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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
NASA NTRS1998

Key Issues for Aerospace Applications of Ceramic Matrix Composites

Ceramic matrix composites (CMC) offer significant advantages for future aerospace applications including turbine engine and liquid rocket engine components, thermal protection systems, and "hot structures". Key characteristics which establish ceramic matrix composites as attractive and often enabling choices are strength retention at high temperatures and reduced weight relative to currently used metallics. However, due to the immaturity of this class of materials which is further compounded by the lack of experience with CMC's in the aerospace industry, there are significant challenges involved in the development and implementation of ceramic matrix composites into aerospace systems. Some of the more critical challenges are attachment and load transfer methodologies; manufacturing techniques, particularly scale up to large and thick section components; operational environment resistance; damage tolerance; durability; repair techniques; reproducibility; database availability; and the lack of validated design and analysis tools. The presentation will examine the technical issues confronting the application of ceramic matrix composites to aerospace systems and identify the key material systems having potential for substantial payoff relative to the primary requirements of light weight and reduced cost for future systems. Current programs and future research opportunities will be described in the presentation which will focus on materials and processes issues.

Clinton, R. G., Jr.↗
NASA NTRS2001

A Two-Stage-to-Orbit Spaceplane Concept With Growth Potential

A two-stage-to-orbit (TSTO) spaceplane concept developed in 1993 is revisited, and new information is provided to assist in the development of the next-generation space transportation vehicles. The design philosophy, TSTO spaceplane concept, and the design method are briefly described. A trade study between cold and hot structures leads to the choice of cold structures with external thermal protection systems. The optimal Mach number for staging the second stage of the TSTO spaceplane (with air-breathing propulsion on the first stage) is 10, based on life-cycle cost analysis. The performance and specification of a prototype/experimental (P/X) TSTO spaceplane with a turbo/ram/scramjet propulsion system and built-in growth potential are presented and discussed. The internal rate of return on investment is the highest for the proposed TSTO spaceplane, vis-A-vis a single-stage-to-orbit (SSTO) rocket vehicle and a TSTO spaceplane without built-in growth. Additional growth potentials for the proposed spaceplane are suggested. This spaceplane can substantially decrease access-to-space cost and risk, and increase safety and reliability in the near term It can be a serious candidate for the next-generation space transportation system.

Mehta, Unmeel B.↗
NASA NTRS2003

Carbon Fiber Reinforced Ceramic Composites for Propulsion Applications

Fiber reinforced ceramic composites are materials of choice for gas turbine engines because of their high thermal efficiency, thrust/weight ratio, and operating temperatures. However, the successful introduction of ceramic composites to hot structures is limited because of excessive cost of manufacturing, reproducibility, nonuniformity, and reliability. Intense research is going on around the world to address some of these issues. The proposed effort is to develop a comprehensive status report of the technology on processing, testing, failure mechanics, and environmental durability of carbon fiber reinforced ceramic composites through extensive literature study, vendor and end-user survey, visits to facilities doing this type of work, and interviews. Then develop a cooperative research plan between NASA GRC and NCA&T (Center for Composite Materials Research) for processing, testing, environmental protection, and evaluation of fiber reinforced ceramic composites.

Freedman, Marc↗
NASA NTRS2003

X-37 and Our Future in Space: Breaking Barriers to Achieve New Milestones in Space Settlement

The X-37 flight demonstrator will serve as a testbed and technology demonstrator for a variety of aerospace technologies needed to produce a successor to the Space Shuttle. Lithium-ion (Li-ion) batteries, thermal protection systems, and hot structures such as flaperons and ruddervators are systems onboard the X-37 which will be of particular use to this effort. This viewgraph presentation identifies stakeholders and participants in the X-37 flight demonstrator program and includes a section of notes which correspond to each of its slides.

