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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 109 records · Page 6

High Temperature Propulsion System Structural Seals for Future Space Launch Vehicles

Durable, flexible sliding seals are required in advanced hypersonic engines to seal the perimeters of movable engine ramps for efficient, safe operation in high heat flux environments at temperatures of 2000 to 2500 F. Current seal designs do not meet the demanding requirements for future engines, so NASA's Glenn Research Center is developing advanced seals and preloading devices to overcome these shortfalls. An advanced ceramic wafer seal design and two types of seal preloading devices were evaluated in a series of compression, scrub, and flow tests. Silicon nitride wafer seals survived 2000 in. (1000 cycles) of scrubbing at room temperature against an Inconel 625 rub surface with no chips or signs of damage. Flow rates measured for the wafers before and after scrubbing were almost identical and were much lower than those recorded for the best braided rope seal flow blockers. Canted coil springs and silicon nitride compression springs showed promise conceptually as potential seal preloading devices to help maintain seal resiliency. A finite element model of the canted coil spring revealed that it should be possible to produce a spring out of high temperature materials for applications at 2000+ F.

Dunlap, Patrick H., Jr.↗

Flame Resistant Foam

Solimide manufactured by Imi-Tech Corporation, is a lightweight fire resistant material produced under a manufacturing process that allows it to be uniformly foamed. Can be produced in a variety of densities and structural configurations and remains resilient under exposure to temperatures ranging from minus 300 to plus 500 degrees Fahrenheit. Is resistant to open flame and generates virtually no smoke or toxic by-products. Used in aircraft for its superior damping characteristics, lighter weight and fire barrier properties, it's also applicable to ships and surface transportation systems such as transit cars, trains, buses and automobiles.

Source record↗

Pressure Actuated Leaf Seals for Improved Turbine Shaft Sealing

This presentation introduces a shaft seal in which leaf seal elements are constructed from slotted shim material formed and layered into a frusto-conical assembly. Limited elastic deflection of seal leaves with increasing system pressure close large startup clearance to a small, non-contacting, steady state running clearance. At shutdown seal elements resiliently retract as differential seal pressure diminishes. Large seal clearance during startup and shutdown provides a mechanism for rub avoidance. Minimum operating clearance improves performance and non-contacting operation promises long seal life. Design features of this seal, sample calculations at differential pressures up to 2400 psid and benefit comparison with brush and labyrinth seals is documented in paper, AIAA 2005 3985, presented at the Advanced Seal Technology session of the Joint Propulsion Conference in Tucson this past July. In this presentation use of bimetallic leaf material will be discussed. Frictional heating of bimetallic leaf seals during a seal rub can relieve the rub condition to some extent with a change in seal shape. Improved leaf seal rub tolerance is expected with bimetallic material.

Grondahl, Clayton↗

A new family of fire-resistant foams

Need for lightweight flame-resistant, nonsmoking materials in interiors of spacecraft has spawned family of foams that could find applications in aircraft and other vehicles. Polyimide-based foams are being developed as resilient fillers for seat cushions, as rigid, low-density wall panels, as high-strength sheets for floors, and as thermal and acoustical insulation.

Gagliani, J.↗

Solid impingement erosion mechanisms and characterization of erosion resistance of ductile metals

Experimental results pertaining to spherical glass bead and angular crushed glass particle impingement are presented. A concept of energy adsorption to explain the failure of material is proposed. The erosion characteristics of several pure metals were correlated with the proposed energy parameters and with other properties. Correlations of erosion and material properties were also carried out with these materials to study the effect of the angle of impingement. Analyses of extensive erosion data indicate that surface energy, strain energy, melting point, bulk modulus, hardness, ultimate resilience, atomic volume and product of linear coefficient of thermal expansion, bulk modulus, and temperature rise required for melting, and ultimate resilience, and hardness exhibit the best correlations. It appears that both energy and thermal properties contribute to the total erosion.

