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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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1,326 records · Page 71

Online Prediction of Battery Discharge and Estimation of Parasitic Loads for an Electric Aircraft

Predicting whether or not vehicle batteries contain sufficient charge to support operations over the remainder of a given flight plan is critical for electric aircraft. This paper describes an approach for identifying upper and lower uncertainty bounds on predictions that aircraft batteries will continue to meet output power and voltage requirements over the remainder of a flight plan. Battery discharge prediction is considered here in terms of the following components; (i) online battery state of charge estimation; (ii) prediction of future battery power demand as a function of an aircraft flight plan; (iii) online estimation of additional parasitic battery loads; and finally, (iv) estimation of flight plan safety. Substantial uncertainty is considered to be an irremovable part of the battery discharge prediction problem. However, high-confidence estimates of flight plan safety or lack of safety are shown to be generated from even highly uncertain prognostic predictions.

Battery Discharge Prediction

Bend Properties of Sapphire Fibers at Elevated Temperatures: Bend Survivability - 1

The effect of temperature on the bend radius that a c-axis-oriented sapphire fiber can withstand was determined for fibers of various diameter. Bend stress rupture tests were performed for times of 1-100 h and temperatures of 300-1700 C. Fibers would survive the bend test undeformed, would fracture or would deform. The bend survival radius was determined to be the radius above which no fibers fractured or deformed for a given time-temperature treatment. It was found that the ability of fibers to withstand curvature decreases substantially with time and increasing temperature and that fibers of smaller diameter (46-83 micron) withstood smaller bend radii than would be expected from just a difference in fiber diameter when compared with the bend results of the fibers of large diameter (144 micron). This was probably due to different flaw populations, causing high temperature bend failure for the tested sapphire fibers of different diameters.

Sapphire

Ejecta Generation and Redistribution on 433 Eros: Modeling Ejecta Launch Conditions

The NEAR-Shoemaker mission to asteroid 433 Eros presents an unprecedented opportunity to gain fundamental new knowledge about the processes governing regolith formation and redistribution on small bodies. NEAR-Shoemaker’s high-resolution imaging of the surface of Eros makes the asteroid a valuable and heretofore unparalleled laboratory for the detailed study of impact ejecta reaccretion and regolith redistribution on low-gravity (of order 10 -3 g) objects. Regolith is produced on asteroids by impact cratering, and the existence of regolith on the smallest solar system bodies supports the view that some of the ejecta from impact events on such objects may be retained. Impact craters and retained ejecta on low-gravity objects like Eros represent valuable natural laboratories for evaluating various models of impact cratering processes, since they may present crater structures or ejecta features that either do not form or are hidden on higher-gravity bodies like the Moon. Further, quantifying the extent to which impact processes generate and redistribute regoliths on small body surfaces (excavation depths, retained fraction, turnover timescales, etc.) is pivotal to the issue of how to relate meteoritical samples to their asteroidal parent bodies when surficial processes ( i.e., “space weathering”) may disguise or cover up underlying material and confound the ability of remote sensing techniques to provide reliable mineralogical assays of the parent objects. The rich variety of data on Eros’ regolith properties and distribution returned by NEAR-Shoemaker now require detailed analysis in order to take full advantage of the clues these observations offer for elucidating details of the impact cratering process on small bodies. Complicating simple interpretations of crater and ejecta morphology are dynamical effects on ejecta emplacement resulting from Eros’ irregular shape, rapid (5.27 hr) rotation, and low gravity. Figure 1 shows the very different ejecta deposit morphology that can result if the effects of rotation alone are neglected. Considering the additional complicating factors of Eros’ irregular shape and complex gravitational field, simple calculations of the extent and thickness of ejecta blankets and the spatial distribution of ejecta blocks from basic crater scaling laws or numerical hydrocodes alone do not suffice. In order to fully interpret the suite of NEAR-Shoemaker observations of regolith features across the surface of Eros and to evaluate various impact models for specific craters on the asteroid, detailed dynamical modeling of the deposition of crater ejecta from those craters is required . Here, I describe some modifications and improvements to the dynamical model being used for these studies.