Sexton, Jeff↗
NASA NTRS2005

Learning Lessons from the X-37 Project

The X-37 was planned as an automated vehicle capable of flight-testing new aerospace technologies in combined environments that are beyond the capability of existing ground or flight platforms. Flight demonstration with the X-37 architecture and configuration in relevant environments was planned to reduce the risk of developing launch vehicle technologies for sustainable, affordable exploration and other aerospace applications. Current plans are for the X-37 Approach and Landing Test Vehicle (ALTV) to be atmospheric tested in 2005 from Scaled Composite's White Knight carrier aircraft at up to 40,000 feet over California's Mojave Spaceport, with and turnaround maintenance performed. The fight Operations Control Center will conduct the mission, using a streamlined operations concept. Taxi-tow and captive-carry tests will be conducted prior to the atmospheric-test series. Sponsored by the Defense Advanced Research Projects Agency (DARPA) with NASA participation, technical objectives are to: (1) mature Computed Air Data System/Remote Pressure Sensor technology, (2) manage energy during Terminal Area Energy Management/Heading Alignment Cone maneuvers, and (3) validate the aerodatabase. The X-37 Project began in 1999 under a cooperative agreement as an element of NASA's Future X Program and transitioned to a NASA Research Announcement under the Space Launch Initiative. In mid-2004, NASA transferred ownership to DARPA, with its heritage of performing high-risk, high-payoff research and development. NASA contributes technical expertise, including risk analysis and system integration. The Boeing Company is the prime contractor, with nationwide suppliers. This recent partnership exemplifies the synergy attainable when NASA Centers, other Government agencies, and industry work together toward a common goal - contributing to the knowledge base for U.S. exploration and other aerospace endeavors. The X-37 team represents a range of space transportation disciplines - from engineering to management. Some members have been with the project since its inception. All have gained priceless experience during the design, manufacturing, and testing of the ALTV, as well as through developing advanced orbital flight technologies, such as state-of-the-art Thermal Protection Systems and hot structures. Throughout this process, the X-37 Project team captures lessons that are directly applicable to other such efforts. The upcoming ALTV flights offer another dimension of data and first-hand experience that will prove invaluable to those designing new generations of reusable spacecraft. And ongoing technology developments will expand the aerospace knowledge base. Delivering prototype hardware is always a risky proposition. During the course of the X-37 effort, the team has experienced many challenging opportunities, delivering significant accomplishments and learning numerous lessons in the process. The ability to manage the risk landscape is key to overcoming obstacles, especially technical hurdles that are encountered in progressing hardware from design to flight. The approach to managing risk under this partnership is evolving but, in general, the team allocates resources to reduce the likelihood of severe-consequence risks, thus maximizing mission success and ensuring that the X-37 Project delivers value to its stakeholders. As the team sharpens its focus on operations, it continues to contribute knowledge to those who would undertake high-risk, high-payoff research and development and provides valuable experience to implement the exploration vision.

