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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 NTRS2009

Control of Structure in Conventional Friction Stir Welds through a Kinematic Theory of Metal Flow

In friction stir welding (FSW), a rotating pin is translated along a weld seam so as to stir the sides of the seam together. Metal is prevented from flowing up the pin, which would result in plowing/cutting instead of welding, by a shoulder on the pin. In conventional FSW, the weld metal rests on an "anvil", which supports the heavy "plunge" load on the tool. In this study, both embedded tungsten wires along and copper plating on the faying surfaces were used to trace the flow of AA2219 weld metal around the C-FSW tool. The effect of tool rotational speed, travel speed, plunge load, and pin thread pitch on the resulting weld metal flow was evaluated. Plan, longitudinal, and transverse section x-ray radiographs were examined to trace the metal flow paths. The results are interpreted in terms of a kinematic theory of metal flow in FSW.

Rubisoff, H.A.↗
NASA NTRS2009

Innovative Tools Advance Revolutionary Weld Technique

The iconic, orange external tank of the space shuttle launch system not only contains the fuel used by the shuttle s main engines during liftoff but also comprises the shuttle s backbone, supporting the space shuttle orbiter and solid rocket boosters. Given the tank s structural importance and the extreme forces (7.8 million pounds of thrust load) and temperatures it encounters during launch, the welds used to construct the tank must be highly reliable. Variable polarity plasma arc welding, developed for manufacturing the external tank and later employed for building the International Space Station, was until 1994 the best process for joining the aluminum alloys used during construction. That year, Marshall Space Flight Center engineers began experimenting with a relatively new welding technique called friction stir welding (FSW), developed in 1991 by The Welding Institute, of Cambridge, England. FSW differs from traditional fusion welding in that it is a solid-state welding technique, using frictional heat and motion to join structural components without actually melting any of the material. The weld is created by a shouldered pin tool that is plunged into the seam of the materials to be joined. The tool traverses the line while rotating at high speeds, generating friction that heats and softens but does not melt the metal. (The heat produced approaches about 80 percent of the metal s melting temperature.) The pin tool s rotation crushes and stirs the plasticized metal, extruding it along the seam as the tool moves forward. The material cools and consolidates, resulting in a weld with superior mechanical properties as compared to those weld properties of fusion welds. The innovative FSW technology promises a number of attractive benefits. Because the welded materials are not melted, many of the undesirables associated with fusion welding porosity, cracking, shrinkage, and distortion of the weld are minimized or avoided. The process is more energy efficient, safe (no toxic smoke or shielding gas, liquid metal splatter, arcing, dangerous voltage, or radiation), and environmentally sound (no consumables, fumes, or noise) than fusion welding. Under computer control, an automated FSW machine can create welds with high reproducibility, improving efficiency and overall quality of manufactured materials. The process also allows for welding dissimilar metals as well as those metals considered to be "unweldable" such as the 7xxx series aluminum alloys. Its effectiveness and versatility makes FSW useful for aerospace, rail, automotive, marine, and military applications. A downside to FSW, however, is the keyhole opening left in the weld when the FSW pin tool exits the weld joint. This is a significant problem when using the FSW process to join circumferential structures such as pipes and storage containers. Furthermore, weld joints that taper in material thickness also present problems when using the conventional FSW pin tool, because the threaded pin rotating within the weld joint material is a fixed length. There must be capability for the rotating pin to both increase and decrease in length in real time while welding the tapered material. (Both circumferential and tapered thickness weldments are found in the space shuttle external tank.) Marshall engineers addressed both the keyhole and tapered material thickness problems by developing the auto-adjustable pin tool. This unique piece of equipment automatically withdraws the pin into the tool s shoulder for keyhole closeout. In addition, the auto-adjustable pin tool retracts, or shortens, the rotating pin while welding a weld joint that tapers from one thickness to a thinner thickness. This year, the impact of the Marshall innovation was recognized with an "Excellence in Technology Transfer Award" from the Federal Laboratory Consortium.

