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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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NASA NTRS1993

Development of test methods for textile composites

NASA's Advanced Composite Technology (ACT) Program was initiated in 1990 with the purpose of developing less costly composite aircraft structures. A number of innovative materials and processes were evaluated as a part of this effort. Chief among them are composite materials reinforced with textile preforms. These new forms of composite materials bring with them potential testing problems. Methods currently in practice were developed over the years for composite materials made from prepreg tape or simple 2-D woven fabrics. A wide variety of 2-D and 3-D braided, woven, stitched, and knit preforms were suggested for application in the ACT program. The applicability of existing test methods to the wide range of emerging materials bears investigation. The overriding concern is that the values measured are accurate representations of the true material response. The ultimate objective of this work is to establish a set of test methods to evaluate the textile composites developed for the ACT Program.

Masters, John E.↗

NASA NTRS1993

Use of negotiated rulemaking in developing technical rules for low-Earth orbit mobile satellite systems

Technical innovations have converged with the exploding market demand for mobile telecommunications to create the impetus for low-earth orbit (LEO) communications satellite systems. The so-called 'Little LEO's' propose use of VHF and UHF spectrum to provide position - location and data messaging services. The so-called 'Big LEO's' propose to utilize the RDSS bands to provide voice and data services. In the United States, several applications were filed with the U.S. Federal Communications Commission (FCC) to construct and operate these mobile satellite systems. To enable the prompt introduction of such new technology services, the FCC is using innovative approaches to process the applications. Traditionally, when the FCC is faced with 'mutually exclusive' applications, e.g. a grant of one would preclude a grant of the others, it uses selection mechanisms such as comparative hearings or lotteries. In the case of the LEO systems, the FCC has sought to avoid these time-consuming approaches by using negotiated rulemakings. The FCC's objective is to enable the multiple applicants and other interested parties to agree on technical and service rules which will enable the grant of all qualified applications. With regard to the VHF/UHF systems, the Advisory Committee submitted a consensus report to the FCC. The process for the systems operating in the bands above 1 GHz involved more parties and more issues but still provided the FCC useful technical information to guide the adoption of rules for the new mobile satellite service.

Taylor, Leslie A.↗

NASA NTRS1994

NASA tech brief evaluations

A major step in transferring technology is to disseminate information about new developments to the appropriate sector(s). A useful vehicle for transferring technology from the government sector to industry has been demonstrated with the use of periodical and journal announcements to highlight technological achievements which may meet the needs of industries other than the one who developed the innovation. To meet this end, NASA has very successfully pursued the goal of identifying technical innovations through the national circulation publication; NASA Tech Briefs. At one time the Technology Utilization Offices of the various centers coordinated the selection of appropriate technologies through a common channel. In recent years, each NASA field center has undertaken the task of evaluating submittals for Tech Brief publication independently of the others. The University of Alabama in Huntsville was selected to assist MSFC in evaluating technology developed under the various programs managed by the NASA center for publication in the NASA Tech Briefs journal. The primary motivation for the NASA Tech Briefs publication is to bring to the attention of industry the various NASA technologies which, in general, have been developed for a specific aerospace requirement, but has application in other areas. Since there are a number of applications outside of NASA that can benefit from innovative concepts developed within the MSPC programs, the ability to transfer technology to other sectors is very high. In most cases, the innovator(s) are not always knowledgeable about other industries which might potentially benefit from their innovation. The evaluation process can therefore contribute to the list of potential users through a knowledgeable evaluator.