Turner, Susan↗
NASA NTRS2005

Learning Lessons from the X-37 Project

The X-37 was planned as an automated vehicle capable of flight-testing new aerospace technologies in combined environments that are beyond the capability of existing ground or flight platforms. Flight demonstration with the X-37 architecture and configuration in relevant environments was planned to reduce the risk of developing launch vehicle technologies for sustainable, affordable exploration and other aerospace applications. Current plans are for the X-37 Approach and Landing Test Vehicle (ALTV) to be atmospheric tested in 2005 from Scaled Composite s White Knight carrier aircraft at up to 40,000 feet over California's Mojave Spaceport, with landing and turnaround maintenance performed. The Flight Operations Control Center will conduct the mission, using a streamlined operations concept. Taxi-tow and captive-carry tests will be conducted prior to the atmospheric-test series. Sponsored by the Defense Advanced Research Projects Agency (DARPA) with NASA participation, technical objectives are to: (1) mature Computed Air Data System/Remote Pressure Sensor technology, (2) manage energy during Terminal Area Energy Management/Heading Alignment Cone maneuvers, and (3) validate the aerodatabase. The X-37 Project began in 1999 under a cooperative agreement as an element of NASA's Future X Program and transitioned to a NASA Research Announcement under the Space Launch Initiative. In mid-2004, NASA transferred ownership to DARPA, with its heritage of performing high-risk, high-payoff research and development (R&D). NASA contributes technical expertise, including risk analysis and system integration. The Boeing Company is the prime contractor, with nationwide suppliers. This partnership exemplifies the synergy attainable when NASA Centers, other Government agencies, and industry work together toward a common goal - contributing to the knowledge base for U.S. exploration and other aerospace endeavors. The X-37 team represents a range of space transportation disciplines - from engineering to management. Some members have been with the project since its inception. All have gained priceless experience during the design, manufacturing, and testing of the ALTV, as well as through developing advanced orbital flight technologies, such as state-of-the-art Thermal Protection Systems and hot structures. Throughout this process, the X-37 Project team captures lessons that are directly applicable to other such efforts. The upcoming ALTV flights offer another dimension of data and first-hand experience that will prove invaluable to those designing new generations of reusable spacecraft. And ongoing technology developments will expand the aerospace knowledge base. Delivering prototype hardware is always a risky proposition. During the course of this effort, the X-37 team has experienced many challenging opportunities, delivering significant accomplishments and learning numerous lessons in the process. The ability to manage the risk landscape is key to overcoming obstacles, especially technical hurdles that are encountered in progressing hardware from design to flight. The approach to managing risk under this partnership is evolving but, in general, the team allocates resources to reduce the likelihood of severe-consequence risks, thus maximizing mission success and ensuring that the X-37 Project delivers value to its stakeholders. As the team sharpens its focus on operations, it continues to contribute knowledge to those who would undertake high-risk, high-payoff R&D and provides valuable experience to implement the Vision for Space Exploration.

Turner, Susan↗
NASA NTRS2006

Aerocapture Technology Development for Planetary Science - Update

Within NASA's Science Mission Directorate is a technological program dedicated to improving the cost, mass, and trip time of future scientific missions throughout the Solar System. The In-Space Propulsion Technology (ISPT) Program, established in 2001, is charged with advancing propulsion systems used in space from Technology Readiness Level (TRL) 3 to TRL6, and with planning activities leading to flight readiness. The program's content has changed considerably since inception, as the program has refocused its priorities. One of the technologies that has remained in the ISPT portfolio through these changes is Aerocapture. Aerocapture is the use of a planetary body's atmosphere to slow a vehicle from hyperbolic velocity to a low-energy orbit suitable for science. Prospective use of this technology has repeatedly shown huge mass savings for missions of interest in planetary exploration, at Titan, Neptune, Venus, and Mars. With launch vehicle costs rising, these savings could be the key to mission viability. This paper provides an update on the current state of the Aerocapture technology development effort, summarizes some recent key findings, and highlights hardware developments that are ready for application to Aerocapture vehicles and entry probes alike. Description of Investments: The Aerocapture technology area within the ISPT program has utilized the expertise around NASA to perform Phase A-level studies of future missions, to identify technology gaps that need to be filled to achieve flight readiness. A 2002 study of the Titan Explorer mission concept showed that the combination of Aerocapture and a Solar Electric Propulsion system could deliver a lander and orbiter to Titan in half the time and on a smaller, less expensive launch vehicle, compared to a mission using chemical propulsion for the interplanetary injection and orbit insertion. The study also identified no component technology breakthroughs necessary to implement Aerocapture on such a mission. Similar studies of Aerocapture applications at Neptune, Venus, and Mars were studied in 2003 through 2005. All showed significant performance improvements for the missions studied. Findings from these studies were used to guide the technology development tasks originally solicited in a 2002 NASA ROSS Research Announcement. The tasks are now in their final year and have provided numerous improvements in modeling and hardware, for use in proposals or new mission starts. Major Accomplishments: Since validation of the Aerocapture maneuver requires a space flight, ground developments have focused on modeling and environment prediction, materials, and sensors. Lockheed Martin has designed and built a 2-meter Carbon-Carbon aeroshell "hot structure." The article utilizes co-cured stiffening ribs and advanced insulation to achieve large scale, and up to a 40% reduction in areal density over the Genesis probe construction. This concept would be an efficient solution for probes that experience heat rates near 800-1000 W/cm(exp 2), such as at Venus and Earth. Applied Research Associates has extensively tested a family of efficient ablative TPS materials that provide solutions for a range of heating conditions. These materials are being applied to high-temperature structures built by ATK Space Systems, led by Langley Research Center. One-meter aeroshells will be thermally tested to validate construction and demonstrate higher bondline temperatures, which can lead to mass savings of up to 30% over traditional heatshields. Ames Research Center has developed aeroshell instrumentation that could measure environmental conditions and material performance during atmospheric entry. Instruments to measure TPS recession, heat flux, and catalycity could be combined with traditional sensors to provide a "plug-and-play" system for minimal mass and power, that would acquire flight data for model improvement and risk reduction on future missions. Improved atmospheric and aerothermodynamic models ha also been a major focus of the program. Next Steps: Aerocapture is one of five technologies in competition for a flight validation opportunity through the New Millennium Program. If selected, a fully autonomous vehicle will perform an Aerocapture at Earth in 2010, and flight data will be used to validate the guidance system and the TPS material for science mission infusion.

