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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS1989

COLD-SAT - An orbital cryogenic hydrogen technology experiment

The COLD-SAT spacecraft will perform subcritical liquid hydrogen storage and transfer experiments under low-gravity conditions to provide engineering data for future space transportation missions. Consisting of an experiment module mated to a spacecraft bus, COLD-SAT will be placed in an initial 460 km circular orbit by an Atlas I commercial launch vehicle. After deployment, the three-axis-controlled spacecraft bus will provide electric power, experiment control and data management, communications, and attitude control along with propulsive acceleration levels ranging from 10 (-6) to 10(-4) g. These accelerations are an important aspect of some of the experiments, as it is desired to know the effects that low gravity levels might have on the heat and mass transfer processes involved. The experiment module will contain the three liquid hydrogen tanks, valves, pressurization equipment, and instrumentation. At launch all the hydrogen will be in the largest tank, which has helium-purged MLI and is loaded and topped off by the hydrogen tanking system used for the Centaur upper stage of the Atlas. The two smaller tanks will be utilized in orbit for performing some of the experiments. The experiments are grouped into two classes on the basis of their priority, and include six regarded as enabling technology and nine regarded as enhancing technology.

Schuster, J. R.↗
NASA NTRS2001

Composite,Cryogenic, Conformal, Common Bulkhead, Aerogel-Insulated Tank (CBAT)

The objective of the Composite, Cryogenic, Conformal, Common Bulkhead, Aerogel-insulated Tank (CBAT) Program is to evaluate the potential for using various new technologies in next generation Reusable Launch Vehicles (RLVs) through design, fabrication, and testing of a subscale system. The new technologies include polymer matrix composites (PMCs), conformal propellant storage, common bulkhead packaging, and aerogel insulation. The National Aeronautics and Space Administration (NASA) and Thiokol Propulsion from Cordant Technologies are working together to develop a design and the processing methodologies which will allow integration of these technologies into a single structural component assembly. Such integration will significantly decrease subsystem weight and reduce shape, volume, and placement restrictions, thereby enhancing overall launch system performance. This paper/presentation focuses on the challenges related to materials and processes that were encountered and overcome during this program to date.

Roberts, J. K.↗
NASA NTRS1988

Ocean color observations of phytoplankton distributions and primary productivity

The primary goal of this activity is to develop the means to assess the mean and variability of phytoplankton biomass and primary productivity on global scales. There are three major approaches whose goals are to provide global scale observations. These are processing and analysis of the complete CZCS data set in a consistent manner; preparing science mission and project implementation plans for the SeaWiFS sensor to be launched on LANDSAT 6 in 1991; and providing guidance to EOS flight projects for ocean color observations using the MODIS sensor planned for the Polar Platform in the mid 1990's. This processing presents the first consistent view of phytoplankton pigments on global scales, and analysis of this temporally undersampled data set is proving very instructive in specifying mission requirements for SeaWiFS and future algorithm development.

Esaias, W.↗
NASA NTRS2013

Elevated Temperature, Notched Compression Performance of Out of Autoclave Processed Composites

Curved honeycomb sandwich panels composed of carbon fiber reinforced toughened-epoxy polymer facesheets are being evaluated for potential use as payload fairing components on the NASA heavy-lift space launch system (HL-SLS). These proposed composite sandwich panels provide the most efficient aerospace launch structures, and offer mass and thermal advantages when compared with existing metallic payload fairing structures. NASA and industry are investigating recently developed carbon fiber epoxy prepreg systems which can be fabricated using out-of autoclave (OOA) processes. Specifically, OOA processes using vacuum pressure in an oven and thereby significantly reducing the cost associated with manufacturing large (up to 10 m diameter) composite structures when compared with autoclave. One of these OOA composite material systems, CYCOM(R) 5320-1, was selected for manufacture of a 1/16th scale barrel portion of the payload fairing; such that, the system could be compared with the well-characterized prepreg system, CYCOM(R) 977-3, typically processed in an autoclave. Notched compression coupons for each material were obtained from the minimum-gauge flat laminate [60/-60/0]S witness panels produced in this manufacturing study. The coupons were also conditioned to an effective moisture equilibrium point and tested according to ASTM D6484M-09 at temperatures ranging from 25 C up to 177 C. The results of this elevated temperature mechanical characterization study demonstrate that, for thin coupons, the OHC strength of the OOA laminate was equivalent to the flight certified autoclave processed composite laminates; the limitations on the elevated temperature range are hot-wet conditions up to 163 C and are only within the margins of testing error. At 25 C, both the wet and dry OOA material coupons demonstrated greater OHC failure strengths than the autoclave processed material laminates. These results indicate a substantial improvement in OOA material development and processing since previous studies have consistently reported OOA material strengths on par or below those of autoclave processed composite laminates.