Rao, V. P.↗

Holographic study of non-affine deformation in copper foam with a negative Poisson's ratio of -0.8

While conventional foams have positive Poisson's ratios (become smaller in cross-section when stretched and larger when compressed), foam materials have recently been defined which possess 'reentrant' cellular architectures; in these, inwardly-protruding cell ribs are responsible for negative Poisson's ratio behavior, yielding greater resilience than conventional foams. Double-exposure holographic interferometry is presently used to examine the microdeformation of a reentrant copper foam. Attention is given to the nonaffine (inhomogeneous) deformation of this foam.

Chen, C. P.↗

Expanding Space with Inflatable Softgoods: Roadmap for In-Space Manufacturing of Resilient Space Structures

Overview of inflatable softgoods and their emerging role in enabling large, resilient space habitats and infrastructure. It highlights the advantages of inflatable systems, such as exceptional packing efficiency and scalable habitable volume, while also addressing challenges related to outfitting, complex material behavior, structural design, manufacturing precision, and testing limitations. Core architectural elements of crewed inflatable habitats are described, along with shell layer composition, structural interfaces, and examples of conceptual habitat configurations for transit, lunar, and surface applications. The presentation concludes by outlining key technology shortfalls, including structural health monitoring, ultra‑high‑strength materials, lifetime performance, and integration strategies, emphasizing the need for continued development to support future in‑space manufacturing and exploration missions.

Habitat↗

Variable force, eddy-current or magnetic damper

An object of the invention is to provide variable damping for resonant vibrations which may occur at different rotational speeds in the range of rpms in which a rotating machine is operated. A variable force damper in accordance with the invention includes a rotating mass carried on a shaft which is supported by a bearing in a resilient cage. The cage is attached to a support plate whose rim extends into an annular groove in a housing. Variable damping is effected by tabs of electrically conducting nonmagnetic material which extend radially from the cage. The tabs at an index position lie between the pole face of respective C shaped magnets. The magnets are attached by cantilever spring members to the housing.

Cunningham, R. E.↗

Genesis Contingency Planning and Mishap Recovery: The Sample Curation View

Planning for sample preservation and curation was part of mission design from the beginning. One of the scientific objectives for Genesis included collecting samples of three regimes of the solar wind in addition to collecting bulk solar wind during the mission. Collectors were fabricated in different thicknesses for each regime of the solar wind and attached to separate frames exposed to the solar wind during specific periods of solar activity associated with each regime. The original plan to determine the solar regime sampled for specific collectors was to identify to which frame the collector was attached. However, the collectors were dislodged during the hard landing making identification by frame attachment impossible. Because regimes were also identified by thickness of the collector, the regime sampled is identified by measuring fragment thickness. A variety of collector materials and thin films applied to substrates were selected and qualified for flight. This diversity provided elemental measurement in more than one material, mitigating effects of diffusion rates and/or radiation damage. It also mitigated against different material and substrate strengths resulting in differing effects of the hard landing. For example, silicon crystal substrates broke into smaller fragments than sapphire-based substrates and diamond surfaces were more resilient to flying debris damage than gold. The primary responsibility of the curation team for recovery was process documentation. Contingency planning for the recovery phase expanded this responsibility to include not only equipment to document, but also gather, contain and identify samples from the landing area and the recovered spacecraft. The team developed contingency plans for various scenarios as part of mission planning that included topographic maps to aid in site recovery and identification of different modes of transport and purge capability depending on damage. A clean tent, set-up at Utah Test & Training Range to control the environment for processing the sample return capsule and cleanly installing a nitrogen purge to the canister, was used to control the environment for extracting collector fragments from the damaged canister and to document and package over 10,000 collector fragments.