Munk, Michelle M.↗
NASA NTRS2006

SACD's Support of the Hyper-X Program

NASA s highly successful Hyper-X program demonstrated numerous hypersonic air-breathing vehicle related technologies including scramjet performance, advanced materials and hot structures, GN&C, and integrated vehicle performance resulting in, for the first time ever, acceleration of a vehicle powered by a scramjet engine. The Systems Analysis and Concepts Directorate (SACD) at NASA s Langley Research Center played a major role in the integrated team providing critical support, analysis, and leadership to the Hyper-X Program throughout the program s entire life and were key to its ultimate success. Engineers in SACD s Vehicle Analysis Branch (VAB) were involved in all stages and aspects of the program, from conceptual design prior to contract award, through preliminary design and hardware development, and in to, during, and after each of the three flights. Working closely with other engineers at Langley and Dryden, as well as industry partners, roughly 20 members of SACD were involved throughout the evolution of the Hyper-X program in nearly all disciplines, including lead roles in several areas. Engineers from VAB led the aerodynamic database development, the propulsion database development, and the stage separation analysis and database development effort. Others played major roles in structures, aerothermal, GN&C, trajectory analysis and flight simulation, as well as providing CFD support for aerodynamic, propulsion, and aerothermal analysis.

Robinson, Jeffrey S.↗
NASA NTRS2006

Materials Development for Hypersonic Flight Vehicles

The DARPA/Air Force Falcon program is planning to flight test several hypersonic technology vehicles (HTV) in the next several years. A Materials Integrated Product Team (MIPT) was formed to lead the development of key thermal protection system (TPS) and hot structures technologies. The technologies being addressed by the MIPT are in the following areas: 1) less than 3000 F leading edges, 2) greater than 3000 F refractory composite materials, 3) high temperature multi-layer insulation, 4) acreage TPS, and 5) high temperature seals. Technologies being developed in each of these areas are discussed in this paper.

Glass, David E.↗
NASA NTRS2007

Aerocapture Technology Developments from NASA's In-Space Propulsion Technology Program

This paper will explain the investment strategy, the role of detailed systems analysis, and the hardware and modeling developments that have resulted from the past 5 years of work under NASA's In-Space Propulsion Program (ISPT) Aerocapture investment area. The organizations that have been funded by ISPT over that time period received awards from a 2002 NASA Research Announcement. They are: Lockheed Martin Space Systems, Applied Research Associates, Inc., Ball Aerospace, NASA's Ames Research Center, and NASA's Langley Research Center. Their accomplishments include improved understanding of entry aerothermal environments, particularly at Titan, demonstration of aerocapture guidance algorithm robustness at multiple bodies, manufacture and test of a 2-meter Carbon-Carbon "hot structure," development and test of evolutionary, high-temperature structural systems with efficient ablative materials, and development of aerothermal sensors that will fly on the Mars Science Laboratory in 2009. Due in large part to this sustained ISPT support for Aerocapture, the technology is ready to be validated in flight.