Grimsley, Brian W.↗
NASA NTRS2008

Final Report on Portable Laser Coating Removal Systems Field Demonstrations and Testing

Processes currently used throughout the National Aeronautics and Space Administration (NASA) to remove corrosion and coatings from structures, ground service equipment and small components results in waste streams consisting of toxic chemicals, spent media blast materials, and waste water. When chemicals are used in these processes they are typically high in volatile organic compounds (VOC) and are considered hazardous air pollutants (HAP). When blast media is used, the volume of hazardous waste generated is increased significantly. Many of the coatings historically used within NASA contain toxic metals such as hexavalent chromium, and lead. These materials are highly regulated and restrictions on worker exposure continue to increase. Most recently the EPA reduced the permissible exposure limit (PEL) for hexavalent chromium. The new standard lowers OSHA's PEL for hexavalent chromium from 52 to 5 micrograms of Cr(V1) per cubic meter of air as an 8-hour time-weighted average. Hexavalent chromium is found in the pretreatment and primer coatings used within the Shuttle Program. In response to the need to continue to protect assets within the agency and the growing concern over these new regulations, NASA is researching different ways to continue the required maintenance of both facility and flight equipment in a safe, efficient and environmentally preferable manner. The use of laser energy to remove prepare surfaces for a variety of processes, such as corrosion and coating removal, weld preparation and non destructive evaluation is a relatively new technology that has shown itself to be environmentally preferable and in many cases less labor intensive than currently used removal methods. The development of a Portable Laser Coating Removal System (PLCRS) started as the goal of a Joint Group on Pollution Prevention (JG-PP) project, led by the Air Force, where several types of lasers in several configurations were thoroughly evaluated. Following this project, NASA decided to evaluate the best performers on processes and coatings specific to the agency. Laser systems used during this project were all of a similar design, most of which had integrated vacuum systems in order to collect materials removed from substrate surfaces during operation. Due to the fact that the technology lends itself to a bide variety of processes, several site demonstrations were organized in order to allow for greater evaluation of the laser systems across NASA. The project consisted of an introductory demonstration and a more in-depth evaluation at Wright-Patterson Air Force Base. Additionally, field demonstrations occurred at Glenn Research Center and Kennedy Space Center. During these demonstrations several NASA specific applications were evaluated, including the removal of coatings within Orbiter tile cavities and Teflon from Space Shuttle Main Engine gaskets, removal of heavy grease from Solid Rocket Booster components and the removal of coatings on weld lines for Shuttle and general ground service equipment for non destructive evaluation (NDE). In addition, several general industry applications such as corrosion removal, structural coating removal, weld-line preparation and surface cleaning were evaluated. This included removal of coatings and corrosion from surfaces containing lead-based coatings and applications similar to launch-structure maintenance and Crawler maintenance. During the project lifecycle, an attempt was made to answer process specific concerns and questions as they arose. Some of these initially unexpected questions concerned the effects lasers might have on substrates used on flight equipment including strength, surface re-melting, substrate temperature and corrosion resistance effects. Additionally a concern was PPE required for operating such a system including eye, breathing and hearing protection. Most of these questions although not initially planned, were fully explored as a part of this project. Generally the results from tesng were very positive. Corrosion was effectively removed from steel, but less successfully from aluminum alloys. Coatings were able to be removed, with varying results, generally dark, matte and thin coatings were easier to remove. Steel and aluminum panels were able to be cleaned for welding, with no known deleterious effects and weld-lines were able to have coatings removed in critical areas for NDE while saving time as compared to other methods.

