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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 NTRS1989

Large scale fabrication of lightweight Si/SiC lidar mirrors

An up-scalable CVD process has been used to fabricate 7.5-cm models of lightweight Si/SiC mirrors consisting of an f/1.6 concave face-plate of SiC coated with CVD Si, in conjunction with a lightweight backup structure of SiC. Due to CVD chamber fabrication, no bonding agent was required to attach the SiC backup structure to the face-plate. Upon up-scaling, the SiC deposition process has been able to produce 40-cm diameter f/1.6 concave mirror face-plates. The mirrors were polished to a 1/5-wave figure and 10 A rms surface finish. There appear to be no intrinsic physical limits to further up-scaling of this mirror-fabrication process.

Goela, Jitendra Singh↗
NASA NTRS1991

Fabrication Of Lightweight Mirrors Via CVD

New chemical-vapor deposition (CVD) process developed for fabricating lightweight Si/SiC mirrors. Process involves three CVD steps: to produce faceplate of mirror; to form lightweight back structure deposited integrally with faceplate; and to deposit layer of optical-grade material onto front surface of faceplate. Figure and finish of mirror fabricated into this latter material. Produces dense, highly pure polycrystalline materials polished to surface figures of high precision and finish.

Goela, Jitendra S.↗
NASA NTRS1991

Fabrication of lightweight Si/SiC LIDAR mirrors

A new, chemical vapor deposition (CVD) process was developed for fabricating lightweight, polycrystalline silicon/silicon-carbide (Si/SiC) mirrors. The process involves three CVD steps: (1) to produce the mirror faceplate; (2) to form the lightweight backstructure, which is deposited integral to the faceplate; and (3) to deposit a layer of optical-grade material, e.g., Si, onto the front surface of the faceplate. The mirror figure and finish are fabricated into the faceplate.

Goela, Jitendra S.↗
NASA NTRS1992

Progress in the development of lightweight nickel electrode for aerospace applications

The NASA Lewis Research Center is currently developing nickel electrodes for nickel-hydrogen (Ni-H2) cells and batteries. These electrodes are lighter in weight and have higher specific energy than the heavy sintered state of the art nickel electrodes. In the present approach, lightweight materials or plaques are used as conductive supports for the nickel hydroxide active material. These plaques (fiber, felt, and nickel plated plastic) are fabricated into nickel electrodes by electrochemically impregnating them with active material. Initial performance tests include capacity measurements at five discharge levels, C/2, 1.0C, 1.37C, 2.0C, and 2.74C. The electrodes that pass the initial tests are life cycle tested at 40 and 80 percent depths of discharge (DOD). Different formulations of nickel fiber materials obtained from several manufacturers are currently being tested as possible candidates for nickel electrodes. Over 7,000 cycles of life cycle testing have been accumulated at 40 percent DOD, using the lightweight fiber electrode in a boiler plate Ni-H2 cell with stable voltage.

Britton, Doris L.↗
NASA NTRS1992

Progress in the development of lightweight nickel electrode

The use of the lightweight nickel electrode, in place of the heavy-sintered state-of-the-art nickel electrode, will lead to improvements in specific energy and performance of the nickel-hydrogen cell. Preliminary testing indicates that a nickel fiber mat is a promising support candidate for the nickel hydroxide active material. Nickel electrodes made from fiber mats, with nickel and cobalt powder added to the fiber, were tested at LeRC. To date, over 8000 cycles have been accumulated, at 40 percent depth-of-discharge, using the lightweight fiber electrode, in a boiler plate nickel-hydrogen cell.

Britton, Doris L.↗
NASA NTRS1990

A comparison of performance of lightweight mirrors

Four lightweight solid contoured back mirror shapes (a double arch, a single arch, a modified single arch, and a double concave mirror) and a cellular sandwich lightweight meniscus mirror, have been considered for the primary mirror of the Space Infrared Telescope Facility (SIRTF). A parametric design study using these shapes for the SIRTF 40 inch primary mirror with a focal ratio f/2 is presented. Evaluations of the optical performance and fundamental frequency analyses are performed to compare relative merits of each mirror configuration. Included in these are structural, optical, and frequency analyses for (1) different back contour shapes, (2) different number and location of the support points, and (3) two gravity orientations (ZENITH and HORIZON positions). The finite element program NASTRAN is used to obtain the structural deflections of the optical surface. For wavefront error analysis, FRINGE and PCFRINGE programs are used to evaluate the optical performance. A scaling law relating the optical and structural performance for various mirror contoured back shapes is developed.