Munk, Michelle M.↗
NASA NTRS2008

Aerocapture Technology Development Overview

This paper will explain the investment strategy, the role of detailed systems analysis, and the hardware and modeling developments that have resulted from the past 5 years of work under NASA's In-Space Propulsion Program (ISPT) Aerocapture investment area. The organizations that have been funded by ISPT over that time period received awards from a 2002 NASA Research Announcement. They are: Lockheed Martin Space Systems, Applied Research Associates, Inc., Ball Aerospace, NASA s Ames Research Center, and NASA s Langley Research Center. Their accomplishments include improved understanding of entry aerothermal environments, particularly at Titan, demonstration of aerocapture guidance algorithm robustness at multiple bodies, manufacture and test of a 2-meter Carbon-Carbon "hot structure," development and test of evolutionary, high-temperature structural systems with efficient ablative materials, and development of aerothermal sensors that will fly on the Mars Science Laboratory in 2009. Due in large part to this sustained ISPT support for Aerocapture, the technology is ready to be validated in flight.

Munk, Michelle M.↗
NASA NTRS2008

High-Temperature Strain Sensing for Aerospace Applications

Thermal protection systems (TPS) and hot structures are utilizing advanced materials that operate at temperatures that exceed abilities to measure structural performance. Robust strain sensors that operate accurately and reliably beyond 1800 F are needed but do not exist. These shortcomings hinder the ability to validate analysis and modeling techniques and hinders the ability to optimize structural designs. This presentation examines high-temperature strain sensing for aerospace applications and, more specifically, seeks to provide strain data for validating finite element models and thermal-structural analyses. Efforts have been made to develop sensor attachment techniques for relevant structural materials at the small test specimen level and to perform laboratory tests to characterize sensor and generate corrections to apply to indicated strains. Areas highlighted in this presentation include sensors, sensor attachment techniques, laboratory evaluation/characterization of strain measurement, and sensor use in large-scale structures.

Piazza, Anthony↗
NASA NTRS2013

Testing of DLR C/C-SiC for HIFiRE 8 Scramjet Combustor

Ceramic Matrix Composites (CMCs) have been proposed for hot structures in scramjet combustors. Previous studies have calculated significant weight savings by utilizing CMCs (active and passive) versus actively cooled metallic scramjet structures. Both a C/C and a C/C-SiC material system fabricated by DLR (Stuttgart, Germany) are being considered for use in a passively cooled combustor design for HIFiRE 8, a joint Australia / AFRL hypersonic flight program, expected to fly at Mach 7 for approximately 30 sec, at a dynamic pressure of 55 kPa. Flat panels of the DLR C/C and the C/C-SiC were tested in the NASA Langley Direct Connect Rig (DCR) at Mach 5 and Mach 6 enthalpy for several minutes. Gaseous hydrogen fuel was used to fuel the scramjet combustor. The test panels were instrumented with embedded Type K and Type S thermocouples. Zirconia felt insulation was used in some of the tests to increase the surface temperature of the C/C-SiC panel for approximately 350degF. The final C/C-SiC panel was tested for 3 cycles totaling over 135 sec at Mach 6 enthalpy. Slightly more erosion was observed on the C/C panel than the C/C-SiC panels, but both material systems demonstrated acceptable recession performance for the HIFiRE 8 flight.

Glass, David E.↗
NASA NTRS2014

Testing of DLR C/C-SiC and C/C for HIFiRE 8 Scramjet Combustor

Ceramic Matrix Composites (CMCs) have been proposed for use as lightweight hot structures in scramjet combustors. Previous studies have calculated significant weight savings by utilizing CMCs (active and passive) versus actively cooled metallic scramjet structures. Both a carbon/carbon (C/C) and a carbon/carbon-silicon carbide (C/C-SiC) material fabricated by DLR (Stuttgart, Germany) are being considered for use in a passively cooled combustor design for Hypersonic International Flight Research Experimentation (HIFiRE) 8, a joint Australia / Air Force Research Laboratory hypersonic flight program, expected to fly at Mach 7 for approximately 30 sec, at a dynamic pressure of 55 kilopascals. Flat panels of the DLR C/C and C/C-SiC materials were installed downstream of a hydrogen-fueled, dual-mode scramjet combustor and tested for several minutes at conditions simulating flight at Mach 5 and Mach 6. Gaseous hydrogen fuel was used to fuel the scramjet combustor. The test panels were instrumented with embedded Type K and Type S thermocouples. Zirconia felt insulation was used during some of the tests to reduce heat loss from the back surface and thus increase the heated surface temperature of the C/C-SiC panel approximately 177 C (350 F). The final C/C-SiC panel was tested for three cycles totaling over 135 sec at Mach 6 enthalpy. Slightly more erosion was observed on the C/C panel than the C/C-SiC panels, but both material systems demonstrated acceptable recession performance for the HIFiRE 8 flight.