Rothgeb, Matthew J.↗
NASA NTRS2014

Environmentally Preferable Coatings for Structural Steel Project

The Ground Systems Development and Operations (GSDO) Program at NASA John F. Kennedy Space Center (KSC) has the primary objective of modernizing and transforming the launch and range complex at KSC to benefit current and future NASA programs along with other emerging users. Described a the "launch support and infrastructure modernization program" in the NASA Authorization Act of 2010, the GSDO Program will develop and implement shared infrastructure and process improvements to provide more flexible, affordable, and responsive capabilities to a multi-user community. In support of the GSDO Program, the objective of this project is to determine the feasibility of environmentally friendly corrosion resistant coatings for launch facilities and ground support equipment. The focus of the project is corrosion resistance and survivability with the goal to reduce the amount of maintenance required to preserve the performance of launch facilities while reducing mission risk. Number of facilities/structures with metallic structural and non-structural components in a highly corrosive environment. Metals require periodic maintenance activity to guard against the insidious effects of corrosion and thus ensure that structures meet or exceed design or performance life. The standard practice for protecting metallic substrates in atmospheric environments is the application of corrosion protective coating system.

Technology Portfolio System↗
NASA NTRS1986

Analysis of Jimsphere pairs for use in assessing Space Vehicle ascent capability

A data base of paired detailed wind profiles was developed for use in evaluating Shuttle Transportation System (STS) ascent capability. Since launch decision is based on a wind measured about 3.5 hr before launch, a data base of paired detailed profiles is needed. Method and technique on the reduction process and analysis is also presented. Guidelines used in selecting the pairs of profiles were established to insure a valid and representative data base. Sigma-U values for 3.5 hr at 12 km altitude show 8 percent increase from the transition case to the winter case and 18 percent decrease from the transition case to the summer case. Sigma-Values for 3.5 hr at 12 km altitude shows 12 percent increase from the transition case to the winter case and 17 percent decrease from the transition case to the summer case. A special feature of the 7- and 10.5-hr cases is that sigma-V increases by as much as 30 percent from the transition to the winter profiles. This large increase does not appear in the sigma-U data. Comparisons of the calculated values of 3.5 hr standard deviations of U and V with actual component deviations measured during space shuttle launch conditions confirm that the statistical values are representative.

Hill, C. K.↗
NASA NTRS2014

Development of Aluminum-Lithium 2195 Gores by the Stretch Forming Process

Aluminum-Lithium alloy 2195 exhibits higher mechanical properties and lower density than aluminum alloy 2219, which is the current baseline material for Space Launch System (SLS) cryogenic tank components. Replacement of Al 2219 with Al-Li 2195 would result in substantial weight savings, as was the case when this replacement was made on the shuttle external tank. A key component of cryogenic tanks are the gores, which are welded together to make the rounded ends of the tanks. The required thicknesses of these gores depend on the specific SLS configuration and may exceed the current experience base in the manufacture of such gores by the stretch forming process. Here we describe the steps taken to enhance the formability of Al-Li 2195 by optimizing the heat treatment and stretch forming processes for gore thicknesses up to 0.75", which envelopes the maximum expected gore thicknesses for SLS tanks. An annealing treatment, developed at Marshall Space Flight Center, increased the forming range and strain hardening exponent of Al-Li 2195 plates. Using this annealing treatment, one 0.525" thick and two 0.75" thick gores were manufactured by the stretch forming process. The annealing treatment enabled the stretch forming of the largest ever cross sectional area (thickness x width) of an Al-Li 2195 plate achieved by the manufacturer. Mechanical testing of the gores showed greater than expected ultimate tensile strength, yield strength, modulus, and elongation values. The gores also exhibited acceptable fracture toughness at room and LN2 temperatures. All of the measured data indicate that the stretch formed gores have sufficient material properties to be used in flight domes.

