Search NASA⌕ Search

SEARCH · Search NASA

Results for “Critical Material”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
NASA NTRS2008

A Versatile Lifting Device for Lunar Surface Payload Handling, Inspection and Regolith Transport Operations

Devices for lifting and transporting payloads and material are critical for efficient Earth-based construction operations. Devices with similar functionality will be needed to support lunar-outpost construction, servicing, inspection, regolith excavation, grading and payload placement. Past studies have proposed that only a few carefully selected devices are required for a lunar outpost. One particular set of operations involves lifting and manipulating payloads in the 100 kg to 3,000 kg range, which are too large or massive to be handled by unassisted astronauts. This paper will review historical devices used for payload handling in space and on earth to derive a set of desirable features for a device that can be used on planetary surfaces. Next, an innovative concept for a lifting device is introduced, which includes many of the desirable features. The versatility of the device is discussed, including its application to lander unloading, servicing, inspection, regolith excavation and site preparation. Approximate rules, which can be used to size the device for specific payload mass and reach requirements, are provided. Finally, details of a test-bed implementation of the innovative concept, which will be used to validate the structural design and develop operational procedures, is provided.

Doggett, William R.↗
NASA NTRS2009

Thermal Analysis and Testing of Candidate Materials for PAIDAE Inflatable Aeroshell

The Program to Advance Inflatable-Decelerators for Atmospheric Entry (PAIDAE) is a NASA project tasked with developing and evaluating viable inflatable-decelerator aeroshell geometries and materials. Thermal analysis of material layups supporting an inflatable aeroshell was completed in order to identify expected material response, failure times, and to establish an experimental test matrix to keep barrier layer materials from reaching critical temperature limits during thermal soak. Material layups were then tested in the 8- foot High Temperature Tunnel (8'HTT), where they were subjected to hypersonic aerothermal heating conditions, similar to those expected for a Mars entry. This paper presents a broad overview of the thermal analysis supporting multiple materials, and layup configurations tested in the 8'HTT at flight conditions similar to those that would be experienced during Mars entry trajectories. Direct comparison of TPS samples tested in the 8'HTT verify that the thermal model accurately predicted temperature profiles when there are up to four materials in the test layup. As the number of material layers in each test layup increase (greater than 4), the accuracy of the prediction decreases significantly. The inaccuracy of the model predictions for layups with more than four material layers is believed to be a result of the contact resistance values used throughout the model being inaccurate. In addition, the harsh environment of the 8'HTT, including hot gas penetrating through the material layers, could also be a contributing factor.

DelCorso, Joseph A.↗
NASA NTRS2011

Carbon Nanotube Coatings as Used in Strain Sensors for Composite Tanks

The next generation of cryogenic fuel tanks, crew habitats and other components for future spacecraft will focus on the usc of lightweight carbon fiber composite materials. A critical issue in the design and optimization of such tanks and structures will bc in structural health monitoring, however, current strain sensors have limitations. In this study, a novel carbon nanotube thin film was applied to carbon fiber composites for structural monitoring. Applying a load using a 3-point bend test to simulate bowing of a tank wall, induced significant increases in the film's electrical resistance at small deflections. Upon release of the load, the resistance returned to its approximate start value and was reproducible over multiple tests. The results show that a carbon nanotube thin film has great potential for the health monitoring of composite structures.

Trigwell, Steve↗
NASA NTRS2014

Thermal Testing of Planetary Probe TPS in Extreme Entry Environments

High temperature testing of thermal protection system (TPS) materials is a critical aspect of heat-shield materials development, as it determines the suitability and performance envelope of the materials. The present talk provides an overview of recent updates to NASAs IHF and AEDCs H3 high temperature arcjet test facilities that to enable higher heat flux (5000-8000 Wcm2) and high pressure (5-14 atm) testing of TPS. Some recent thermal tests of fully dense carbon phenolic will be discussed in this paper. These new facility upgrades will help improve the TRL level of novel TPS materials and will help qualifycertify heritage TPS material candidates for future missions that are expected to encounter extreme entry conditions, such as entry into Venus or Saturn.

