Search NASA⌕ Search

SEARCH · Search NASA

Results for “LIGHTWEIGHT”

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 NTRS2003

Superalloy Lattice Block Developed for Use in Lightweight, High-Temperature Structures

Successful development of advanced gas turbine engines for aircraft will require lightweight, high-temperature components. Currently titanium-aluminum- (TiAl) based alloys are envisioned for such applications because of their lower density (~4 g/cm3) in comparison to superalloys (~8.5 g/cm3), which have been utilized for hot turbine engine parts for over 50 years. However, a recently developed concept (lattice block) by JAMCORP, Inc., of Willmington, Massachusetts, would allow lightweight, high-temperature structures to be directly fabricated from superalloys and, thus, take advantage of their well-known, characterized properties. In its simplest state, lattice block is composed of thin ligaments arranged in a three dimensional triangulated trusslike configuration that forms a structurally rigid panel. Because lattice block can be fabricated by casting, correctly sized hardware is produced with little or no machining; thus very low cost manufacturing is possible. Together, the NASA Glenn Research Center and JAMCORP have extended their lattice block methodology for lower melting materials, such as Al alloys, to demonstrate that investment casting of superalloy lattice block is possible. This effort required advances in lattice block pattern design and assembly, higher temperature mold materials and mold fabrication technology, and foundry practice suitable for superalloys (ref. 1). Lattice block panels have been cast from two different Ni-base superalloys: IN 718, which is the most commonly utilized superalloy and retains its strength up to 650 C; and MAR M247, which possesses excellent mechanical properties to at least 1100 C. In addition to the open-cell lattice block geometry, same-sized lattice block panels containing a thin (~1-mm-thick) solid face on one side have also been cast from both superalloys. The elevated-temperature mechanical properties of the open cell and face-sheeted superalloy lattice block panels are currently being examined, and the microstructure is being characterized in terms of casting defects. In addition, a small study (ref. 3) is being undertaken with GE Aircraft Engines to determine the suitability of superalloy lattice block for engine components.

Hebsur, Mohan G.↗
NASA NTRS2004

Vibration Characteristics Determined for Stainless Steel Sandwich Panels With a Metal Foam Core for Lightweight Fan Blade Design

The goal of this project at the NASA Glenn Research Center is to provide fan materials that are safer, weigh less, and cost less than the currently used titanium alloy or polymer matrix composite fans. The proposed material system is a sandwich fan construction made up of thin solid face sheets and a lightweight metal foam core. The stiffness of the sandwich structure is increased by separating the two face sheets by the foam layer. The resulting structure has a high stiffness and lighter weight in comparison to the solid facesheet material alone. The face sheets carry the applied in-plane and bending loads (ref. 1). The metal foam core must resist the transverse shear and transverse normal loads, as well as keep the facings supported and working as a single unit. Metal foams have ranges of mechanical properties, such as light weight, impact resistance, and vibration suppression (ref. 2), which makes them more suitable for use in lightweight fan structures. Metal foams have been available for decades (refs. 3 and 4), but the difficulties in the original processes and high costs have prevented their widespread use. However, advances in production techniques and cost reduction have created a new interest in this class of materials (ref. 5). The material chosen for the face sheet and the metal foam for this study was the aerospace-grade stainless steel 17-4PH. This steel was chosen because of its attractive mechanical properties and the ease with which it can be made through the powder metallurgy process (ref. 6). The advantages of a metal foam core, in comparison to a typical honeycomb core, are material isotropy and the ease of forming complex geometries, such as fan blades. A section of a 17-4PH sandwich structure is shown in the following photograph. Part of process of designing any blade is to determine the natural frequencies of the particular blade shape. A designer needs to predict the resonance frequencies of a new blade design to properly identify a useful operating range. Operating a blade at or near the resonance frequencies leads to high-cycle fatigue, which ultimately limits the blade's durability and life. So the aim of this study is to determine the variation of the resonance frequencies for an idealized sandwich blade as a function of its face-sheet thickness, core thickness, and foam density. The finite element method is used to determine the natural frequencies for an idealized rectangular sandwich blade. The proven Lanczos method (ref. 7) is used in the study to extract the natural frequency.