Volz, M. P.↗
NASA NTRS2014

Development of Aluminum-Lithium 2195 Gores by the Stretch Forming Process

Aluminum-Lithium alloy 2195 exhibits higher mechanical properties and lower density than aluminum alloy 2219, which is the current baseline material for Space Launch System (SLS) cryogenic tank components. Replacement of Al 2219 with Al-Li 2195 would result in substantial weight savings, as was the case when this replacement was made on the shuttle external tank. A key component of cryogenic tanks are the gores, which are welded together to make the rounded ends of the tanks. The required thicknesses of these gores depend on the specific SLS configuration and may exceed the current experience base in the manufacture of such gores by the stretch forming process. Here we describe the steps taken to enhance the formability of Al-Li 2195 by optimizing the heat treatment and stretch forming processes for gore thicknesses up to 0.75", which envelopes the maximum expected gore thicknesses for SLS tanks. An annealing treatment, developed at Marshall Space Flight Center, increased the forming range and strain hardening exponent of Al-Li 2195 plates. Using this annealing treatment, one 0.525" thick and two 0.75" thick gores were manufactured by the stretch forming process. The annealing treatment enabled the stretch forming of the largest ever cross sectional area (thickness x width) of an Al-Li 2195 plate achieved by the manufacturer. Mechanical testing of the gores showed greater than expected ultimate tensile strength, yield strength, modulus, and elongation values. The gores also exhibited acceptable fracture toughness at room and LN2 temperatures. All of the measured data indicate that the stretch formed gores have sufficient material properties to be used in flight domes.

Volz, M. P.↗
NASA NTRS1981

The capture of lunar materials in low lunar orbit

A scenario is presented for the retrieval of lunar materials sent into lunar orbit to be used as raw materials in space manufacturing operations. The proposal is based on the launch of material from the lunar surface by an electromagnetic mass driver and the capture of this material in low lunar orbit by a fleet of mass catchers which ferry the material to processing facilities when full. Material trajectories are analyzed using the two-body equations of motion, and intercept requirements and the sensitivity of the system to launch errors are determined. The present scenario is shown to be superior to scenarios that place a single mass catcher at the L2 libration point due to increased operations flexibility, decreased mass driver performance requirements and centralized catcher servicing.

Floyd, M. A.↗
NASA NTRS1993

New mission requirements methodologies for services provided by the Office of Space Communications

The Office of Space Communications, NASA Headquarters, has recently revised its methodology for receiving, accepting and responding to customer requests for use of that office's tracking and communications capabilities. This revision is the result of a process which has become over-burdened by the size of the currently active and proposed missions set, requirements reviews that focus on single missions rather than on mission sets, and negotiations most often not completed early enough to effect needed additions to capacity or capability prior to launch. The requirements-coverage methodology described is more responsive to project/program needs and provides integrated input into the NASA budget process early enough to effect change, and describes the mechanisms and tools in place to insure a value-added process which will benefit both NASA and its customers. Key features of the requirements methodology include the establishment of a mechanism for early identification of and systems trades with new customers, and delegates the review and approval of requirements documents to NASA centers in lieu of Headquarters, thus empowering the system design teams to establish and negotiate the detailed requirements with the user. A Mission Requirements Request (MRR) is introduced to facilitate early customer interaction. The expected result is that the time to achieve an approved set of implementation requirements which meet the customer's needs can be greatly reduced. Finally, by increasing the discipline in requirements management, through the use of base lining procedures, a tighter coupling between customer requirements and the budget is provided. A twice-yearly projection of customer requirements accommodation, designated as the Capacity Projection Plan (CPP), provides customer feedback allowing the entire mission set to be serviced.