Gasch, M.↗
NASA NTRS2014

Thermal Testing of Thermal Protection System (TPS) Materials

High temperature testing of thermal protection system (TPS) materials is a critical aspect of heat-shield materials development, as it determines the suitability and performance envelope of the materials. The present talk provides an overview of different high temperature test facilities that are available for conducting thermal tests for TPS materials. The facilities include arcjet testing, solar tower testing facilities and laser test facility. The facilities are selected based on the requirements and objectives of the tests and each have their benefits and limitations. The paper also describes the process of determining the test environments based on mission profiles and requirements. Some of the recent thermal tests of TPS materials are discussed in this paper. These tests have helped improve the TRL (Technology Readiness Level) level of novel TPS materials and make them viable TPS material candidates for future missions.

Thermal Protection Materials↗
NASA NTRS2018

Stress Corrosion Cracking of Metals in Propellants

Stress corrosion cracking (SCC) of a fracture critical metallic material can cause a premature failure if the material is susceptible in the unique service environment. Material fluid compatibility is an area of interest for the current NASA programs leading the human exploration path to Mars. White Sands Test Facility, the agency's lead on hypergolic propellant testing, identifies a lack in stress corrosion cracking susceptibility data for metallic materials in hypergolic propellants. The development of a stress corrosion cracking screening method is necessary to bridge the knowledge gap and enable the community to more confidently select materials for the use in systems containing corrosive fluids.

Alcantara, Ilse↗
NASA NTRSDate not supplied

Understanding Space Weathering of Carbonaceous Asteroids through H+ and He+ Ion Irradiation of the Murchison Meteorite

Airless planetary bodies are subject to space weathering processes such as micrometeoroid bombardment and solar wind irradiation. These processes alter the microstructural, chemical, and optical properties of planetary regoliths and, in turn, complicate interpretations of surface composition from remote sensing data and matching of meteorites to their parent bodies. Unlike lunar and ordinary chondrite materials, space weathering studies of primitive carbonaceous chondrites are still evolving [1]. Investigations that examine the spectral, microstructural, and chemical effects of space weathering on carbonaceous materials are critical for maximizing the scientific return of ongoing and future missions to C-complex asteroids, like the NASA OSIRIS-REx (Bennu) and JAXA Hayabusa2 (Ryugu) missions[2,3]. Here, we present results from our experimental simulation of solar wind weathering on organic-rich, C-complex asteroid surfaces in which we irradiated a slab of the Murchison CM2 chondrite with 1 keV/amu H+ and He+ ions.

D. L. Laczniak↗
NASA NTRSDate not supplied

Spacecraft Material Characterization Using Reflectance Spectra Extracted from RGB/IR Color Images

The space environment is detrimental to the exterior of the spacecraft and imposes stringent requirements on spacecraft materials. Space materials are often expected to perform for 15-20 years in the harsh space environment without significant degradation of their optical, electrical, mechanical and thermal properties. Further, as commercial activities increase in the space domain, development of predictive capability for material evolution is critical for agile adaption of novel materials. Therefore, it is very important to understand the effects of the space environments on the spacecraft materials. The Materials on the International Space Station Experiment Flight Facility (MISSE-FF) has flown numerous material samples to investigate the effect of LEO space weather exposure on the performance and durability of materials and devices. We are manifest on the MISSE-16 mission, scheduled to launch in June 2022, to fly fifteen novel and well-characterized materials in the LEO environment for a duration of six months. Changes in spectral reflectivity will be measured in real time throughout the mission with an RGB/IR camera. These time-resolved data will function as a "space-truth" reference for our team's ongoing laboratory-based space weather-material interaction experiments. Correlation of the MISSE-16 data with extensive ground testing of duplicate samples under simulated space weather conditions will enable development of fundamental chemical models for material degradation. This paper discusses preliminary results from the ground test campaign to collect the RGB/IR images for pristine and damaged materials and the development of machine learning algorithms to extract reflectance spectra from the color images.

