were determined at Electroimpact, Inc., measuring material temperatures utilizing a forward looking infrared (FLIR) thermal imaging camera and thermocouples. The material temperature, tool temperature, and placement speed were varied for resulting consolidation quality assessment. The resulting temperature data were also utilized to calibrate thermal analysis models under development at NASA. The experimental temperature data confirmed analytical results. The quality of the resulting test panels was evaluated by both non-destructive evaluation as well as destructively by photo-microscopy. The effect on interlaminar strength was determined by short beam strength testing. Test results of carbon fiber laminates fabricated by ICAT using polyetheretherketone (PEEK), polyetherketoneketone (PEKK), and low-melt polyaryletherketone (LM-PAEK) at various placement temperatures and placement speeds are presented.

thermoplastic composites↗
NASA NTRSDate not supplied

Joining, Disassembly, and Reconfiguration of Thermoplastic Composites for Space Applications

Thermoplastic composites are increasingly being investigated for aerospace applications because of their relatively short processing time, good chemical and radiation resistance, and potential for reforming and reuse via melting. The manufacturing, reforming, and reuse of thermoplastic composites can be leveraged to advance joining, disassembly, and reassembly of structures for space exploration activities. Potential applications include, but are not limited to, habitats and on-orbit assembly and reassembly of large-scale truss structures. This work focuses on demonstrating the feasibility of joining, disassembly, and reassembly of a thermoplastic bond using heat and pressure. Polyether ether ketone (PEEK) composite adherends were joined using low-melt polyaryl ether ketone (LM-PAEK) thermoplastic films at the bonding interface. The single lap shear specimens with LM-PAEK film were tested and had a maximum shear strength between 5 and 8 MPa and consistently failed adhesively at the bondline. Reassembly of disassembled specimens was successfully demonstrated using additional thermoplastic interlayers. Thus, the reassembly of thermoplastic composite joints was found to be feasible. However, additional work is required to reduce film flowout and optimize consolidation parameters for an in space environment.

thermoplastic composites↗
NASA NTRSDate not supplied

Laser Angle of Incidence Effects on in-Situ Consolidation of Automated Fiber Placement of Polyaryletherketone Composites

NASA and Electroimpact, Inc. ® in conjunction with other U.S. industry partners are performing research as a part of the NASA High-rate Composites for Aircraft Manufacturing (HiCAM) Project to fabricate thermoplastic panels using automated fiber placement (AFP) to increase manufacturing rates of aircraft structural composites. This work focuses on evaluating the in-situ consolidation AFP of thermoplastics (ICAT) process. Previous studies of the ICAT process using semi-crystalline, polyaryletherketone (PAEK) slit-tape have resulted in an adequate degree of intimate contact between plies; however, the resulting interlaminar strength have been less than laminates fabricated in an autoclave. To improve these properties, the effect of reducing the laser angle of incidence (AoI) during placement to increase the degree of auto-hesion was evaluated. The AoI of the laser assisted AFP head was varied between 12° and 16° to fabricate multiple quasi-isotropic and unidirectional test panels. Physics-based thermal models developed at the NASA Langley Research Center were utilized to predict the temperature profile. Laminate processing temperature was measured experimentally, and panel quality was evaluated by both non-destructive evaluation (NDE) as well as destructively by photo-microscopy. The effect on interlaminar strength was determined by short beam strength testing. Test results of carbon fiber laminates fabricated by ICAT using polyetheretherketone (PEEK), polyetherketoneketone (PEKK), and low-melt polyaryletherketone (LM-PAEK) at various laser angles of incidence, placement temperatures and placement speeds are presented.

Thermoplastic Composites↗
NASA NTRSDate not supplied

A NASA Airborne Lens Into Air Quality Field Studies of the Last Decade

Field studies add an enhanced perspective to our everyday observing system for air quality with the goals of better understanding the air we breathe and identifying solutions toward a healthier future. Over the last decade, over 10 air quality field studies were conducted around the US with other ranging internationally with support through large agency-led efforts down to the grass-roots collaborative style. This presentation will highlight how NASA airborne observations have fit as one piece of the integrated observing system for air quality during these field studies. Research topics to be discussed are centered around the idea of the transition to geostationary air quality satellite observations. Specific topics include how temporally and spatially resolved measurements help us learn about knowledge gaps in NOx emissions, satellite-proxies for surface air quality, as well as evaluating state-of-the-art chemical transport models and using the enhanced observations as tools for understand what models/satellites can and cannot resolve. Each research topic will aim to discuss how the field measurement strategies that made this work possible as well as specific challenges that still exist to take these results further. Lastly, this presentation will discuss strategies to be carried forward as well as new ones as a peek into future air quality airborne field work.

Laura Judd↗
NASA NTRS2026

Beyond Melting: Amorphous Bonding for Joining and Consolidation

Crystallization may be the hidden constraint in thermoplastic composite manufacturing. It requires tightly controlled cooling, induces residual stresses through shrinkage, and introduces path-dependent behavior that complicates predictive modeling yet remains essential for structural performance. This work asks: can bonding be achieved without relying on melt-driven crystallization? To address this, thin (5–20 μm) polyetherimide (PEI) interlayers are pre-healed to slow-cooled polyaryletherketone (PAEK) in two contexts. The first, Thermabond®, is sub-melt joining of low melt-PAEK laminates. Results show that bond quality is governed primarily by processing (i.e., adequate healing and film handling) rather than modest changes in interlayer thickness. This concept is then extended to laminate-scale manufacturing through an architecture known as OATMEAL (Out-of-autoclave Amorphous/semicrystalline Thermoplastic Material for Energy-efficient Aerospace-grade Laminates). PEI is healed to carbon fiber reinforced polyetheretherketone (PEEK) at the prepreg and excess PEI is then ablated from the surface. Crystallinity is developed off-line during prepreg fabrication, while subsequent consolidation occurs below the melt temperature to preserve it. Cross-ply warpage experiments show that, contrary to intuition, repeated amorphous interfaces reduce global curvature by lowering the effective stress lock-in temperature and eliminating crystallization shrinkage from the lamina response. Correspondingly, laminate behavior is accurately predicted using classical laminate theory (CLT) with a single effective stress-free temperature, whereas conventional CF/PEEK requires accounting for crystallization-driven effects. By decoupling interfacial healing from crystallization, OATMEAL enables sub-melt consolidation, reduces energy consumption by up to 75%, and increases manufacturing throughput by fivefold. These results demonstrate that amorphous bonding is not only a joining strategy, but a pathway to more predictable and scalable thermoplastic composite manufacturing.

solidification↗
NASA NTRS1970

Motor brush wear measured with strain gages

Balanced bridge circuit, supplied with low-voltage direct current and connected to a readout device, measures remaining brush material, rate of brush wear, armature runout, and brush signature.

Farrell, W. T.↗
NASA NTRS1972

Two successful geomagnetic-field-line tracing experiments.

Two field-line tracing experiments were conducted on an L = 1.26 magnetic flux tube over Kauai, Hawaii. Barium vapor was created by the detonation of a highly explosive shaped charge aligned with the geomagnetic field at a 467-km altitude. Barium ions traveled along the field line to the conjugate ionosphere in a tube 3 to 5 km in diameter, producing a visible streak along the entire 6900-km path length. Electric fields perpendicular to the magnetic field caused the ions to drift away from the true conjugate during transit, but extrapolation from subsequent ion drift rates allowed the conjugate to be identified and compared with several field models. Differing ion drift rates and directions at the conjugate points indicated that the electric field is not transferred unattenuated along field lines.

Wescott, E. M.↗