Ghosn, Louis J.↗
NASA NTRS2005

Mechanically Strong Lightweight Materials for Aerospace Applications (x-aerogels)

The X-Aerogel is a new NASA-developed strong lightweight material made by reacting the mesoporous surfaces of 3-D networks of inorganic nanoparticles with polymeric crosslinkers. Since the relative amount of the crosslinker and the backbone are comparable, X-Aerogels can be viewed either as aerogels modified by templated accumulation of polymer on the skeletal nanoparticles, or as nanoporous polymers made by templated casting of polymeric precursors on a nanostructured framework. The most striking feature of X-Aerogels is that for a nominal 3-fold increase in density (still a ultralightweight material), the mechanical strength can be up to 300 times higher than the strength of the underlying native aerogel. Thus, X-Aerogels combine a multiple of the specific compressive strength of steel, with the thermal conductivity of styrofoam. XAerogels have been demonstrated with several polymers such as polyurethanes/polyureas, epoxies and polyolefins, while crosslinking of approximately 35 different oxide aerogels yields a wide variety of dimensionally stable, porous lightweight materials with interesting structural, magnetic and optical properties. X-Aerogels are evaluated for cryogenic rocket fuel storage tanks and for Advanced EVA suits, where they will play the dual role of the thermal insulator/structural material. Along the same lines, major impact is also expected by the use of X-Aerogels in structural components/thermal protection for small satellites, spacecrafts, planetary vehicles and habitats.

Leventis, Nicholas↗
NASA NTRS2006

Rapid Fabrication of Lightweight SiC Optics using Reactive Atom Plasma (RAP) Processing

Reactive Atom Plasma (RAP) processing is a non-contact, plasma-based processing technology that can be used to generate damage-free optical surfaces. We have developed tools and processes using RAP that allow us to shape extremely lightweight mirror Surfaces made from extremely hard-to-machine materials (e.g. SiC). We will describe our latest results using RAP in combination with other technologies to produce finished lightweight SiC mirrors and also discuss applications for RAP in the rapid fabrication of mirror segments for reflective and grazing incidence telescopes.

Fiske, Peter S.↗
NASA NTRS2004

Compact, Lightweight Dual- Frequency Microstrip Antenna Feed for Future Soil Moisture and Sea Surface Salinity Missions

The development of a compact, lightweight, dual frequency antenna feed for future soil moisture and sea surface salinity (SSS) missions is described. The design is based on the microstrip stacked-patch array (MSPA) to be used to feed a large lightweight deployable rotating mesh antenna for spaceborne L-band (approx. 1 GHz) passive and active sensing systems. The design features will also enable applications to airborne sensors operating on small aircrafts. This paper describes the design of stacked patch elements, 16-element array configuration and power-divider beam forming network The test results from the fabrication of stacked patches and power divider were also described.

sea surface salinity↗
NASA NTRS2006

Compact, Lightweight Dual-Frequency Microstrip Antenna Feed for Future Soil Moisture and Sea Surface Salinity Missions

The development of a compact, lightweight, dual-frequency antenna feed for future soil moisture and sea surface salinity (SSS) missions is described. The design is based on the microstrip stacked-patch array (MSPA) to be used to feed a large lightweight deployable rotating mesh antenna for spaceborne L-band (approx.1 GHz) passive and active sensing systems. The design features will also enable applications to airborne soil moisture and salinity remote sensing sensors operating on small aircrafts. This paper describes the design of stacked patch elements and 16-element array configuration. The results from the return loss, antenna pattern measurements and sky tests are also described.

microstrip antennas↗
NASA NTRS2007

Strong, Lightweight, Porous Materials

A new class of strong, lightweight, porous materials has been invented as an outgrowth of an effort to develop reinforced silica aerogels. The new material, called X-Aerogel is less hygroscopic, but no less porous and of similar density to the corresponding unmodified aerogels. However, the property that sets X-Aerogels apart is their mechanical strength, which can be as much as two and a half orders of magnitude stronger that the unmodified aerogels. X-Aerogels are envisioned to be useful for making extremely lightweight, thermally insulating, structural components, but they may also have applications as electrical insulators, components of laminates, catalyst supports, templates for electrode materials, fuel-cell components, and filter membranes.