Jainisha R. Shah↗
NASA NTRSDate not supplied

Spacecraft Material Characterization Using Reflectance Spectra Extracted from RGB/IR Color Images

The space environment is detrimental to the exterior of the spacecraft and imposes stringent requirements on spacecraft materials. Space materials are often expected to perform for 15-20 years in the harsh space environment without significant degradation of their optical, electrical, mechanical and thermal properties. Further, as commercial activities increase in the space domain, development of predictive capability for material evolution is critical for agile adaption of novel materials. Therefore, it is very important to understand the effects of the space environments on the spacecraft materials. The Materials on the International Space Station Experiment Flight Facility (MISSE-FF) has flown numerous material samples to investigate the effect of LEO space weather exposure on the performance and durability of materials and devices. We are manifest on the MISSE-16 mission, scheduled to launch in June 2022, to fly fifteen novel and well-characterized materials in the LEO environment for a duration of six months. Changes in spectral reflectivity will be measured in real time throughout the mission with an RGB/IR camera. These time-resolved data will function as a "space-truth" reference for our team's ongoing laboratory-based space weather-material interaction experiments. Correlation of the MISSE-16 data with extensive ground testing of duplicate samples under simulated space weather conditions will enable development of fundamental chemical models for material degradation. This paper discusses preliminary results from the ground test campaign to collect the RGB/IR images for pristine and damaged materials and the development of machine learning algorithms to extract reflectance spectra from the color images.

Jainisha R. Shah↗
NASA NTRS1989

An overview of charging environments

A brief synopsis of the natural environments that play a role in spacecraft charging is presented. Environments that cause both surface and internal charging are discussed along with the mechanisms involved. The geosynchronous and low altitude regions of the Earth's magnetosphere/ionosphere are considered and simple descriptions of each environment presented. As material properties are critical to the charging process, definition of material properties important to charging, which can be affected by the environment, are also described. Several space experiments are proposed that would help fill the gaps in the knowledge of the performance of materials in a charging environment.

Gabriel, S. B.↗
NASA NTRS2004

Ultralight Linerless Composite Tanks for In-Space Applications

NASA missions are becoming increasingly more demanding of propulsion capability, driving the mass of propulsion systems higher, even as the science mass of electronics is reduced. Typically, the propulsion tank is the single largest highest dry mass item of an in-space propulsion system. Ultralight linerless composite tanks (ULLCTs) promise to achieve the efficiencies that will make future propulsion systems viable and minimize propulsion system mass growth. ULLCTS may offer up to a 25 percent weight reduction compared to conventional metal lined composite overwrapped tanks, allowing increased reactant storage and/or reduced launch mass. For successful design of such a tank, the composite shell itself is required to provide an integral impermeable barrier, in addition to carrying the pressure and environmental loads for in-space propulsion. Significant materials technologies are required to achieve the microcrack resistance of the composites in order to contain small molecule gases such as helium (He). The goal is to develop a material that can limit the leakage rate of gaseous He to 10(exp -4) scc/sec at 1% biaxial strain level. The current paper details an integrated systematic approach to developing novel composite materials that can meet such performance requirements. It also explains how micromechanical models and material testing can be combined to define material performance indicators critical for designing an ULLCT, such as the material's resistance to microcracking and permeability.

lightweight propellant tanks↗
NASA NTRS1991

Development of high Tc (greater than 110K) Bi, Tl and Y-based materials as superconducting circuit elements

This report is presented in two parts. Part 1 deals primarily with Bi-based materials and a small amount of work on a Y-based composition while Part 2 covers work on Tl-based materials. In Part 1, a reliable and reproducible process for producing bulk bismuth-based superconductors has been developed. It is noted however, that a percentage of the tapecast material experiences curling and fracturing after a 30 hour sintering period and is thus in need of further examination. The Bi-Sr-Ca-Cu-O (BSCCO) material has been characterized by critical temperature data, X-ray diffraction data, and surface morphology. In the case of T sub c, it is not critical to anneal the material. It appears that the BSCCO material has the possibility of producing a better grounding strap than that of the 123 material. Attempts to reproduce near room temperature superconductors in the Y-Ba-Cu-O system were unsuccessful. In Part 2, several methods of processing the high temperature superconductor Tl2Ba2Ca2Cu3O10 were investigated; i.e., different precursor compositions were sintered at various sintering times and temperatures. The highest superconductig temperature was found to be 117.8K when fired at 900 C for three hours. Higher sintering temperatures produced a melted sample which was nonsuperconducting at liquid nitrogen temperature. Also, a preliminary study found Li2O substitutions for copper appeared to increase the transition temperature and create fluxing action upon sintering. It was suggested that lower sintering temperatures might be obtained with lithium additions to produce reliable Tl2Ba2Ca2Cu3O10 processing methods.