Glass, David E.↗
NASA NTRS2015

Update on CMH-17 Volume 5: Ceramic Matrix Composites

CMC components are projected to enter service in commercial aircraft in 2016. A wide range of issues must be addressed prior to certification of this hardware. The Composite Materials Handbook-17, Volume 5 on ceramic matrix composites is being revised to support FAA certification of CMCs for hot structure and other elevated temperature applications. The handbook supports the development and use of CMCs through publishing and maintaining proven, reliable engineering information and standards that have been thoroughly reviewed. Volume 5 will contain detailed sections describing CMC materials processing, design analysis guidelines, testing procedures, and data analysis and acceptance. A review of the status of and plans for two of these areas, which are being addressed by the M and P Working Group and the Testing Working Group, will be presented along with a timeline for the preparation of CMH-17, Volume 5.

design↗
NASA NTRSDate not supplied

TPSAS-NF1676L-16463-DND

Ceramic Matrix Composites (CMCs) have been proposed for hot structures in scramjet combustors. Previous studies have calculated significant weight savings by utilizing CMCs (active and passive) versus actively cooled metallic scramjet structures. Both a C/C and a C/C-SiC material system fabricated by DLR (Stuttgart, Germany) are being considered for use in a passively cooled combustor design for HIFiRE 8, a joint Australia / AFRL hypersonic flight program, expected to fly at Mach 7 for ~ 30 sec, at a dynamic pressure of 55 kPa. Flat panels of the DLR C/C and the C/C-SiC were tested in the NASA Langley Direct Connect Rig (DCR) at Mach 5 and Mach 6 enthalpy for several minutes. Gaseous hydrogen fuel was used to fuel the scramjet combustor. The test panels were instrumented with embedded Type K and Type S thermocouples. Zirconia felt insulation was used in some of the tests to increase the surface temperature of the C/C-SiC panel ~ 350?F. The final C/C-SiC panel was tested for 3 cycles totaling over 135 sec at Mach 6 enthalpy. Slightly more erosion was observed on the C/C panel than the C/C-SiC panels, but both material systems demonstrated acceptable recession performance for the HIFiRE 8 flight.

David E Glass↗
NASA NTRSDate not supplied

Assessing Degradation of Advanced Coatings for Carbon/Carbon Composites

Carbon/carbon (C/C) composites are a well-utilized material system for hot structures to enable hypersonic flight. However, C/C materials are susceptible to attack by environmental degradation mechanisms, notably oxidation, which can limit the durability of components resulting in premature failure. Environmental barrier coatings (EBCs) have been developed to mitigate deleterious oxidation. Coating compositions based on silicon carbide (SiC) offer promise as a protective coating material for C/C composites. Under particular hypersonic flight conditions, a passivating silica scale can form at the surface of the EBC, acting as a barrier that can protect the underlying coating and substrate. However, the transition from passive to active oxidation, which varies with temperature and pressure, causes the formation of gaseous SiO that volatilizes leading to detrimental consumption of the SiC coating. In this work, arc-jet testing of SiC-based coatings developed to protect Advanced C/C-6 (ACC-6) was performed under a range of conditions to replicate varying oxidation conditions. In-situ optical emission spectroscopic measurements of the gas-surface interactions were collected and evaluated to render compositional degradation of the coating and underlying composite during arc-jet testing. Specimens were evaluated before, during and after arc-jet testing using destructive and non-destructive materials characterization methods, including optical and scanning electron microscopy and energy dispersive spectroscopy.

Coatings, Hypersonics, Composites↗