Leventis, Nicholas↗
NASA NTRS2011

Overview of Lightweight Structures for Rotorcraft Engines and Drivetrains

This is an overview presentation of research being performed in the Advanced Materials Task within the NASA Subsonic Rotary Wing Project. This research is focused on technology areas that address both national goals and project goals for advanced rotorcraft. Specific technology areas discussed are: (1) high temperature materials for advanced turbines in turboshaft engines; (2) polymer matrix composites for lightweight drive system components; (3) lightweight structure approaches for noise and vibration control; and (4) an advanced metal alloy for lighter weight bearings and more reliable mechanical components. An overview of the technology in each area is discussed, and recent accomplishments are presented.

Roberts, Gary D.↗
NASA NTRS2006

Lightweight, Segmented, Mostly Silicon Telescope Mirror

A document presents the concept of a curved telescope primary reflector structure, made mostly of silicon, that would have an areal mass density 1 kg/m2 and would be deployed in outer space, where it would be operated at a temperature in the cryogenic range. The concept provides for adjustment of the shape of the mirror to maintain the required precise optical surface figure despite the flexibility inherent in the ultra-lightweight design. The structure would include a thin mirror layer divided into hexagonal segments supported by flexure hinges on a lightweight two-layer backing structure. Each segment would also be supported at three points by sets of piezoelectric linear microactuators that could impose small displacements along the optical axis. The excitations applied to the aforementioned microactuators would be chosen to effect fine adjustments of the axial positions and the orientations of the segments relative to the supporting structure. Other piezoelectric linear microactuators embedded in the backing structure would enable control of the displacements of the segments along the hexagonal axes; they would also enable control of the curvature of the backing structure and, thus, additional control of the curvature of the reflector.

Yang, Eui-Hyeok↗
NASA NTRS2011

Recent Developments in the Design, Capabilities and Autonomous Operations of a Lightweight Surface Manipulation System and Test-bed

The first generation of a versatile high performance device for performing payload handling and assembly operations on planetary surfaces, the Lightweight Surface Manipulation System (LSMS), has been designed and built. Over the course of its development, conventional crane type payload handling configurations and operations have been successfully demonstrated and the range of motion, types of operations and the versatility greatly expanded. This enhanced set of 1st generation LSMS hardware is now serving as a laboratory test-bed allowing the continuing development of end effectors, operational techniques and remotely controlled and automated operations. This paper describes the most recent LSMS and test-bed development activities, that have focused on two major efforts. The first effort was to complete a preliminary design of the 2nd generation LSMS that has the capability for limited mobility and can reposition itself between lander decks, mobility chassis, and fixed base locations. A major portion of this effort involved conducting a study to establish the feasibility of, and define, the specifications for a lightweight cable-drive waist joint. The second effort was to continue expanding the versatility and autonomy of large planetary surface manipulators using the 1st generation LSMS as a test-bed. This has been accomplished by increasing manipulator capabilities and efficiencies through both design changes and tool and end effector development. A software development effort has expanded the operational capabilities of the LSMS test-bed to include; autonomous operations based on stored paths, use of a vision system for target acquisition and tracking, and remote command and control over a communications bridge.