Haertling, Gene H.↗
NASA NTRSDate not supplied

Capturing, Analyzing, Maintaining, and Disseminating Shape Memory Material Data Between Information Management Systems

With an increased demand on reducing the time, cost, and effort to develop new materials, Integrated Computational Materials Engineering (ICME) has received widespread attention in various engineering disciplines as a catalyst for significantly reducing experimental testing during the material design process. An ICME approach to design can enable ‘fit-for-purpose’ materials to be realized in engineering applications by incorporating well-understood process-property-performance relationships between the various length and time scales in a material’s structure, enabling material optimization. However, such an approach requires validated multiscale models at the various length scales for a material, which in turn requires a large amount of data, a robust means of storing the data, and the ability to link data to developed material models. The NASA Vision 2040 [1] has identified nine key elements to enabling ICME approaches in system level design, with one being “Data, Information, and Visualization”, thus outlining the importance of a robust information management system for ICME. As the relationship between microstructure, properties, and material performance become better understood and incorporated into multiscale models that can be leveraged in application design, the emergence of new materials with application-driven properties can be realized. One such new material class that has seen growing attention are shape memory materials (SMM), in which a material can transition between a deformed and undeformed state via a reversible phase transformation when subject to a thermal, mechanical, or magnetic load [2]. SMMs have been used widely in aerospace and biomedical industries, including applications such as actuators, low-shock mechanisms, medical staples, braces, and stents [3, 4]. These materials exhibit unique behavior due to their ability to transition between phases, and thus the mechanisms that enable this transition must be captured in a data information management system and incorporated into SMM material models. At NASA Glenn Research Center, the Shape Memory Materials Database (SMMD) Tool has been developed to capture the necessary information that governs SMM material behavior and provide users the ability to select and visualize various SMMs for a specific application [5]. The database contains point-wise data for published SMM materials, along with the pedigree metadata for traceability necessary for a robust information management system. The database is also capable of storing in-house test data performed at NASA GRC by interacting with the developed Shape Memory Alloy (SMA) Analytics tool to extract the necessary point-wise values and populate the database. Although the SMMD Tool offers its users a single, authoritative source for SMM material data that is critical for model development and material design, the full material pedigree of the in-house test data for SMMs is not currently captured and is out of the scope for the SMMD tool. In this work, the schema for capturing SMM test data within the larger NASA GRC ICME Schema [6, 7, 8, 9] will be developed and implemented for thermomechanical tests conducted at NASA GRC. The developed schema will not only store the relevant data needed for the SMMD tool, but also the material pedigree (i.e., production of the bulk material, bulk material analysis, sample cut-out diagrams, sample fabrication procedure, etc.), test pedigree (i.e., test equipment used, measurement systems used, raw test data), and analysis pedigree (i.e., how the data in the SMMD tool is calculated). Furthermore, a Python-based framework will be developed to seamlessly interact between the SMA Analytics and SMMD tools, which will write the full dataset and associated metadata to the GRC Information Management System before passing the required point-wise data to the SMMD tool. Data informatics is a key element of the NASA Vision 2040, which requires not only that data is stored and maintained throughout the material lifecycle, but that the data is also accessible and reusable such that material development efforts can be minimized. Therefore, for an ICME design approach to be realized, a centralized information management system that drives the ICME process must be able to communicate with other databases. The work that will be presented in this presentation will therefore not only demonstrate the ability of NASA GRC’s information management system to capture SMM data, but also its ability to interact with pre-existing tools specialized for such materials.