Holmes, Dwight P.↗
NASA NTRS2000

New Alloys for Electroformed Replicated X-Ray Optics

The process of electroforming x-ray mirror shells off a superpolished mandrel has been widely used. The recently launched XMM mission is a good example of this, containing 174 such mirror shells of diameters ranging from 0.3-0.7 m and thicknesses of 0.47-1.07 mm. To continue to utilize this technique for the next generation of x-ray observatories, where ever-larger collecting areas will be required within the constraints of tight weight budgets, demands that new alloys be developed that can withstand the large stresses imposed on very thin shells by the replication and handling processes. Towards this end, we began a development program in late 1997 to produce a high-strength alloy suitable for electroforming very thin high-resolution x-ray optics. The requirements for this task are quite severe; not only must the electroformed deposit be very strong, it must also have extremely low residual stresses to prevent serious figure distortions in large thin-walled shells. Further, the electroforming must be performed at near room temperature, as large temperature changes will modify the figure of the mandrel, in an environment that is not corrosive for the mandrel. The figure of merit for the strength of the electroformed deposit is its Precision Elastic Limit (PEL). This is a measure of permanent strain, at the few parts per million level, under applied stress. Pure nickel is very ductile and will permanently deform, at the parts-per-million level under loads of a few x 10(exp 7) Pa. These stresses are easily exceeded when thin-walled shells (150 micron thick) are replicated. Our goal was to develop an alloy an order of magnitude stronger than this. We will present the results of our development program, showing the evolution of our plating baths through to our present 'glassy' nickel alloy that satisfies the goals above. For each we will show the electroforming characteristics of the bath and the PEL measurements for the resulting alloys. We estimate the ultimate limit on shell thickness and mass for x-ray mirrors produced in these baths.

Engelhaupt, D.↗
NASA NTRS1998

X-33 Telemetry Best Source Selection, Processing, Display, and Simulation Model Comparison

The X-33 program requires the use of multiple telemetry ground stations to cover the launch, ascent, transition, descent, and approach phases for the flights from Edwards AFB to landings at Dugway Proving Grounds, UT and Malmstrom AFB, MT. This paper will discuss the X-33 telemetry requirements and design, including information on fixed and mobile telemetry systems, best source selection, and support for Range Safety Officers. A best source selection system will be utilized to automatically determine the best source based on the frame synchronization status of the incoming telemetry streams. These systems will be used to select the best source at the landing sites and at NASA Dryden Flight Research Center to determine the overall best source between the launch site, intermediate sites, and landing site sources. The best source at the landing sites will be decommutated to display critical flight safety parameters for the Range Safety Officers. The overall best source will be sent to the Lockheed Martin's Operational Control Center at Edwards AFB for performance monitoring by X-33 program personnel and for monitoring of critical flight safety parameters by the primary Range Safety Officer. The real-time telemetry data (received signal strength, etc.) from each of the primary ground stations will also be compared during each nu'ssion with simulation data generated using the Dynamic Ground Station Analysis software program. An overall assessment of the accuracy of the model will occur after each mission. Acknowledgment: The work described in this paper was NASA supported through cooperative agreement NCC8-115 with Lockheed Martin Skunk Works.

Burkes, Darryl A.↗
NASA NTRS2005

Project LAUNCH: Bringing Space into Math and Science Classrooms

Project LAUNCH is a K-12 teacher professional development program, which has been created in collaboration between the Whitaker Center for Science, Mathematics and Technology Education at Florida Gulf Coast University (FGCU), and the Florida Space Research Institute (FSRI). Utilizing Space as the overarching theme it is designed to improve mathematics and science teaching, using inquiry based, hands-on teaching practices, which are aligned with Florida s Sunshine State Standards. Many students are excited about space exploration and it provides a great venue to get them involved in science and mathematics. The scope of Project LAUNCH however goes beyond just providing competency in the subject area, as pedagogy is also an intricate part of the project. Participants were introduced to the Conceptual Change Model (CCM) [1] as a framework to model good teaching practices. As the CCM closely follows what scientists call the scientific process, this teaching method is also useful to actively engage institute participants ,as well as their students, in real science. Project LAUNCH specifically targets teachers in low performing, high socioeconomic schools, where the need for skilled teachers is most critical.