Source record↗
NASA NTRS2010

Silica/Polymer and Silica/Polymer/Fiber Composite Aerogels

Aerogels that consist, variously, of neat silica/polymer alloys and silica/polymer alloy matrices reinforced with fibers have been developed as materials for flexible thermal-insulation blankets. In comparison with prior aerogel blankets, these aerogel blankets are more durable and less dusty. These blankets are also better able to resist and recover from compression . an important advantage in that maintenance of thickness is essential to maintenance of high thermal-insulation performance. These blankets are especially suitable as core materials for vacuum- insulated panels and vacuum-insulated boxes of advanced, nearly seamless design. (Inasmuch as heat leakage at seams is much greater than heat leakage elsewhere through such structures, advanced designs for high insulation performance should provide for minimization of the sizes and numbers of seams.) A silica/polymer aerogel of the present type could be characterized, somewhat more precisely, as consisting of multiply bonded, linear polymer reinforcements within a silica aerogel matrix. Thus far, several different polymethacrylates (PMAs) have been incorporated into aerogel networks to increase resistance to crushing and to improve other mechanical properties while minimally affecting thermal conductivity and density. The polymethacrylate phases are strongly linked into the silica aerogel networks in these materials. Unlike in other organic/inorganic blended aerogels, the inorganic and organic phases are chemically bonded to each other, by both covalent and hydrogen bonds. In the process for making a silica/polymer alloy aerogel, the covalent bonds are introduced by prepolymerization of the methacrylate monomer with trimethoxysilylpropylmethacrylate, which serves as a phase cross-linker in that it contains both organic and inorganic monomer functional groups and hence acts as a connector between the organic and inorganic phases. Hydrogen bonds are formed between the silanol groups of the inorganic phase and the carboxyl groups of the organic phase. The polymerization process has been adapted to create interpenetrating PMA and silica-gel networks from monomers and prevent any phase separations that could otherwise be caused by an overgrowth of either phase. Typically, the resulting PMA/silica aerogel, without or with fiber reinforcement, has a density and a thermal conductivity similar to those of pure silica aerogels. However, the PMA enhances mechanical properties. Specifically, flexural strength at rupture is increased to 102 psi (=0.7 MPa), about 50 times the flexural strength of typical pure silica aerogels. Resistance to compression is also increased: Applied pressure of 17.5 psi (=0.12 MPa) was found to reduce the thicknesses of several composite PMA/silica aerogels by only about 10 percent.

Ou, Danny↗
NASA NTRS2008

A Brief Introduction to the Theory of Friction Stir Welding

Friction stir welding (FSW) is a solid state welding process invented in 1991 at The Welding Institute in the United Kingdom. A weld is made in the FSW process by translating a rotating pin along a weld seam so as to stir the sides of the seam together. FSW avoids deleterious effects inherent in melting and is already an important welding process for the aerospace industry, where welds of optimal quality are demanded. The structure of welds determines weld properties. The structure of friction stir welds is determined by the flow field in the weld metal in the vicinity of the weld tool. A simple kinematic model of the FSW flow field developed at Marshall Space Flight Center, which enables the basic features of FSW microstructure to be understood and related to weld process parameters and tool design, is explained.

Nunes, Arthur C., Jr.↗
NASA NTRS2006

Improvement in Recursive Hierarchical Segmentation of Data

A further modification has been made in the algorithm and implementing software reported in Modified Recursive Hierarchical Segmentation of Data (GSC- 14681-1), NASA Tech Briefs, Vol. 30, No. 6 (June 2006), page 51. That software performs recursive hierarchical segmentation of data having spatial characteristics (e.g., spectral-image data). The output of a prior version of the software contained artifacts, including spurious segmentation-image regions bounded by processing-window edges. The modification for suppressing the artifacts, mentioned in the cited article, was addition of a subroutine that analyzes data in the vicinities of seams to find pairs of regions that tend to lie adjacent to each other on opposite sides of the seams. Within each such pair, pixels in one region that are more similar to pixels in the other region are reassigned to the other region. The present modification provides for a parameter ranging from 0 to 1 for controlling the relative priority of merges between spatially adjacent and spatially non-adjacent regions. At 1, spatially-adjacent-/spatially- non-adjacent-region merges have equal priority. At 0, only spatially-adjacent-region merges (no spectral clustering) are allowed. Between 0 and 1, spatially-adjacent- region merges have priority over spatially- non-adjacent ones.