Data management↗
NASA NTRSDate not supplied

Development of Additive Manufacturing Technologies for 3D Printing of Spacecraft Heat Shields

Introduction: Ablative heat shields are an enabling technology for entry into planetary atmospheres. From the PICA heatshields used for several Mars rovers to the carbon phenolic material used for Galileo’s Jupiter entry probe, the heat shield manages the heat load transferred to the payload, protecting the sensitive scientific instruments carried on entry probes. The Additive Manufacturing of Thermal Protection Systems (AMTPS) project, an Early Career Initiative (ECI) funded by NASA’s Space Technology Mission Directorate and led by NASA Johnson Space Center, seeks to develop materials and processes for 3D printing ablative heat shields for spacecraft. Current methods for producing ablative heat shields are extremely labor intensive and re-quire extensive hands-on processes and quality control characterization. Additive manufacturing (AM) offers the possibility of reduced production times, improved reliability, and enhanced performance via graded compositions. Costs will also be reduced by reducing the time and labor required for heat shield production. Direct integration of the heat shield onto the structure during processing simplifies integration and reduces risk. Material Development: A critical challenge for the project is development of a material system that can (1) be printed in a near-net shape process and (2) perform well as an ablator. Achieving printability requires the material to flow under applied pressure, but maintain its shape once extruded from the printer nozzle. Ablative performance is measured by a multitude of markers, including char yield, char strength, thermal conductivity, and recession rate. Furthermore, there are several mechanical and thermal property considerations for vehicle integration including coefficient of thermal expansion (CTE) and residual stress. AM technology will be leveraged to grade the material formulation and properties through the thickness of the heat shield, an architecture not possible with current manufacturing processes. To this end, “robust” material formulations have been pre-pared with higher density for use on the surface where most ablation will occur. “Insulative” material formulations, with lower density and lower thermal conductivity, are prepared for use in the depth of the heat shield. This graded architecture will re-duce the overall mass of the heat shield and reduce costs and/or increase scientific payload capacities. To achieve a material system with the required properties, multiple resins have been investigated in collaboration with NASA Ames Research Center. To tune printability and performance, resin additives were studied to improve flexibility of the cured material while maintaining acceptable ablative performance. Material coupons were printed and studied via a suite of mechanical and thermal characterization methods. Arc jet testing was conducted at NASA Ames Research Center to evaluate ablative performance and thermal protection under conditions expected in atmospheric entry. Manufacturing Scale-Up: A partnership with Oak Ridge National Laboratory (ORNL) aims to enable full-scale fabrication of a 3D printed heat shield. Leveraging expertise in manufacturing and 3D printing at ORNL, a mid-scale manufacturing demonstration unit will be built and tested, using a dual-layer ablative system printed directly onto the titanium structure. Work on robotic system integration is ongoing and efforts to scale up material mixing with a material compound will ensure accurate and homogenous composition. Flight Test: A hypersonic sub-orbital flight test will provide a rigorous test of material performance ranging from ablation, thermal management, and mechanical integrity. Design of the capsule has taken place in collaboration with the University of Kentucky. Data collected from the flight will inform future design efforts in material formulation, printing methodology, and heat shield-capsule integration.

additive manufacturing↗
NASA NTRSDate not supplied

Space Charge Analysis Capabilities for the Evaluation of High Voltage Insulation Materials

Materials development is crucial for the advancement of electric aviation. Current research focusing on novel multifunctional materials is underway to solve the needs for aerospace systems; however, additional testing of these materials to understand their failure modes is equally critical. This project will utilize pulsed electroacoustic (PEA) instrumentation to investigate space charge accumulation of multifunctional composites and other insulation materials critical to robust high power transmission systems. Evaluating the space charge phenomena in dielectric materials will provide unique and fundamentally necessary data to determine the feasibility and lifetime of any high voltage insulation system. When electrical charge is injected into a solid dielectric, charge can accumulate and become trapped, leading to the failure of the insulation via breakdown or arcing events. This study will discuss the pulsed electroacoustic methodology and its use on evaluating various dielectric polymer and composite films.

pulsed electroacoustic↗
NASA NTRS2004

Strategic Research Directions In Microgravity Materials Science

The Office of Biological and Physical Research (OBPR) is moving aggressively to align programs, projects, and products with the vision for space exploration. Research in advanced materials is a critical element in meeting exploration goals. Research in low gravity materials science in OBPR is being focused on top priority needs in support of exploration: 1) Space Radiation Shielding; 2) In Situ Resource Utilization; 3) In Situ Fabrication and Repair; 4) Materials Science for Spacecraft and Propulsion Systems; 5) Materials Science for Advanced Life Support Systems. Roles and responsibilities in low gravity materials research for exploration between OBPR and the Office of Exploration Systems are evolving.