Workman, Gary L.↗

NASA NTRS2000

Active Control Technology at NASA Langley Research Center

NASA Langley has a long history of attacking important technical opportunities from a broad base of supporting disciplines. The research and development at Langley in this subject area range from the test tube to the test flight. The information covered here will range from the development of innovative new materials, sensors and actuators, to the incorporation of smart sensors and actuators in practical devices, to the optimization of the location of these devices, to, finally, a wide variety of applications of these devices utilizing Langley's facilities and expertise. Advanced materials are being developed for sensors and actuators, as well as polymers for integrating smart devices into composite structures. Contributions reside in three key areas: computational materials; advanced piezoelectric materials; and integrated composite structures. The computational materials effort is focused on developing predictive tools for the efficient design of new materials with the appropriate combination of properties for next generation smart airframe systems. Research in the area of advanced piezoelectrics includes optimizing the efficiency, force output, use temperature, and energy transfer between the structure and device for both ceramic and polymeric materials. For structural health monitoring, advanced non-destructive techniques including fiber optics are being developed for detection of delaminations, cracks and environmental deterioration in aircraft structures. The computational materials effort is focused on developing predictive tools for the efficient design of new materials with the appropriate combination of properties for next generation smart airframe system. Innovative fabrication techniques processing structural composites with sensor and actuator integration are being developed.

Antcliff, Richard R.↗

NASA NTRS2000

Application of Rapid Prototyping and Wire Arc Spray to the Fabrication of Injection Mold Tools (MSFC Center Director's Discretionary Fund)

Rapid prototyping (RP) is a layer-by-layer-based additive manufacturing process for constructing three-dimensional representations of a computer design from a wax, plastic, or similar material. Wire arc spray (WAS) is a metal spray forming technique, which deposits thin layers of metal onto a substrate or pattern. Marshall Space Flight Center currently has both capabilities in-house, and this project proposed merging the two processes into an innovative manufacturing technique, in which intermediate injection molding tool halves were to be fabricated with RP and WAS metal forming.

Cooper, K. G.↗

NASA NTRS2003

Corrosion of Highly Specular Vapor Deposited Aluminum (VDA) on Earthshade Door Sandwich Structure

High-resolution infrared (IR) imaging requires spacecraft instrument design that is tightly coupled with overall thermal control design. The JPL Tropospheric Emission Spectrometer (TES) instrument measures the 3-dimensional distribution of ozone and its precursors in the lower atmosphere on a global scale. The TES earthshade must protect the 180-K radiator and the 230-K radiator from the Earth IR and albedo. Requirements for specularity, emissivity, and solar absorptance of inner surfaces could only be met with vapor deposited aluminum (VDA). Circumstances leading to corrosion of the VDA are described. Innovative materials and processing to meet the optical and thermal cycle requirements were developed. Examples of scanning electronmicroscope (SEM), atomic force microscope (AFM), and other surface analysis techniques used in failure analysis, problem solving, and process development are given. Materials and process selection criteria and development test results are presented in a decision matrix. Examples of conditions promoting and preventing galvanic corrosion between VDA and graphite fiber-reinforced laminates are provided.

Plaskon, Daniel↗

NASA NTRS1996

The New Millennium Program: Technology for the 21(sup st) Century

NASA's New Millennium Program (NMP) is a space flight technology demonstration program that will validate the technologies needed to carry out the science missions that NASA envisions for the 21(sup st)century. The NMP is employing an innovative decision making process to select the specific technologies that will be flight validated.

Space flight technology decision-making process NM↗

NASA NTRS2010

Public Risk Assessment Program

The Public Entry Risk Assessment (PERA) program addresses risk to the public from shuttle or other spacecraft re-entry trajectories. Managing public risk to acceptable levels is a major component of safe spacecraft operation. PERA is given scenario inputs of vehicle trajectory, probability of failure along that trajectory, the resulting debris characteristics, and field size and distribution, and returns risk metrics that quantify the individual and collective risk posed by that scenario. Due to the large volume of data required to perform such a risk analysis, PERA was designed to streamline the analysis process by using innovative mathematical analysis of the risk assessment equations. Real-time analysis in the event of a shuttle contingency operation, such as damage to the Orbiter, is possible because PERA allows for a change to the probability of failure models, therefore providing a much quicker estimation of public risk. PERA also provides the ability to generate movie files showing how the entry risk changes as the entry develops. PERA was designed to streamline the computation of the enormous amounts of data needed for this type of risk assessment by using an average distribution of debris on the ground, rather than pinpointing the impact point of every piece of debris. This has reduced the amount of computational time significantly without reducing the accuracy of the results. PERA was written in MATLAB; a compiled version can run from a DOS or UNIX prompt.