Dorsey, John T.↗
NASA NTRS2011

Advances in the Lightweight Air-Liquid Composite Heat Exchanger Development for Space Exploration Applications

An advanced, lightweight composite modular Air/Liquid (A/L) Heat Exchanger (HX) Prototype for potential space exploration thermal management applications was successfully designed, manufactured, and tested. This full-scale Prototype consisting of 19 modules, based on recommendations from its predecessor Engineering Development unit (EDU) but with improved thermal characteristics and manufacturability, was 11.2 % lighter than the EDU and achieves potentially a 42.7% weight reduction from the existing state-of-the-art metallic HX demonstrator. However, its higher pressure drop (0.58 psid vs. 0.16 psid of the metal HX) has to be mitigated by foam material optimizations and design modifications including a more systematic air channel design. Scalability of the Prototype design was validated experimentally by comparing manufacturability and performance between the 2-module coupon and the 19-module Prototype. The Prototype utilized the thermally conductive open-cell carbon foam material but with lower density and adopted a novel high-efficiency cooling system with significantly increased heat transfer contact surface areas, improved fabricability and manufacturability compared to the EDU. Even though the Prototype was required to meet both the thermal and the structural specifications, accomplishing the thermal requirement was a higher priority goal for this first version. Overall, the Prototype outperformed both the EDU and the corresponding metal HX, particularly in terms of specific heat transfer, but achieved 93.4% of the target. The next generation Prototype to achieve the specification target, 3,450W would need 24 core modules based on the simple scaling factor. The scale-up Prototype will weigh about 14.7 Kg vs. 21.6 Kg for the metal counterpart. The advancement of this lightweight composite HX development from the original feasibility test coupons to EDU to Prototype is discussed in this paper.

Shin, E. Eugene↗
NASA NTRS2005

Lightweight Thermal Insulation for a Liquid-Oxygen Tank

A proposed lightweight, reusable thermal-insulation blanket has been designed for application to a tank containing liquid oxygen, in place of a non-reusable spray-on insulating foam. The blanket would be of the multilayer-insulation (MLI) type and equipped with a pressure-regulated nitrogen purge system. The blanket would contain 16 layers in two 8-layer sub-blankets. Double-aluminized polyimide 0.3 mil (.0.008 mm) thick was selected as a reflective shield material because of its compatibility with oxygen and its ability to withstand ionizing radiation and high temperature. The inner and outer sub-blanket layers, 1 mil (approximately equals 0.025 mm) and 3 mils (approximately equals 0.076 mm) thick, respectively, would be made of the double-aluminized polyimide reinforced with aramid. The inner and outer layers would provide structural support for the more fragile layers between them and would bear the insulation-to-tank attachment loads. The layers would be spaced apart by lightweight, low-thermal-conductance netting made from polyethylene terephthalate.

Willen, G. Scott↗
NASA NTRS2004

Lightweight, Self-Deploying Foam Antenna Structures

Lightweight, deployable antennas for a variety of outer-space and terrestrial applications would be designed and fabricated according to the concept of cold hibernated elastic memory (CHEM) structures, according to a proposal. Mechanically deployable antennas now in use are heavy, complex, and unreliable, and they utilize packaging volume inefficiently. The proposed CHEM antenna structures would be simple and would deploy themselves without need for any mechanisms and, therefore, would be more reliable. The proposed CHEM antenna structures would also weigh less, could be packaged in smaller volumes, and would cost less, relative to mechanically deployable antennas. The CHEM concept was described in two prior NASA Tech Briefs articles: "Cold Hibernated Elastic Memory (CHEM) Expandable Structures" (NPO-20394), Vol. 23, No. 2 (February 1999), page 56; and "Solar Heating for Deployment of Foam Structures" (NPO-20961), Vol. 25, No. 10 (October 2001), page 36. To recapitulate from the cited prior articles: The CHEM concept is one of utilizing opencell foams of shape-memory polymers (SMPs) to make lightweight, reliable, simple, and inexpensive structures that can be alternately (1) compressed and stowed compactly or (2) expanded, then rigidified for use. A CHEM structure is fabricated at full size from a block of SMP foam in its glassy state [at a temperature below the glass-transition temperature (Tg) of the SMP]. The structure is heated to the rubbery state of the SMP (that is, to a temperature above Tg) and compacted to a small volume. After compaction, the structure is cooled to the glassy state of the SMP. The compacting force can then be released and the structure remains compact as long as the temperature is kept below Tg. Upon subsequent heating of the structure above Tg, the simultaneous elastic recovery of the foam and its shape-memory effect cause the structure to expand to its original size and shape. Once thus deployed, the structure can be rigidified by cooling below Tg. Once deployed and rigidified, the structure could be heated and recompacted. In principle, there should be no limit on the achievable number of compaction/deployment/ rigidification cycles. Thus far, several different designs of a 3.5-m-long CHEM conical corrugated horn antenna have been analyzed (see figure). A small CHEM structural antenna model was fabricated and a thin, electrically conductive layer of aluminum was deposited on the inner surface of the model. This structural model was then subjected to the compaction and deployment treatments described above to demonstrate the feasibility of a CHEM corrugated horn antenna.