D D Durda

Metallurgical and Thermal Properties of 57Ni-40Ti-3Hf (wt%)

Selected properties of 57Ni-40Ti-3Hf (wt%) were measured to further develop this material for use in aerospace rolling-element bearings. The average grain size and microindentation hardness of the material at room temperature were 90 μm and 549 HV, respectively. From room temperature to 500 °C, electrical resistivity increased from 8.9×10–7 to 11.3×10–7 Ω⋅m, thermal expansion coefficients varied from 1.1×10–5 to 1.2×10–5 mm/mm⋅°C, specific heat increased from 0.44 to 0.53 W⋅sec/g⋅K, thermal diffusivity rose from approximately 0.003 to 0.005 cm2/sec and thermal conductivity increased from approximately 0.09 to 0.19 W/cm⋅K. The behavior of the material can be explained by well-known metallurgical theory. These results are expected to provide a basis for design and modeling of future aerospace components.

rule of mixtures

Carbon Fiber Composite Processing Using Isothermal Resins

To meet future demand for single-aisle composite aircraft production, manufacturing rates are expected to increase by up to six times current production rates. Resin infusion is a manufacturing method that has potential to enable fabrication of structures at the desired rates. However, production cycle times with currently available commercial infusion resins cannot support the rates needed for an estimated 80 aircraft per month. Recently, rapid-curing isothermal resins were developed that can reduce the overall processing time. These resins can be infused, cured, and demolded at a single temperature below 100 °C, thereby eliminating the need for time consuming temperature ramps and shortening the overall cure time. In addition, the low temperatures enable use of low-cost tooling during production. This presentation will discuss the use of resin transfer molding to produce composites with rapid-curing isothermal resins, manufacturing considerations, and performance characteristics of the composites.

John M Gardner

Access to Space for NASA SmallSats: Current and Future Needs

Small spacecraft technology advancements have fundamentally shifted how NASA’s Science Mission Directorate (SMD) executes science investigations. To support this approach, the SMD Rideshare Office (SRO) was established in 2020 to lead the definition and implementation of a directorate-wide rideshare strategy. Serving as the central point of contact for coordinating compatible NASA payloads with launch opportunities, the SRO maximizes science, exploration, and technology return on investment by enabling rideshare or other access to space opportunities for small spacecraft on SMD primary mission launches, VADR commercial launch procurements, and other government agency launch opportunities. As NASA seeks to reduce costs and increase the rate of discovery, small satellites and multi manifest access to space have become integral to achieving the agency’s strategic vision. While NASA has created the above-mentioned mechanisms to expand access to space and achieve lower launch costs for its small satellites, many factors have limited full exploit of the opportunity these mechanisms can bring. NASA continues to evolve its mission cultures and technical requirements to adapt and take advantage of burgeoning commercial launch and rideshare advancements. To do so NASA requires collaboration with small satellite manufacturers, principal investigators, and commercial industry partners. Current needs include technical development and design of structurally robust spacecraft buses capable of withstanding varied launch loads, which will increase rideshare interchangeability and versatility. Further, instrument and spacecraft designs must also evolve to handle diverse launch environments and loads factors, while reducing reliance on complex purge and cleanliness constraints, sensitivities to silicones and hydrocarbons, and magnetic requirements. Continued maturation of small and medium launch providers in the near-term is also essential to drive down costs through competition. The current mission selection cadence often complicates the ability to synchronize multiple missions on a single launch. Future needs can include affordable space maneuverability options such as enhanced spacecraft propulsion systems and unique orbital maneuvering capabilities for our individual smallsats or constellations. These emerging capabilities offer a path to unique science orbits for NASA small satellites, but only under the condition that their cost remains affordable and competitive to accommodate inherently smaller mission budgets. Additionally, the projected surge of multiple SMD small satellites launching simultaneously and to unique deep space science orbits necessitates evaluation of expanding deep space communications capabilities. This presentation provides a comprehensive overview of NASA SMD’s access to space landscape and offers further unique insights and discussion, backed by NASA rideshare experiences and lessons learned, on the current and future developments required to unleash the full potential of rideshare opportunities.