Stansbery, E. K.↗

Advances in Integrally Formed Metallic Structures

NASA Langley Research Center (LaRC) is applying flow forming technology to aerospace aluminum alloys for the manufacture of integrally stiffened cylinders that meet aircraft fuselage or launch vehicle specifications. High-strength 2xxx series alloys, in various temper/product form conditions, are being compared with medium-strength, very formable AA 6061 as the benchmark. Screening of candidate materials traditionally relies on empirical forming trials, but more recently on metrics derived from constant nominal strain rate tensile testing. In this work, the established hierarchy of formability metrics is adopted as the baseline; tensile area reduction, work hardening exponent, and modulus of resilience. The suite of metrics can be expanded based on phenomenological and mechanistic considerations of plastic flow instabilities to incorporate anisotropy ratio, rate of work hardening, and dynamic strain aging effects. Separate research thrusts at LaRC are aimed at formulating a protocol for scalable production of fully formed, defect-free components: 1) quantifying the extended set of formability metrics from constant and jump strain rate tensile tests with digital image correlation (DIC); 2) using statistically designed experiments on a vertical spin/flow forming facility (WF VUD-600®) to isolate the effect of convenient process variables, such as axial feed rate and thickness reduction; and 3) predicting the effect of feed ratio (roller translation relative to mandrel rotation speeds) on material response via process modeling using the DEFORM® simulation software. Current results will be discussed in terms of correlating intrinsic material properties with the bulk workability characteristics to successfully fabricate cylinders with complex cross-sections.

Aluminum↗

Resilient Flexible Pressure-Activated Seal

A resilient, flexible, pressure-activated, high-temperature seal is adapted to be interposed between high and low pressure regions to provide sealing between opposing surfaces of adjacent relatively movable structures. The seal comprises at least one C-shaped sheet element. The C-shaped element design enables the seal to be pressure-activated to provide a radially outward biasing force, responsive to a seal-activating pressure differential acting across the seal thereby increasing resiliency. A centrally-located, resilient core structure provides load bearing and insulating properties. In an exemplary embodiment where at least two seal elements are used, each layer has a cutout slot pattern and the remaining strip material pattern. The slots provide flexibility to the seal, enabling the seal to be manually contoured to seal around corners and curves. The strip material of each layer covers the slots in each adjacent layer to minimize leakage through the slots. Attached barrier strips can block interface leakage between the seal and the opposing surfaces.

Steinetz, Bruce M.↗

Surface Evaluation by XPS of High Performance Foams After Exposure to Oxygen Plasma

This report will present the results of a study done during a 10-week summer faculty fellowship during the summer of 2001 working with Ms. Martha Williams of the Testbeds Group at Kennedy Space Center. The work was in a new area for this faculty and was both interesting and enjoyable. An imide is a compound in which nitrogen is bonded directly to an R group and to two other R groups through carbonyls. Polyimides have a number of properties that make them highly desirable materials for use on structures that are exposed to extreme conditions. They are strong, fire resistant, minimally outgasing, stable over a large temperature range, resistant to chemical attack, transparent to infrared and microwaves, and have a low density. One polyimide, solimide, commercially available as a foam, retains resiliency from -300 F to +500 F, is highly flame retardant, and decomposes with virtually no smoke or toxic byproduct formation. The density of this product is such that its use in place of fiberglass in the lower lobe of a 747 saves 400 lb. Shipboard applications have resulted in literally tons of weight reduction. While polyimide films have been used in structures to be placed in low earth orbit (LEO) for many years, polyimide foams have found only minimal application in this realm. NASA Langley Research Center has developed new technology that allows for the processing of new polyimide foams. The resulting increased availability of these materials, along with their highly desirable properties, has prompted a study to determine the suitability of these materials for use in structures to be placed in LEO.