Sokolowski, Witold↗
NASA NTRS2004

Lightweight Deployable Mirrors with Tensegrity Supports

The upper part of Figure 1 shows a small-scale prototype of a developmental class of lightweight, deployable structures that would support panels in precise alignments. In this case, the panel is hexagonal and supports disks that represent segments of a primary mirror of a large telescope. The lower part of Figure 1 shows a complete conceptual structure containing multiple hexagonal panels that hold mirror segments. The structures of this class are of the tensegrity type, which was invented five decades ago by artist Kenneth Snelson. A tensegrity structure consists of momentfree compression members (struts) and tension members (cables). The structures of this particular developmental class are intended primarily as means to erect large segmented primary mirrors of astronomical telescopes or large radio antennas in outer space. Other classes of tensegrity structures could also be designed for terrestrial use as towers, masts, and supports for general structural panels. An important product of the present development effort is the engineering practice of building a lightweight, deployable structure as an assembly of tensegrity modules like the one shown in Figure 2. This module comprises two octahedral tensegrity subunits that are mirror images of each other joined at their plane of mirror symmetry. In this case, the plane of mirror symmetry is both the upper plane of the lower subunit and the lower plane of the upper subunit, and is delineated by the midheight triangle in Figure 2. In the configuration assumed by the module to balance static forces under mild loading, the upper and lower planes of each sub-unit are rotated about 30 , relative to each other, about the long (vertical) axis of the structure. Larger structures can be assembled by joining multiple modules like this one at their sides or ends. When the module is compressed axially (vertically), the first-order effect is an increase in the rotation angle, but by virtue of the mirror arrangement, the net first-order rotation between the uppermost and lowermost planes is zero. The need to have zero net rotation between these planes under all loading conditions in a typical practical structure is what prompts the use of the mirror configuration. Force and moment loadings other than simple axial compression produce only second-order deformations through strains in the struts and cables.

Zeiders, Glenn W.↗
NASA NTRS2011

High Angular Resolution and Lightweight X-Ray Optics for Astronomical Missions

X-ray optics with both high angular resolution and lightweight is essential for further progress in x-ray astronomy. High angular resolution is important in avoiding source confusion and reducing background to enable the observation of the most distant objects of the early Universe. It is also important in enabling the use of gratings to achieve high spectral resolution to study, among other things, the myriad plasmas that exist in planetary, stellar, galactic environments, as well as interplanetary, inter-stellar, and inter-galactic media. Lightweight is important for further increase in effective photon collection area, because x-ray observations must take place on space platforms and the amount of mass that can be launched into space has always been very limited and is expected to continue to be very limited. This paper describes an x-ray optics development program and reports on its status that meets these two requirements. The objective of this program is to enable Explorer type missions in the near term and to enable flagship missions in the long term.