Mendeck, Gavin↗

NASA NTRS2012

Monitoring of International Space Station Telemetry Using Shewhart Control Charts

Shewhart control charts have been established as an expedient method for analyzing dynamic, trending data in order to identify anomalous subsystem performance as soon as such performance would exceed a statistically established baseline. Additionally, this leading indicator tool integrates a selection methodology that reduces false positive indications, optimizes true leading indicator events, minimizes computer processor unit duty cycles, and addresses human factor concerns (i.e., the potential for flight-controller data overload). This innovation leverages statistical process control, and provides a relatively simple way to allow flight controllers to focus their attention on subtle system changes that could lead to dramatic off-nominal system performance. Finally, this capability improves response time to potential hardware damage and/or crew injury, thereby improving space flight safety. Shewhart control charts require normalized data. However, the telemetry from the ISS Early External Thermal Control System (EETCS) was not normally distributed. A method for normalizing the data was implemented, as was a means of selecting data windows, the number of standard deviations (Sigma Level), the number of consecutive points out of limits (Sequence), and direction (increasing or decreasing trend data). By varying these options, and treating them like dial settings, the number of nuisance alerts and leading indicators were optimized. The goal was to capture all leading indicators while minimizing the number of nuisances. Lean Six Sigma (L6S) design of experiment methodologies were employed. To optimize the results, Perl programming language was used to automate the massive amounts of telemetry data, control chart plots, and the data analysis.

Fitch, Jeffery T.↗

NASA NTRS2012

Concept Design of Cryogenic Propellant Storage and Transfer for Space Exploration

NASA is in the planning and investigation process of developing innovative paths for human space exploration that strengthen the capability to extend human and robotic presence beyond low Earth orbit and throughout the solar system. NASA is establishing the foundations to enable humans to safely reach multiple potential destinations, including the Moon, asteroids, Lagrange points, and Mars and its environs through technology and capability development. To achieve access to these destinations within a reasonable flight time will require the use of high performance cryogenic propulsion systems. Therefore NASA is examining mission concepts for a Cryogenic Propellant Storage and Transfer (CPST) Flight Demonstration which will test and validate key capabilities and technologies required for future exploration elements such as large cryogenic propulsion stages and propellant depots. The CPST project will perform key ground testing in fiscal year 2012 and execute project formulation and implementation leading to a flight demonstration in 2017.

Free, James M.↗

NASA NTRS2012

Space Launch System Accelerated Booster Development Cycle

With the retirement of the Space Shuttle, NASA is seeking to reinvigorate the national space program and recapture the public s interest in human space exploration by developing missions to the Moon, near-earth asteroids, Lagrange points, Mars, and beyond. The would-be successor to the Space Shuttle, NASA s Constellation Program, planned to take humans back to the Moon by 2020, but due to budgetary constraints was cancelled in 2010 in search of a more "affordable, sustainable, and realistic" concept2. Following a number of studies, the much anticipated Space Launch System (SLS) was unveiled in September of 2011. The SLS core architecture consists of a cryogenic first stage with five Space Shuttle Main Engines (SSMEs), and a cryogenic second stage using a new J-2X engine3. The baseline configuration employs two 5-segment solid rocket boosters to achieve a 70 metric ton payload capability, but a new, more capable booster system will be required to attain the goal of 130 metric tons to orbit. To this end, NASA s Marshall Space Flight Center recently released a NASA Research Announcement (NRA) entitled "Space Launch System (SLS) Advanced Booster Engineering Demonstration and/or Risk Reduction." The increased emphasis on affordability is evident in the language used in the NRA, which is focused on risk reduction "leading to an affordable Advanced Booster that meets the evolved capabilities of SLS" and "enabling competition" to "enhance SLS affordability. The purpose of the work presented in this paper is to perform an independent assessment of the elements that make up an affordable and realistic path forward for the SLS booster system, utilizing advanced design methods and technology evaluation techniques. The goal is to identify elements that will enable a more sustainable development program by exploring the trade space of heavy lift booster systems and focusing on affordability, operability, and reliability at the system and subsystem levels5. For this study, affordability is defined as lifecycle cost, which includes design, development, test, and engineering (DDT&E), production and operational costs (P&O). For this study, the system objectives include reducing DDT&E schedule by a factor of three, showing 99.9% reliability, flying up to four times per year, serving both crew and cargo missions, and evolving to a lift capability of 130 metric tons.3 After identifying gaps in the current system s capabilities, this study seeks to identify non-traditional and innovative technologies and processes that may improve performance in these areas and assess their impacts on booster system development. The DDT&E phase may be improved by incorporating incremental development testing and integrated demonstrations to mitigate risk. To further reduce DDT&E, this study will also consider how aspects of the booster system may have commonality with other users, such as the Department of Defense, commercial applications, or international partners; by sharing some of the risk and investment, the overall development cost may be reduced. Consideration is not limited to solid and liquid rocket boosters. A set of functional performance characteristics, such as engine thrust, specific impulse (Isp), mixture ratio, and throttle range are identified and their impacts on the system are evaluated. This study also identifies how such characteristics affect overall life cycle cost, including DDT&E and fixed and variable P&O.