Tilton, James C.↗
NASA NTRS2011

Stage Cylindrical Immersive Display

Panoramic images with a wide field of view intend to provide a better understanding of an environment by placing objects of the environment on one seamless image. However, understanding the sizes and relative positions of the objects in a panorama is not intuitive and prone to errors because the field of view is unnatural to human perception. Scientists are often faced with the difficult task of interpreting the sizes and relative positions of objects in an environment when viewing an image of the environment on computer monitors or prints. A panorama can display an object that appears to be to the right of the viewer when it is, in fact, behind the viewer. This misinterpretation can be very costly, especially when the environment is remote and/or only accessible by unmanned vehicles. A 270 cylindrical display has been developed that surrounds the viewer with carefully calibrated panoramic imagery that correctly engages their natural kinesthetic senses and provides a more accurate awareness of the environment. The cylindrical immersive display offers a more natural window to the environment than a standard cubic CAVE (Cave Automatic Virtual Environment), and the geometry allows multiple collocated users to simultaneously view data and share important decision-making tasks. A CAVE is an immersive virtual reality environment that allows one or more users to absorb themselves in a virtual environment. A common CAVE setup is a room-sized cube where the cube sides act as projection planes. By nature, all cubic CAVEs face a problem with edge matching at edges and corners of the display. Modern immersive displays have found ways to minimize seams by creating very tight edges, and rely on the user to ignore the seam. One significant deficiency of flat-walled CAVEs is that the sense of orientation and perspective within the scene is broken across adjacent walls. On any single wall, parallel lines properly converge at their vanishing point as they should, and the sense of perspective within the scene contained on only one wall has integrity. Unfortunately, parallel lines that lie on adjacent walls do not necessarily remain parallel. This results in inaccuracies in the scene that can distract the viewer and subtract from the immersive experience of the CAVE.

Abramyan, Lucy↗
NASA NTRS2011

Automatic Tie Pointer for In-Situ Pointing Correction

The MARSAUTOTIE program generates tie points for use with the Mars pointing correction software "In-Situ Pointing Correction and Rover Microlocalization," (NPO-46696) Soft ware Tech Briefs, Vol. 34, No. 9 (September 2010), page 18, in a completely automated manner, with no operator intervention. It takes the place of MARSTIE, although MARSTIE can be used to interactively edit the tie points afterwards. These tie points are used to create a mosaic whose seams (boundaries of input images) have been geometrically corrected to reduce or eliminate errors and mis-registrations. The methods used to find appropriate tie points for use in creating a mosaic are unique, having been designed to work in concert with the "MARSNAV" program to be most effective in reducing or eliminating geometric seams in a mosaic. The program takes the input images and finds overlaps according to the nominal pointing. It then finds the most interesting areas using a scene activity metric. Points with higher scene activity are more likely to correlate successfully in the next step. It then uses correlation techniques to find matching points in the overlapped image. Finally, it performs a series of steps to reduce the number of tie points to a manageable level. These steps incorporate a number of heuristics that have been devised using experience gathered by tie pointing mosaics manually during MER operations. The software makes use of the PIG library as described in "Planetary Image Geometry Library" (NPO-46658), NASA Tech Briefs, Vol. 34, No. 12 (December 2010), page 30, so it is multi-mission, applicable without change to any in-situ mission supported by PIG. The MARSAUTOTIE algorithm is automated, so it requires no user intervention. Although at the time of this reporting it has not been done, this program should be suitable for integration into a fully automated mosaic production pipeline.

Deen, Robert G/↗
NASA NTRS2012

In Situ Mosaic Brightness Correction

In situ missions typically have pointable, mast-mounted cameras, which are capable of taking panoramic mosaics comprised of many individual frames. These frames are mosaicked together. While the mosaic software applies radiometric correction to the images, in many cases brightness/contrast seams still exist between frames. This is largely due to errors in the radiometric correction, and the absence of correction for photometric effects in the mosaic processing chain. The software analyzes the overlaps between adjacent frames in the mosaic and determines correction factors for each image in an attempt to reduce or eliminate these brightness seams.