Zhang, W. W.↗
NASA NTRS2011

Lightweight High Efficiency Electric Motors for Space Applications

Lightweight high efficiency electric motors are needed across a wide range of space applications from - thrust vector actuator control for launch and flight applications to - general vehicle, base camp habitat and experiment control for various mechanisms to - robotics for various stationary and mobile space exploration missions. QM Power?s Parallel Path Magnetic Technology Motors have slowly proven themselves to be a leading motor technology in this area; winning a NASA Phase II for "Lightweight High Efficiency Electric Motors and Actuators for Low Temperature Mobility and Robotics Applications" a US Army Phase II SBIR for "Improved Robot Actuator Motors for Medical Applications", an NSF Phase II SBIR for "Novel Low-Cost Electric Motors for Variable Speed Applications" and a DOE SBIR Phase I for "High Efficiency Commercial Refrigeration Motors" Parallel Path Magnetic Technology obtains the benefits of using permanent magnets while minimizing the historical trade-offs/limitations found in conventional permanent magnet designs. The resulting devices are smaller, lower weight, lower cost and have higher efficiency than competitive permanent magnet and non-permanent magnet designs. QM Power?s motors have been extensively tested and successfully validated by multiple commercial and aerospace customers and partners as Boeing Research and Technology. Prototypes have been made between 0.1 and 10 HP. They are also in the process of scaling motors to over 100kW with their development partners. In this paper, Parallel Path Magnetic Technology Motors will be discussed; specifically addressing their higher efficiency, higher power density, lighter weight, smaller physical size, higher low end torque, wider power zone, cooler temperatures, and greater reliability with lower cost and significant environment benefit for the same peak output power compared to typically motors. A further discussion on the inherent redundancy of these motors for space applications will be provided.

Robertson, Glen A.↗
NASA NTRS2012

LEGION: Lightweight Expandable Group of Independently Operating Nodes

LEGION is a lightweight C-language software library that enables distributed asynchronous data processing with a loosely coupled set of compute nodes. Loosely coupled means that a node can offer itself in service to a larger task at any time and can withdraw itself from service at any time, provided it is not actively engaged in an assignment. The main program, i.e., the one attempting to solve the larger task, does not need to know up front which nodes will be available, how many nodes will be available, or at what times the nodes will be available, which is normally the case in a "volunteer computing" framework. The LEGION software accomplishes its goals by providing message-based, inter-process communication similar to MPI (message passing interface), but without the tight coupling requirements. The software is lightweight and easy to install as it is written in standard C with no exotic library dependencies. LEGION has been demonstrated in a challenging planetary science application in which a machine learning system is used in closed-loop fashion to efficiently explore the input parameter space of a complex numerical simulation. The machine learning system decides which jobs to run through the simulator; then, through LEGION calls, the system farms those jobs out to a collection of compute nodes, retrieves the job results as they become available, and updates a predictive model of how the simulator maps inputs to outputs. The machine learning system decides which new set of jobs would be most informative to run given the results so far; this basic loop is repeated until sufficient insight into the physical system modeled by the simulator is obtained.

Burl, Michael C.↗
NASA NTRS2012

Precise Alignment and Permanent Mounting of Thin and Lightweight X-ray Segments

To provide observations to support current research efforts in high energy astrophysics. future X-ray telescope designs must provide matching or better angular resolution while significantly increasing the total collecting area. In such a design the permanent mounting of thin and lightweight segments is critical to the overall performance of the complete X-ray optic assembly. The thin and lightweight segments used in the assemhly of the modules are desigued to maintain and/or exceed the resolution of existing X-ray telescopes while providing a substantial increase in collecting area. Such thin and delicate X-ray segments are easily distorted and yet must be aligned to the arcsecond level and retain accurate alignment for many years. The Next Generation X-ray Optic (NGXO) group at NASA Goddard Space Flight Center has designed, assembled. and implemented new hardware and procedures mth the short term goal of aligning three pairs of X-ray segments in a technology demonstration module while maintaining 10 arcsec alignment through environmental testing as part of the eventual design and construction of a full sized module capable of housing hundreds of X-ray segments. The recent attempts at multiple segment pair alignment and permanent mounting is described along with an overview of the procedure used. A look into what the next year mll bring for the alignment and permanent segment mounting effort illustrates some of the challenges left to overcome before an attempt to populate a full sized module can begin.

Biskach, Michael P.↗