Arockiam, Nicole↗

NASA NTRS2020

NASA Capacity Building Program Intern Team Findings Final Report

NASA’s Capacity Building Program (CBP) provides individuals and institutions with workforce development, training activities, and collaborative projects to strengthen understanding of Earth observations and expand their use around the world. The team of eight interns set out this summer to work with CBP leadership to explore opportunities & innovations and identify process improvements within the program. For the 10-week summer term, the interns virtually assembled from Washington, Montana, Virginia, Maine, and Puerto Rico to collaborate on this project. The work was divided into four sub-projects: Data Analysis, Communications, Web Development and Strategy.

Grace Finstrom↗

NASA NTRS2018

ASTERIA Operations Demonstrates the Value of Combining the Mission Assurance and Fault Protection Roles on CubeSats

On November 20, 2017, ASTERIA (Arcsecond Space Telescope Enabling Research in Astrophysics), a 6U CubeSat performing a technology demonstration of astrophysical measurements, deployed from the ISS. The technology demonstration goals to achieve precision photometry via arcsecond-level line-of-sight pointing error and highly stable focal plane temperature control were met by February 2018. Extended mission operations are ongoing, with the primary focus on observing nearby stars for transiting exoplanets. Throughout development and operations, the roles of mission assurance and fault protection have proven critical to achieving the primary technical goals and to maintaining a healthy spacecraft through multiple extended missions. Given the budget and schedule constraints typical of a CubeSat, innovative tailoring of processes has been critical to success throughout both development and operations of ASTERIA. Mission assurance plays an important role in identifying and evaluating risk and developing cost-effective mitigations. Flexibility in the fault protection design offers a variety of options for implementing risk mitigations as risks have been uncovered both in pre-delivery testing and in mission operations. This paper will discuss the approach taken on ASTERIA to implement mission assurance and fault protection and the resulting benefits to operational efficiency and success. It will briefly address the advantages of this approach during development, in which the combination of the roles provided mission assurance significant insight to system risks, which feeds back into testing methodologies and directly into fault protection design. Operations will be discussed in detail. During this phase, the roles merge to identify in-flight fault protection updates to efficiently respond to anomalies and improve the likelihood of successful technology demonstrations. The paper will also detail the tools that are used to analyse data, identify anomalies, and develop the updates to uplink to the spacecraft. Finally, the general operational approach will be discussed to highlight the usefulness of the ASTERIA processes and their applicability to future CubeSat missions.