Cho, Myung K.↗
NASA NTRS1990

Electrochemical impregnation and cycle life of lightweight nickel electrodes for nickel-hydrogen cells

Development of a high specific energy nickel electrode is the main goal of the lightweight nickel electrode program at NASA-Lewis. The approach was to improve the nickel electrode by continuing combined in-house and contract efforts to develop a more efficient and lighter weight electrode for the nickel-hydrogen cell. Lightweight plaques are used as conductive supports for the nickel hydroxide active material. These plaques are commercial products that are fabricated into nickel electrodes by electrochemically impregnating them with active material. The electrodes are life cycle tested in a low earth orbit regime at 40 and 80 percent depths-of-discharge.

Britton, Doris L.↗
NASA NTRS1992

SiC lightweight telescopes for advanced space applications. I - Mirror technology

A SiC based telescope is an extremely attractive emerging technology which offers the lightweight and stiffness features of beryllium, the optical performance of glass to diffraction limited visible resolution, superior optical/thermal stability to cryogenic temperatures, and the cost advantages of an aluminum telescope. SSG has developed various SiC mirrors with and without a silicon coating and tested these mirrors over temperature ranges from +50 C to -250 C. Our test results show less than 0.2 waves P-V in visible wavefront change and no hysteresis over this wide temperature range. Several SSG mirrors are representative of very lightweight SiC/Si mirrors including (1) a 9 cm diameter, high aspect ratio mirror weighing less than 30 grams and (2) a 23 cm diameter eggcrated mirror weighing less than 400 grams. SSG has also designed and analyzed a 0.6 meter SiC based, on axis, three mirror reimaging telescope in which the primary mirror weighs less than 6 kg and a 0.5 meter GOES-like scan mirror. SSG has also diamond turned several general aspheric SiC/Si mirrors with excellent cryo optical performance.

Anapol, Michael I.↗
NASA NTRS1991

Rigid lightweight optical bench for a spaceborne FUV spatial heterodyne interferometer

Requirements for spaceflight optical instruments usually dictate that for the structures be rigid, lightweight, and thermally stable. In addition, for interferometric far ultraviolet (FUV) spectrometers, the requirements for torsional deflection are more severe than with conventional spectrometers. To meet the challenge for rigid and lightweight optical instruments, this paper explores the design of a high-stiffness structure for the support of an FUV spatial heterodyne interferometer where the torsional deflection of the instrument is on the order of 10 arc seconds. The structure is based on use of a thin, hollow section beam with weight-relieving between optical elements. The design also uses a modular and self-contained positioning mechanism that is removed after final optical alignment. Several specific material properties are presented as criteria for material selection. The parameters which affect the particular design requirements are identified with respect to the desired material properties and physical design features. Although large thin sections are susceptible to thermal gradients, this could be minimized by a trade-off for weight, where adequate margin exists. This paper describes the preliminary design for the structure and presents an analysis to verify compliance with the requirements.

Tom, James L.↗
NASA NTRS1993

Lightweight nickel electrodes for nickel/hydrogen cells

Thick nickel electrodes with lightweight substrate material have been prepared and tested in Ni/H2 boilerplate cells containing 26 percent KOH electrolyte. Lightweight substrates used were either 85 or 90 percent in porosity and either 0.8 or 2 mm in thickness, respectively, compared with 80 to 82 percent porosity and 0.75 to 0.8 mm thickness of the state-of-the-art sintered plaque substrate. All of these thick electrodes had substantially improved theoretical (or chemical) capacity over that of state-of-the-art sintered nickel plaque electrodes. However, utilization of the active material was low (65 to 80 percent) compared with that of the state-of-the-art electrodes (approximately 90 percent) in 26 percent KOH. Due to this low utilization, the electrodes using 85 percent porous substrates did not show any advantage over the state-of-the-art ones. The electrodes using a 90 percent porous substrate, however, showed 17 percent higher usable specific capacity (about 0.13 Ah/g in 26 percent KOH) than that of the state-of-the-art nickel electrodes despite the low utilization. These electrodes achieved up to 4860 cycles at 40 percent depth-of-discharge with neither capacity loss nor any significant changes of rate capability and charging efficiency with cycling.