Deen, Robert G.↗
NASA NTRS2012

The Evolution of Friction Stir Welding Theory at Marshall Space Flight Center

From 1995 to the present the friction stir welding (FSW) process has been under study at Marshall Space Flight Center (MSFC). This is an account of the progressive emergence of a set of conceptual tools beginning with the discovery of the shear surface, wiping metal transfer, and the invention of a kinematic model and making possible a treatment of both metallurgical structure formation and process dynamics in friction stir welding from a unified point of view. It is generally observed that the bulk of the deformation of weld metal around the FSW pin takes place in a very narrow, almost discontinuous zone with high deformation rates characteristic of metal cutting. By 1999 it was realized that this zone could be treated as a shear surface like that in simple metal cutting models. At the shear surface the seam is drawn out and compressed and pressure and flow conditions determine whether or not a sound weld is produced. The discovery of the shear surface was followed by the synthesis of a simple 3- flow kinematic model of the FSW process. Relative to the tool the flow components are: (1) an approaching translational flow at weld speed V, (2) a rotating cylindrical plug flow with the angular velocity of the tool , and (3) a relatively slow ring vortex flow (like a smoke ring) encircling the tool and driven by shoulder scrolls and pin threads. The rotating plug flow picks up an element of weld metal, rotates it around with the tool, and deposits it behind the tool ( wiping metal transfer ); it forms plan section loops in tracers cut through by the tool. Radially inward flow from the ring vortex component retains metal longer in the rotating plug and outward flow expels metal earlier; this interaction forms the looping weld seam trace and the tongue and groove bimetallic weld contour. The radial components of the translational and ring vortex flows introduce parent metal intrusions into the small grained nugget material close to the tool shoulder; if this feature is pronounced, nugget collapse may result. Certain weld features, in particular internal banding seen in transverse section as onion rings and associated surface ridges called tool marks , have long implied an oscillation flow component, but have only recently been attributed in the literature to tool eccentricity. Rotating plug shape, typically a hollow cylinder flared at the end where it sticks to the shoulder, varies as pressure distribution on the tool determines where sticking occurs. Simplified power input estimates balanced against heat loss estimates give reasonable temperature estimates, explain why the power requirement changes hardly at all over a wide range of RPM s, and yield isotherms that seem to fall along boundaries of parameter windows of operation.

Nunes, Arthur C.↗
NASA NTRS2018

Overview of Heatshield for Extreme Entry Environment Technology (HEEET) Engineering Test Unit (ETU) Manufacturing and Integration

The Heatshield for Extreme Entry Environment Technology (HEEET) projects objective is to mature a 3-D Woven Thermal Protection System (TPS) to Technical Readiness Level (TRL) 6 to support future NASA missions to destinations such as Venus and Saturn. A key aspect of the project has been the development of the manufacturing and integration processes/procedures necessary to build a heat shield utilizing the HEEET 3D-woven material. This has culminated in the building of a 1meter diameter Engineering Test Unit (ETU) representative of what would be used for a Saturn probe. This presentation will provide an overview of the manufacturing and integration processes utilized to build the ETU, with a focus on the seam design. The seam design represented the most challenging aspect of the HEEET development, given the aerothermal and structural requirements it needs to meet.

Thermal Protection System↗
NASA NTRS2018

Thermal Radiation in the Cryogenic Regime

The effectiveness of using a patchTFAWS 2018 – August 20-24, 2018 21• Surroundings added as a very closely spaced surfacenear the outer layer of the MLI stack• same emissivity of 0.61• Resulting heat leak -5.78 W/m2– Close to ideal, floating shields case with no seams– Suggests that patching over seams ought to be very effective

Elchert, Justin P.↗
NASA NTRS2019

Challenges in Qualification of Thermal Protection Systems in Extreme Entry Environments

Planetary entry vehicles employ ablative TPS materials to shield the aeroshell from entry aeroheating environments. To ensure mission success, it must be demonstrated that the heat shield system, including local features such as seams, does not fail at conditions that are suitably margined beyond those expected in flight. Furthermore, its thermal response must be predictable, with acceptable fidelity, by computational tools used in heat shield design. Mission assurance is accomplished through a combination of ground testing and material response modelling. A material's robustness to failure is verified through arcjet testing while its thermal response is predicted by analytical tools that are verified against experimental data. Due to limitations in flight-like ground testing capability and lack of validated high-fidelity computational models, qualification of heat shield materials is often achieved by piecing together evidence from multiple ground tests and analytical simulations, none of which fully bound the flight conditions and vehicle configuration. Extreme heating environments (>2000 W/sq. cm heat flux and >2 atm pressure), experienced during entries at Venus, Saturn and Ice Giants, further stretch the current testing and modelling capabilities for applicable TPS materials. Fully-dense Carbon Phenolic was the material of choice for these applications; however, since heritage raw materials are no longer available, future uses of re-created Carbon Phenolic will require re-qualification. To address this sustainability challenge, NASA is developing a new dual-layer material based on 3D weaving technology called Heat shield for Extreme Entry Environments (HEEET). Regardless of TPS material, extreme environments pose additional certification challenges beyond what has been typical in recent NASA missions. Scope of this presentation: This presentation will give an overview of challenges faced in verifying TPS performance at extreme heating conditions. Examples include: (1) Bounding aeroheating parameters (heat flux, pressure, shear and enthalpy) in ground facilities. How to certify TPS if environments can't be bounded or aeroheating parameters can't be simultaneously achieved. (2) Higher uncertainties in ground test environments (facility calibration and analytical predictions) at extreme conditions. (3) Testing in flows similar to planetary atmosphere composition (H2/He for Gas and Ice Giants). (4) Test sample size limitations for qualifying seam designs. (5) Lack of computational tools capable of simulating all significant aspects of TPS performance (including initiation and propagation of failures). This presentation will provide recommendations on how the EDL community can address these challenges and mitigate some of the risks involved in flying TPS materials at extreme conditions. Examples include: (1) Dedicated activity to understanding TPS failure modes. Develop computational tools capable of modelling fluid interaction with material's thermostructural response. Validate these tools through failure testing. A better understanding of failure mechanisms may eliminate the need to fully bound all aeroheating parameters in ground testing. (2) Enhancements to current testing facilities to simulate flight-like ablation mechanism (ex. testing in Nitrogen at Ames Interaction Heating Facility to limit oxidation in favor of more sublimation). (3) Improved characterization of test conditions with new diagnostic methods and determination of environment uncertainty through rigorous statistical analysis of available data. (4) Design margin policies that are directly tied to uncertainties in ground test environments and modelling fidelity