Fauerbach, M.↗
NASA NTRS2011

InSAR Scientific Computing Environment

This computing environment is the next generation of geodetic image processing technology for repeat-pass Interferometric Synthetic Aperture (InSAR) sensors, identified by the community as a needed capability to provide flexibility and extensibility in reducing measurements from radar satellites and aircraft to new geophysical products. This software allows users of interferometric radar data the flexibility to process from Level 0 to Level 4 products using a variety of algorithms and for a range of available sensors. There are many radar satellites in orbit today delivering to the science community data of unprecedented quantity and quality, making possible large-scale studies in climate research, natural hazards, and the Earth's ecosystem. The proposed DESDynI mission, now under consideration by NASA for launch later in this decade, would provide time series and multiimage measurements that permit 4D models of Earth surface processes so that, for example, climate-induced changes over time would become apparent and quantifiable. This advanced data processing technology, applied to a global data set such as from the proposed DESDynI mission, enables a new class of analyses at time and spatial scales unavailable using current approaches. This software implements an accurate, extensible, and modular processing system designed to realize the full potential of InSAR data from future missions such as the proposed DESDynI, existing radar satellite data, as well as data from the NASA UAVSAR (Uninhabited Aerial Vehicle Synthetic Aperture Radar), and other airborne platforms. The processing approach has been re-thought in order to enable multi-scene analysis by adding new algorithms and data interfaces, to permit user-reconfigurable operation and extensibility, and to capitalize on codes already developed by NASA and the science community. The framework incorporates modern programming methods based on recent research, including object-oriented scripts controlling legacy and new codes, abstraction and generalization of the data model for efficient manipulation of objects among modules, and well-designed module interfaces suitable for command- line execution or GUI-programming. The framework is designed to allow users contributions to promote maximum utility and sophistication of the code, creating an open-source community that could extend the framework into the indefinite future.

Rosen, Paul A.↗
NASA NTRS2014

United States Nuclear Rocket Company (USNRC)

Historically, the development of advanced space technology has been accomplished by the federal government providing funding to commercial companies through the standard contracting process. Although recently, commercial space ventures, such as Space X, have begun to develop enhanced commercial space launch capabilities, and many companies provide space related services - including satellite development and operations, advanced technology development still requires (and should require) participation by the federal agency assigned this role - the National Aeronautics and Space Administration (NASA). However, this standard funding model may not be the most efficient and stable means of developing the advanced technology systems. And while the federal government does not need to be involved in areas where private industry can reasonably operate, it should remain the leader in supporting the development of new and advanced space technologies to further increase our national capability. And as these technologies mature, then private industry can begin the commercialization process, freeing up resources and funds for NASA to develop the next generations of advanced space technology. In fact, simply examining the last decades of space technology development shows that there is room for improvement. Part of the problem is that there are realistically two space frontiers. There is the commercialization frontier (the realm of Space X and others) and the exploratory frontier (the realm of NASA.). Often technologies that can support the exploratory frontier can also immediately support the commercialization frontier. Yet, these technologies are still developed under the standard model of federal funding and contracting. Is that really the best way to proceed? In this paper, the argument is put forward that a new process is required, a new paradigm. A consortium of federal agencies as well as commercial companies is needed - in a collaborative rather than a contractual relationship.

Hardin, L. A.↗
NASA NTRS1994

Application of statistical process control and process capability analysis procedures in orbiter processing activities at the Kennedy Space Center

Successful ground processing at KSC requires that flight hardware and ground support equipment conform to specifications at tens of thousands of checkpoints. Knowledge of conformance is an essential requirement for launch. That knowledge of conformance at every requisite point does not, however, enable identification of past problems with equipment, or potential problem areas. This paper describes how the introduction of Statistical Process Control and Process Capability Analysis identification procedures into existing shuttle processing procedures can enable identification of potential problem areas and candidates for improvements to increase processing performance measures. Results of a case study describing application of the analysis procedures to Thermal Protection System processing are used to illustrate the benefits of the approaches described in the paper.

Safford, Robert R.↗
NASA NTRS2015

Environmentally-Preferable Launch Coatings

The Ground Systems Development and Operations (GSDO) Program at NASA Kennedy Space Center (KSC), Florida, has the primary objective of modernizing and transforming the launch and range complex at KSC to benefit current and future NASA programs along with other emerging users. Described as the launch support and infrastructure modernization program in the NASA Authorization Act of 2010, the GSDO Program will develop and implement shared infrastructure and process improvements to provide more flexible, affordable, and responsive capabilities to a multi-user community. In support of NASA and the GSDO Program, the objective of this project is to determine the feasibility of environmentally friendly corrosion protecting coatings for launch facilities and ground support equipment (GSE). The focus of the project is corrosion resistance and survivability with the goal to reduce the amount of maintenance required to preserve the performance of launch facilities while reducing mission risk. The project compares coating performance of the selected alternatives to existing coating systems or standards.

ground support equipment↗