Lim, Hong S.↗
NASA NTRS1994

Development of a lightweight, light-trapped, thin GaAs solar cell for spacecraft applications

This paper describes ultra-lightweight, high performance, thin, light trapping GaAs solar cells for advanced space power systems. The device designs can achieve 24.5 percent efficiency at AMO and 1X conditions, corresponding to a power density of 330 W/m2. A significant breakthrough lies in the potential for a specific power of 2906 W/kg because the entire device is less than 1.5 microns thick. This represents a 440 percent improvement over conventional 4-mil silicon solar cells. In addition to being lightweight, this thin device design can result in increased radiation tolerance. The attachment of the cover glass support to the front surface has been demonstrated by both silicone and electrostatic bonding techniques. Device parameters of 1.002 volts open-circuit voltage, 80 percent fill factor, and a short-circuit current of 24.3 mA/sq cm have been obtained. This demonstrates a conversion efficiency of 14.4 percent resulting in a specific power of 2240 W/kg. Additionally, this new technology offers an alternative approach for enabling multi-bandgap solar cells and high output space solar power devices. The thin device structure can be applied to any 3-5 based solar cell application, yielding both an increase in specific power and radiation tolerance.

Hannon, Margaret H.↗
NASA NTRS1994

Amorphous silicon thin films: The ultimate lightweight space solar cell

Progress is reported with respect to the development of thin film amorphous (alpha-Si) terrestrial solar cells for space applications. Such devices promise to result in very lightweight, low cost, flexible arrays with superior end of life (EOL) performance. Each alpha-Si cell consists of a tandem arrangement of three very thin p-i-n junctions vapor deposited between film electrodes. The thickness of this entire stack is approximately 2.0 microns, resulting in a device of negligible weight, but one that must be mechanically supported for handling and fabrication into arrays. The stack is therefore presently deposited onto a large area (12 by 13 in), rigid, glass superstrate, 40 mil thick, and preliminary space qualification testing of modules so configured is underway. At the same time, a more advanced version is under development in which the thin film stack is transferred from the glass onto a thin (2.0 mil) polymer substrate to create large arrays that are truly flexible and significantly lighter than either the glassed alpha-Si version or present conventional crystalline technologies. In this paper the key processes for such effective transfer are described. In addition, both glassed (rigid) and unglassed (flexible) alpha-Si cells are studied when integrated with various advanced structures to form lightweight systems. EOL predictions are generated for the case of a 1000 W array in a standard, 10 year geosynchronous (GEO) orbit. Specific powers (W/kg), power densities (W/sq m) and total array costs ($/sq ft) are compared.

Vendura, G. J., Jr.↗
NASA NTRS1995

Lightweight, light-trapped, thin GaAs solar cell for spacecraft applications: Progress and results update

Progress is reported with respect to the development of ultra-lightweight, high performance, thin, light trapped GaAs solar cells for advanced space power systems. Conversion efficiencies of over 17.7% have been demonstrated for a 3 micron thick, 1 sq cm silicone bonded solar cell. This results in a specific power of over 1020 W/kg. Device parameters were 1.011 V open circuit voltage, 80% fill factor, and a short-circuit current density of 29.5 mA/sq cm . In addition to silicone bonding, the use of electrostatic bonding to attach the coverglass support to the front surface enables an ultra-thin, all back contact design that survives processing temperatures greater than 750 C. This also results in a 10% reduction of the cell weight for a potential specific power of 1270 W/kg. All back contact, ultra-thin, electrostatically bonded GaAs solar cell prototypes have been completed demonstrating an open circuit voltage of 1 volt for a cell base thickness of 1 micron with a 0.5 micron emitter. This technology will result in a revolutionary improvement in survivability, performance, and manufacturability of lightweight GaAs solar cell products for future Earth-orbiting science and space exploration missions. The thin, electrostatically bonded, all back contact GaAs device technology has multiple uses for specialty high performance solar cells and other optoelectronic devices.