Knapp, Mary↗

NASA NTRS2021

Propellant Delivery via VDC Driven Pump

The SMART (Scalable Mobile Autonomous Rocket engine Test) testbed system initiative at SSC was conceived to attempt to address many of the principal cost drivers in developing and maintaining a rocket engine test facility. The system (optimized to test engines and components generating up to 10K lbf nominal thrust) is serving as a testbed for innovative technologies and processes to provide lower cost test services with a rapid test cadence and expedient turnaround times. The system can also potentially be used as a testbed to test other related technologies relevant to surface situations (e.g., moon, Mars associated with crogenic fluid management, engine/component testing, autonomous operations, etc.). This FY20 CIF project, being conducted as part of the SMART testbed system, is developing and testing a propellant delivery system via electrically driven centrifugal pumps (obviating dependence upon Multi-Layer Pressure Vessels) with configuration and operation by a minimal number of personnel. During FY20 the team identified the requirements and worked with P3 and Masten Space Systems to develop the long lead (9 months after receipt of order) items, the 400 VDC pumps, for delivery in mid FY21. Since control of the 400 VDC pump motor is not well developed the team has established heuristics to control flows in LN2 at off nominal shaft speeds to allow deep throttling of the pump in flow test scenarios. Various test scenarios including nominal i.e. high flow high pressure, high flow low pressure, low flow high pressure, low flow low pressure, minimum throttle step change, and low inlet pressure cavitation testing were developed ahead of the anticipated hardware delivery and test. FY20 COVID Stage 3 conditions restricted access to the center and hindered lab work, so efforts focused on the system design and testing plans along with the project procurement paperwork for the hardware... now with its anticipated delivery in spring FY21. Some limited access to the center is expected by spring/summer FY21 for the continuing second year (FY21) CIF project effort meant to be focused upon system integration and initial testing.

Aaron Head↗

NASA NTRS2023

Development of an Ultra High-Pressure Metals Promoted Combustion in Oxygen Test Apparatus

Materials flammability data is needed at pressures higher than ever tested before (greater than 10,000 psi). WSTF has designed and is currently building a metals flammability apparatus that can test metals up to 30,000 psi. Solid progress was achieved on the chamber in terms of system build up and fulfilling requirements to perform a NASA Test Readiness Review. Understanding metals flammability data at extreme pressure opens the doors for higher pressure and higher performance oxygen systems. Proposed systems include more reliable/higher performance propulsion systems and more reliable/lighter Environmental Control Life Support Systems (ECLSS). The test system needed for this testing required significant research and development to select a pressurization method and eliminate contact with potentially flammable materials back to the chamber. No additional promoted combustion data was collected in FY21. This International Research & Development (IRAD) proposal was critical to getting the system very close to operational status. This capability is critical to collect forward leaning material flammability data for future spacecraft and ground systems. Forward work has been identified and funding is being sought outside of the Center Innovation Fund (CIF) process for late FY23/FY24.

promoted combustion↗

NASA NTRSDate not supplied

High Performance Access to Archival Data Stored in HDF4 and HDF5 on Cloud Object Stores Without Reformatting the Files

Cloud computing offers numerous advantages for users of extensive Earth science data collections. These benefits encompass direct online access to data files and granules from any location, scalable access supporting parallel computing workflows, and flexible computing tools enabling innovative experimentation with processing techniques. However, older archival file formats designed for distinct computing systems hinder efficient access to decade-long time-series data when compared to data stored in modern cloud-optimized formats like Web Object Stores (WOS), exemplified by Amazon Web Services’ Simple Storage Service (S3). We describe DMR++ (Dataset Metadata Response plus plus), a technology facilitating efficient access to HDF5 (Hierarchical Data Format, version 5) and HDF4 files stored on WOS systems without requiring data reformatting. DMR++ achieves performance comparable to technologies like Zarr while preserving the original file structure, a substantial benefit considering the vast quantity of archival files held by organizations such as NASA. Moreover, DMR++ typically outperforms cloud-optimized versions of HDF5. Essentially an XML (Extensible Markup Language) document usually stored alongside the described data, DMR++ can also be generated on-the-fly but is generally created during data staging to the WOS. Archival files that use HDF4/5 often store large arrays of numerical data. The data in these files is often compressed, typically reducing their size by a factor of four or more. To achieve efficient access to portions of those arrays, they are 'chunked' into smaller sub-arrays, each individually compressed. The chunk size is a compromise, where spinning disks can efficiently access data in smaller chunks while S3 favors larger chunks. A simple optimization of aggregating smaller chunks that are stored adjacently, transferring them in a single access and then individually decompressing them will improve performance. NASA data pose an additional challenge: special Application Programmer Interface (API) libraries are often needed to compute some variables. These libraries are incompatible with WOS environments. Our solution involves storing computed values in the DMR++ document or a companion file, making them accessible like other variables and eliminating the need for specialized APIs. We outline specific optimizations for both satellite grid and swath data stored in HDF4-EOS2 (Earth Observing System).