Clinton, Raymond G., Jr.↗
NASA NTRS1996

The VTLA System of Course Delivery and Faculty Development in Materials Education

There is a national need for high-quality, upper division courses that address critical topics in materials synthesis, particularly those beyond the present expertise of the typical university department's faculty. A new project has been started to test a novel distance education and faculty development system, called Video Tape Live Audio (VTLA). This, if successful, would at once enlarge the national Materials Science and Engineering (MSE) student cohort studying material synthesis and develop faculty expertise at the receiving sites. The mechanics for the VTLA scheme are as follows: A course is designed in the field selected for emphasis and for which there is likely to be considerable demand, in this example 'Ceramic Materials Synthesis: Theory and Case Studies'. One of the very best researcher/teachers records lectures of TV studio quality with appropriate visuals. Universities and colleges which wish to offer the course agree to offer it at the same hour at least once a week. The videotaped lectures and accompanying text, readings and visuals are shipped to the professor in charge, who has an appropriate background. The professor arranges the classroom TV presentation equipment and supervises the course. Video lectures are played during regular course hours twice a week with time for discussion by the supervising professor. Typically the third weekly classroom period is scheduled by all sites at a common designated hour, during which the course author/presenter answers questions, provides greater depth, etc. on a live audio link to all course sites. Questions are submitted by fax and e-mail prior to the audio tutorial. coordinating professors at various sites have separate audio teleconferences at the beginning and end of the course, dealing with the philosophical and pedagogical approach to the course, content and mechanics. Following service once or twice as an 'apprentice' to the course, the coordinating professors may then offer it without the necessity of the live audio tutorial.

Berrettini, Robert↗
NASA NTRS2015

Metallography of Battery Resistance Spot Welds

Li-ion cells provide an energy dense solution for systems that require rechargeable electrical power. However, these cells can undergo thermal runaway, the point at which the cell becomes thermally unstable and results in hot gas, flame, electrolyte leakage, and in some cases explosion. The heat and fire associated with this type of event is generally violent and can subsequently cause damage to the surrounding system or present a dangerous risk to the personnel nearby. The space flight environment is especially sensitive to risks particularly when it involves potential for fire within the habitable volume of the International Space Station (ISS). In larger battery packs such as Robonaut 2 (R2), numerous Li-ion cells are placed in parallel-series configurations to obtain the required stack voltage and desired run-time or to meet specific power requirements. This raises a second and less obvious concern for batteries that undergo certification for space flight use: the joining quality at the resistance spot weld of battery cells to component wires/leads and battery tabs, bus bars or other electronic components and assemblies. Resistance spot welds undergo materials evaluation, visual inspection, conductivity (resistivity) testing, destructive peel testing, and metallurgical examination in accordance with applicable NASA Process Specifications. Welded components are cross-sectioned to ensure they are free of cracks or voids open to any exterior surface. Pore and voids contained within the weld zone but not open to an exterior surface, and are not determined to have sharp notch like characteristics, shall be acceptable. Depending on requirements, some battery cells are constructed of aluminum canisters while others are constructed of steel. Process specific weld schedules must be developed and certified for each possible joining combination. The aluminum canisters' positive terminals were particularly difficult to weld due to a bi-metal strip that comes ultrasonically pre-welded by the manufacturer. This was further complicated as the maximum electrode force was limited to low-electrode force to prevent deflection of the aluminum can during welding. Other Li-ion cells are comprised of smaller diameter cylindrical steel canisters which are inherently capable of handling greater force from the electrodes. Allowing higher-electrode forces aids greatly in insuring a consistent resistance network for the weld. Overall lessons learned: developing good jigs is critical to insure the parts and electrodes are planer to one another and the location of the weld sites remains accurate and repeatable; maintaining strict control over materials is critical--materials must be of a specific hardness and chemical composition to insure that a weld schedule is repeatable; accuracy of the die used to stamp the projections is critical and worth the investment; and proper seasoning of the electrodes is critical to producing consistent welds--once the electrodes have been properly seasoned, cleaning/dressing should be avoided until it is absolutely necessary.

Martinez, J. E.↗