Hampton, Michael D.↗

A Comparison of Materials Issues for Cermet and Graphite-Based NTP Fuels

This paper compares material issues for cermet and graphite fuel elements. In particular, two issues in NTP fuel element performance are considered here: ductile to brittle transition in relation to crack propagation, and orificing individual coolant channels in fuel elements. Their relevance to fuel element performance is supported by considering material properties, experimental data, and results from multidisciplinary fluid/thermal/structural simulations. Ductile to brittle transition results in a fuel element region prone to brittle fracture under stress, while outside this region, stresses lead to deformation and resilience under stress. Poor coolant distribution between fuel element channels can increase stresses in certain channels. NERVA fuel element experimental results are consistent with this interpretation. An understanding of these mechanisms will help interpret fuel element testing results.

Nuclear Propulsion↗

The Effect of Electrolyte Additives upon the Lithium Kinetics of Li-Ion Cells Containing MCMB and LiNi(x)Co(1-x)O2 Electrodes and Exposed to High Temperatures

With the intent of improving the performance of lithium-ion cells at high temperatures, we have investigated the use of a number of electrolyte additives in experimental MCMB- Li(x)Ni(y)Co(1-y)O2 cells, which were exposed to temperatures as high as 80 C. In the present work, we have evaluated the use of a number of additives, namely vinylene carbonate (VC), dimethyl acetamide (DMAc), and mono-fluoroethylene carbonate (FEC), in an electrolyte solution anticipated to perform well at warm temperature (i.e., 1.0M LiPF6 in EC+EMC (50:50 v/v %). In addition, we have explored the use of novel electrolyte additives, namely lithium oxalate and lithium tetraborate. In addition to determining the capacity and power losses at various temperatures sustained as a result of high temperature cycling (cycling performed at 60 and 80 C), the three-electrode MCMB-Li(x)Ni(y)Co(1-y)O2 cells (lithium reference) enabled us to study the impact of high temperature storage upon the solid electrolyte interphase (SEI) film characteristics on carbon anodes (MCMB-based materials), metal oxide cathodes, and the subsequent impact upon electrode kinetics.

High Temperture Resilience↗

The Enigmatic Longevity of Granular Materials on Mars: The Case for Geologically Episodic Dune Formation

Martian sand dunes are concentrated in vast sand seas in the circumpolar belt of the planet's northern hemisphere, but they are also pervasive over the whole planet. Their occurrence is to be expected on a super-arid planetary surface subjected to boundary layer drag from a continually active atmosphere. Whilst their occurrence is to be expected, their survival is enigmatic. But the enigma only arises if the martian system is considered similar to Earth's --where sand is moved highly frequently, more or less on a seasonal basis. Experimentally it is readily demonstrated that active sand will soon wear down to small grains and eventually diminish to below the critical sand size required to sustain dune formation. According to conventional wisdom, sand moves at higher speeds on Mars than on Earth, and if it were to move as frequently as it does on Earth, then the dune-forming sand population should have long since disappeared, given the great longevity of the martian aeolian system (Sagan coined the term "kamikaze" grains to express this disappearance). No supply of sand could keep pace with this depletion, especially in light of the fact that Mars does not have very active weathering, nor significant crustal differentiation. On Earth, plate tectonics, magmatic activity, and general crustal differentiation over geological time have produced great concentrations of quartz crystals in the continental crustal masses. Not only are these quartz grains chemically and mechanically resilient, they are about the right size for being transported by either wind or water. Add to this, the geologically recent contribution of glacial grinding, and it is easy to see why there are dune field on Earth. So what are the martian dunes composed of, and how does the material survive the eons of attrition? In addition to experimental demonstrations of sand comminution in laboratory aeolian simulations, the problem can be approached from first principles. Sagan showed that by simple considerations of material strength versus mechanical work applied to the material, comminution to sub-sand size would be inevitable. Another semi-analytical approach might be taken by considering that the archetypal aeolian sand surface texture is an irregularly pitted ("frosted") surface composed of chipping hollows approximately 10 microns in diameter, 5 microns deep. Their volume = about 250 cubic microns, or about 1/25000 of the volume of a 100 micron diameter dune grain. Because a saltating grain always strikes another grain, then two surfaces are impacted. Thus each grain undergoes two impacts for every one saltation leap, when the impact statistics are considered for a closed dune system (it can be calculated that a grain can never undergo <1 impact, and never >2 per saltation leap). Hence, if we conservatively assume that there is damage to a grain each time it bounces, but with the minimum damage of only 2 microscopic craters per impact, then approximately 12,500 impacts are required to completely eliminate the grain. Of course, it would require only a fraction of this amount to reduce the grain to below sand size. A grain will make only several tens of saltation leaps on the stoss side of a dune before becoming buried on the lee slope. The dune then has to move its full length before the grain is exhumed again for abrasion. Even with this hiatus in transport, it is easy to see that terrestrial dunes need resupplying with sand in order to survive. In recent theoretical work it has been shown that martian aeolian transport may be initiated with high-speed grains, but this converts to a lower energy dynamic transport equilibrium in which a reptation population dominates grain transport (on Earth, at least half of the flux is by reptation and creep). On Mars, therefore, average grain speeds may be lower than those on Earth, or at least comparable. This would permit greater longevity for martian sands, but it would not go far enough to solve the survival problem. It may, however, explain why martian dunes are about the same size as terrestrial dunes. If martian saltation leaps were significantly longer than on Earth (as usually assumed), then a dune's lee slope would have to be correspondingly longer in order to trap the sand; this would scale up the whole dune structure. But with shorter trajectories in a reptation population, larger dunes would be unnecessary. Additional information is contained in the original.