James Gallagher↗

NASA NTRS1999

Health Physics Innovations Developed During Cassini for Future Space Applications

The long history of space flight includes missions that used Space Nuclear Auxiliary Power devices, starting with the Transit 4A Spacecraft (1961), continuing through the Apollo, Pioneer, Viking, Voyager, Galileo, Ulysses, Mars Pathfinder, and most recently, Cassini (1997). All Major Radiological Source (MRS) missions were processed at Kennedy Space Center/Cape Canaveral Air Station (KSC/CCAS) Launch Site in full compliance with program and regulatory requirements. The cumulative experience gained supporting these past missions has led to significant innovations which will be useful for benchmarking future MRS mission ground processing. Innovations developed during ground support for the Cassini mission include official declaration of sealed-source classifications, utilization of a mobile analytical laboratory, employment of a computerized dosimetry record management system, and cross-utilization of personnel from related disciplines.

Nickell, Rodney E.↗

NASA NTRS2005

Improved Method of Manufacturing SiC Devices

The phrase, "common-layered architecture for semiconductor silicon carbide" ("CLASSiC") denotes a method of batch fabrication of microelectromechanical and semiconductor devices from bulk silicon carbide. CLASSiC is the latest in a series of related methods developed in recent years in continuing efforts to standardize SiC-fabrication processes. CLASSiC encompasses both institutional and technological innovations that can be exploited separately or in combination to make the manufacture of SiC devices more economical. Examples of such devices are piezoresistive pressure sensors, strain gauges, vibration sensors, and turbulence-intensity sensors for use in harsh environments (e.g., high-temperature, high-pressure, corrosive atmospheres). The institutional innovation is to manufacture devices for different customers (individuals, companies, and/or other entities) simultaneously in the same batch. This innovation is based on utilization of the capability for fabrication, on the same substrate, of multiple SiC devices having different functionalities (see figure). Multiple customers can purchase shares of the area on the same substrate, each customer s share being apportioned according to the customer s production-volume requirement. This makes it possible for multiple customers to share costs in a common foundry, so that the capital equipment cost per customer in the inherently low-volume SiC-product market can be reduced significantly. One of the technological innovations is a five-mask process that is based on an established set of process design rules. The rules provide for standardization of the fabrication process, yet are flexible enough to enable multiple customers to lay out masks for their portions of the SiC substrate to provide for simultaneous batch fabrication of their various devices. In a related prior method, denoted multi-user fabrication in silicon carbide (MUSiC), the fabrication process is based largely on surface micromachining of poly SiC. However, in MUSiC one cannot exploit the superior sensing, thermomechanical, and electrical properties of single-crystal 6H-SiC or 4H-SiC. As a complement to MUSiC, the CLASSiC five-mask process can be utilized to fabricate multiple devices in bulk single-crystal SiC of any polytype. The five-mask process makes fabrication less complex because it eliminates the need for large-area deposition and removal of sacrificial material. Other innovations in CLASSiC pertain to selective etching of indium tin oxide and aluminum in connection with multilayer metallization. One major characteristic of bulk micromachined microelectromechanical devices is the presence of three-dimensional (3D) structures. Any 3D recesses that already exist at a given step in a fabrication process usually make it difficult to apply a planar coat of photoresist for metallization and other subsequent process steps. To overcome this difficulty, the CLASSiC process includes a reversal of part of the conventional flow: Metallization is performed before the recesses are etched.

Okojie, Robert S.↗