Hannon, M. H.↗
NASA NTRS1996

Lightweight, Thermally Insulating Structural Panels

Lightweight, thermally insulating panels that also serve as structural members developed. Honeycomb-core panel filled with low-thermal-conductivity, opacified silica aerogel preventing convection and minimizes internal radiation. Copper coating on face sheets reduces radiation. Overall thermal conductivities of panels smaller than state-of-art commercial non-structurally-supporting foam and fibrous insulations. On Earth, panels suitable for use in low-air-pressure environments in which lightweight, compact, structurally supporting insulation needed; for example, aboard high-altitude aircraft or in partially evacuated panels in refrigerators.

Eisen, Howard J.↗
NASA NTRS1996

NASA space shuttle lightweight seat

The Space Shuttle Lightweight Seat-Mission Specialist (LWS-MS) is a crew seat for the mission specialists who fly aboard the Space Shuttle. The LWS-MS is a lightweight replacement for the mission specialist seats currently flown on the Shuttle. Using state-of-the-art analysis techniques, a team of NASA and Lockheed engineers from the Johnson Space Center (JSC) designed a seat that met the most stringent requirements demanded of the new seats by the Shuttle program, and reduced the weight of the seats by 52%.

Hansen, Chris↗
NASA NTRS1996

Nonlinear Analysis of the Space Shuttle Super-Lightweight External Fuel Tank

The results of buckling and nonlinear analyses of the Space Shuttle External Tank super-lightweight liquid oxygen (LOX) tank are presented. Modeling details and results are presented for two prelaunch loading conditions and for two full-scale structural tests conducted on the original external tank. These results illustrate three distinctly different types of nonlinear responses for thin-walled shells subjected to combined mechanical and thermal loads. These nonlinear response phenomena consist of bifurcation-type buckling, short-wavelength nonlinear bending, and nonlinear collapse associated with a limit point. For each case, the results show that accurate predictions of nonlinear behavior generally require a large scale high-fidelity finite element model. Results are also presented that show that a fluid filled launch vehicle shell can be highly sensitive to initial geometric imperfections. In addition, results presented for two full scale structural tests of the original standard weight external tank suggest that the finite element modeling approach used in the present study is sufficient for representing the nonlinear behavior of the super lightweight LOX tank.

Nemeth, Michael P.↗
NASA NTRS1997

Lightweight Ceramic Composition of Carbon Silicon Oxygen and Boron

Lightweight, monolithic ceramics resistant to oxidation in air at high temperatures are made by impregnating a porous carbon preform with a sol which contains a mixture of tetraethoxysilane, dimethyldiethoxysilane and trimethyl borate. The sol is gelled and dried on the carbon preform to form a ceramic precursor. The precursor is pyrolyzed in an inert atmosphere to form the ceramic which is made of carbon, silicon, oxygen and boron. The carbon of the preform reacts with the dried gel during the pyrolysis to form a component of the resulting ceramic. The ceramic is of the same size, shape and form as the carbon precursor. Thus, using a porous, fibrous carbon precursor, such as a carbon felt, results in a porous, fibrous ceramic. Ceramics of the invention are useful as lightweight tiles for a reentry spacecraft.

Leiser, Daniel B.↗
NASA NTRS1997

Advanced Lightweight Optics Development for Space Applications

A considerable amount of effort over the past year has been devoted to exploring ultra-lightweight optics for two specific NASA programs, the Next Generation Space Telescope (NGST), and the High Throughput X-ray Spectrometer (HTXS). Experimental investigations have been undertaken in a variety of materials including glass, composites, nickel, beryllium, Carbon Silicon Carbide, Reaction Bonded Silicon Carbide, Chemical Vapor Deposited Silicon Carbide, and silicon. Overall results of these investigations will be summarized, and specific details will be provided concerning the in-house development of ultra-lightweight nickel replication for both grazing incidence and normal incidence optics. This will include x-ray test results of the grazing incidence optic and cryogenic test results of the normal incidence optic. The status of two 1.5 meter diameter demonstration mirrors for NGST will also be presented. These two demonstrations are aimed at establishing the capability to manufacture and test mirrors that have an areal density of 15 kilograms per square meter.

Bilbro, James W.↗