Marshall, J.↗

Cyclic tests of P-bulb end-seal designs for a shuttle-type wing-elevon cove membrane seal

Four P-bulb end seal designs were tested at room temperature in a cyclic seal test apparatus. Test results show that all the P-bulb end seals have the durability required for a 100 mission life (neglecting possible elevated-temperature effects) and three of the four P-bulbs provide an adequate seal against a 7.0-kPa air pressure differential. Antifriction material attached to the P-bulb rub surface reduced friction slightly but could degrade the sealing effectiveness. A flat rub surface molded into the P-bulb discouraged wrinkling and rolling and thereby reduced leakage. However, the P-bulbs lacked resilience, as indicated by increased leakage when P-bulb compression was reduced. The best P-bulb design tested included an antifriction interface bonded to a flat surface molded into the P-bulb.

Hunt, L. R.↗

Apparatus for disintegrating kidney stones

The useful life of the wire probe in an ultrasonic kidney stone disintegration instrument is enhanced and prolonged by attaching the wire of the wire probe to the tip of an ultrasonic transducer by means of a clamping arrangement. Additionally, damping material is applied to the wire probe in the form of a damper tube through which the wire probe passes in the region adjacent the transducer tip. The damper tube extends outwardly from the transducer tip a predetermined distance, terminating in a resilient soft rubber joint. Also, the damper tube is supported intermediate its length by a support member. The damper system thus acts to inhibit lateral vibrations of the wire in the region of the transducer tip while providing little or no damping to the linear vibrations imparted to the wire by the transducer.

Angulo, E. D.↗

Modeling Off-Nominal Behavior in SysML

Specification and development of fault management functionality in systems is performed in an ad hoc way - more of an art than a science. Improvements to system reliability, availability, safety and resilience will be limited without infusion of additional formality into the practice of fault management. Key to the formalization of fault management is a precise representation of off-nominal behavior. Using the upcoming Soil Moisture Active-Passive (SMAP) mission for source material, we have modeled the off-nominal behavior of the SMAP system during its initial spin-up activity, using the System Modeling Language (SysML). In the course of developing these models, we have developed generic patterns for capturing off-nominal behavior in SysML. We show how these patterns provide useful ways of reasoning about the system (e.g., checking for completeness and effectiveness) and allow the automatic generation of typical artifacts (e.g., success trees and FMECAs) used in system analyses.

fault protection↗