Mahzari, Milad↗
NASA NTRS2019

Durability Characterization of Mechanical Interfaces in Solar Sail Membrane Structures

The construction of a solar sail from commercially available metallized film presents several challenges. The solar sail membrane is made by seaming together strips of metallized polymer film. This requires seaming together a preselected width and thickness of a base material into the required geometry, and folding the assembled sail membranes into a small stowage volume prior to launch. The sail membranes must have additional features for connecting to rigid structural elements (e.g., sail booms) and must be electrically grounded to the spacecraft bus to prevent charge build up. Space durability of the material and mechanical interfaces of the sail membrane assemblies will be critical for the success of any solar sail mission. In this study, interfaces of polymer/metal joints in a representative solar sail membrane assembly were tested to ensure that the adhesive interfaces and the fastening grommets could withstand the temperature range and expected loads required for mission success. Various adhesion methods, such as surface treatment, commercial adhesives, and fastening systems, were experimentally evaluated and will be discussed.

Interface↗
NASA NTRSDate not supplied

TPS to Enable a Uranus Orbiter Probe

Recent mission studies point to delivery of the probe either at Uranus or at Neptune will require 3-D Woven TPS, either the two layer HEEET or the single layer 3MDCP. Recent studies point to 3MDCP being more mass efficient. The 3MDCP capability being developed to support MSR EES is sufficient if the probe size is 1.25 m or less. If the prove diameter is larger than 1.25 m, a possibility then Dual layer HEEET which is scalable is at TRL 6 is certified and ready. It is possible to develop a seam approach that would allow 3MDCP and the mass savings could warrant development of a seam capability. Depending on the outcome of the planned Flagship mission study that Ames plans to support, Ames is already working on a concept that can be developed and demonstrated in the coming years. If in case Aerocapture is demonstrated through a Earth Flight Test and becomes part of the mission design for Uranus, this makes delivery of the probes from orbit easier. Whether the probe is to delivered from Orbit or not, still 3-D Woven (HEEET or 3MDCP) is the only TPS qualified to enable the Ice Giant in situ probes.

Matthew J Gasch↗
NASA NTRS1964

Vacuum-type backup bar speeds weld repairs

A backup bar designed to use both vacuum and air pressure provides a method of sealing the weld root of a faulty section of seam weld. With slight redesign, the bar can be made sufficiently flexible to fit any large cylindrical surface.

Carmody, R. J.↗
NASA NTRS1964

New inflatable liferaft is nontippable

A one-seamed lightweight life raft has three underwater ballast buckets as stabilizers. Nontippable, it can be compactly packaged and inflated with carbon dioxide.

Radnofsky, M. I.↗
NASA NTRS1966

Rotating mandrel speeds assembly of plastic inflatables

Rotating mandrel permits the accurate cutting, forming, and sealing of plastic gores for assembly of an inflatable surface of revolution. The gores remain on the mandrel until the final seam is reached. Tolerances are tightly controlled by the mandrel configuration.

Mac Fadden, J. A.↗