Rideshare

Access to Space for NASA Small Sats: Current and Future Needs

Small spacecraft technology advancements have fundamentally shifted how NASA’s Science Mission Directorate (SMD) executes science investigations. To support this approach, the SMD Rideshare Office (SRO) was established in 2020 to lead the definition and implementation of a directorate-wide rideshare strategy. Serving as the central point of contact for coordinating compatible NASA payloads with launch opportunities, the SRO maximizes science, exploration, and technology return on investment by enabling rideshare or other access to space opportunities for small spacecraft on SMD primary mission launches, VADR commercial launch procurements, and other government agency launch opportunities. As NASA seeks to reduce costs and increase the rate of discovery, small satellites and multi manifest access to space have become integral to achieving the agency’s strategic vision. While NASA has created the above-mentioned mechanisms to expand access to space and achieve lower launch costs for its small satellites, many factors have limited full exploit of the opportunity these mechanisms can bring. NASA continues to evolve its mission cultures and technical requirements to adapt and take advantage of burgeoning commercial launch and rideshare advancements. To do so NASA requires collaboration with small satellite manufacturers, principal investigators, and commercial industry partners. Current needs include technical development and design of structurally robust spacecraft buses capable of withstanding varied launch loads, which will increase rideshare interchangeability and versatility. Further, instrument and spacecraft designs must also evolve to handle diverse launch environments and loads factors, while reducing reliance on complex purge and cleanliness constraints, sensitivities to silicones and hydrocarbons, and magnetic requirements. Continued maturation of small and medium launch providers in the near-term is also essential to drive down costs through competition. The current mission selection cadence often complicates the ability to synchronize multiple missions on a single launch. Future needs can include affordable space maneuverability options such as enhanced spacecraft propulsion systems and unique orbital maneuvering capabilities for our individual smallsats or constellations. These emerging capabilities offer a path to unique science orbits for NASA small satellites, but only under the condition that their cost remains affordable and competitive to accommodate inherently smaller mission budgets. Additionally, the projected surge of multiple SMD small satellites launching simultaneously and to unique deep space science orbits necessitates evaluation of expanding deep space communications capabilities. This presentation provides a comprehensive overview of NASA SMD’s access to space landscape and offers further unique insights and discussion, backed by NASA rideshare experiences and lessons learned, on the current and future developments required to unleash the full potential of rideshare opportunities.

Rideshare

A Predictive Bubble Point Pressure Model for Porous Liquid Acquisition Device Screens

This article presents a simplified model for porous screen channel liquid acquisition devices based on a maximum bubble point pressure method from Adamson and Gast (1997). To validate the model, three 304 stainless steel (325 × 2300, 450 × 2750, and 510 × 3600) mesh samples were tested in methanol, acetone, isopropyl alcohol, and water. Screen pores are estimated based on analysis from scanning electron microscopy, historical data, and current test data. Results show that the bubble point pressure is proportional to the surface tension of the fluid only when accounting for nonzero contact angles. The previous assumption that bubble point pressure scales inversely with effective pore diameter is shown to be invalid, as the second finest 450 × 2750 produced the highest bubble point of the three screens. The simplified bubble point model can be used to make predictions for any pure fluid when pore diameters are based on bubble point tests and not SEM analysis.

Liquid Acquisition Device

The Detection of Water Vapor on Mars

We have found eleven weak lines of water vapor on a high dispersion near-infrared spectrogram of Mars taken at the coudè focus of the Mount Wilson 100-inch reflector on April 12/13,1963. We exposed 43 hours on ammoniated IV-N emulsion with a dispersion of 5.6 A/mm; the plate is well exposed at the poles and somewhat overexposed at the center of the planet’s disk. The Martian H 2 O lines in the X 8200 water-vapor band are displaced 0.42 A longward of their telluric counterparts due to the relative velocities of the earth and Mars: AV = +15 km/sec on that date. The Martian lines are strongest over the poles of the planet-we set the spectrograph slit daost north-south to cover both polar regions. This apparent polar strengthening of the Martian H 2 O lines is at least partially due to the increased air mass through the line of sight to high latitudes.

MARS /PLANET/

A Review of Medical Results of Gemini 7 and Related Flights

On August 23, 1966, a review of the medical findings of the fourteen day Gemini 7 mission and related flights was conducted. This review was organized at the request of Dr. George E. Mueller, Associate Administrator for Manned Space Flight, and consisted of presentations by the Principal Investigators of the Gemini Medical Flight Experiments and by the Director, Medical Research and Operations, Manned Spacecraft Center. This document is a compilation of the material presented at the review. The Principals cooperated most significantly by reviewing a transcription of a tape recording of their presentation, editing and providing a final version for publication. Without this most generous assistance, this document could not have been published. Table I, which follows immediately after this Introduction, is presented to acquaint the reader with the scope and sequence of medical measurements and experiments which were conducted during Project Gemini. This review was held prior to the conduct of the Gemini 11 and 12 missions, therefore, material derived from those flights is not included in this document.

E J McLaughlin

Dust Composition of Comet 81P/Wild 2 From JWST Spectroscopy Compared to Stardust’s Fine-Grained Materials and Gems-Rich IDPS

The Stardust Mission returned samples from the coma of Jupiter Family comet 81P/Wild 2 for detailed laboratory analyses. Here we present and discuss the best-fit thermal dust model for the coma dust of comet 81P/Wild 2 as observed by JWST. Comet 81P was observed through JWST GO 018xx, using NIRSpec (2.9–5.3µm, λ/∆λ≈1000) and MRS IFU (4.9–28.1µm, λ/∆λ≈3000) on 2023-03-20 UT and 2023-03-24 UT, respectively, at a heliocentric distance of 1.85 au and JWST distance of 1.43 au (phase angle of 32 degrees). The dust coma of 81P as revealed by JWST offers a salient compliment to laboratory studies of Stardust samples that typically are bigger than 2 µm and up to 60 µm in size.

D H Wooden

A Missed Thrust Framework for Low-Thrust Spiral Trajectories to the NRHO

A framework is developed by which end-to-end optimization of many-revolution low-thrust spiral trajectories can be completed in the presence of missed thrust events. This framework is applied to the Lunar Transit trajectory by which the initial capability of NASA’s Gateway lunar space station will be delivered to a Near Rectilinear Halo Orbit. This low-thrust mission consists of three subphases, each designed according to the specific objectives and dynamical regimes encountered as the mission progresses from a medium Earth insertion orbit to cislunar space. The presented framework accounts for the unique considerations demanded by each mission phase and incorporates appropriate capabilities into a novel mission analysis tool. This methodology enables large scale and reliable analyses of missed thrust events across the end-to-end Lunar Transit to verify the robustness of flight trajectories across the full range of considered launch dates.

missed thrust

Artemis Suit Material Effects of Calendaring Woven Fabrics on Dust Resistance

This paper presents one element of an ongoing NASA technology-infusion effort to design, fabricate, and test a new outer shell fabric for a lunar Extravehicular Activity (EVA) space suit, a critical component of sustained lunar exploration. A primary challenge for suit textiles is preventing lunar dust, which is highly abrasive, electrostatically charged, and capable of infiltrating even tightly woven fabrics from penetrating the Environment Protection Garment (EPG) and compromising suit durability and astronaut safety. To enhance dust-blocking performance, the Artemis Suit Materials Team investigated calendaring, a continuous roll to roll mechanical finishing process in which fabric passes through heated rollers under high pressure to compress and flatten the weave, thereby reducing pore size and modifying surface texture without significantly affecting other properties. Targeted testing of calendared Teflon™ T-162 and Ortho Fabric samples provides new insight into how calendaring influences dust resistance, informing future material development and advancing EVA suit technology for long-duration lunar missions.

Dust

Artemis Suit Material Effects of Calendaring Woven Fabrics on Dust Resistance

This paper presents one element of an ongoing NASA technology-infusion effort to design, fabricate, and test a new outer shell fabric for a lunar Extravehicular Activity (EVA) space suit, a critical component of sustained lunar exploration. A primary challenge for suit textiles is preventing lunar dust, which is highly abrasive, electrostatically charged, and capable of infiltrating even tightly woven fabrics from penetrating the Environment Protection Garment (EPG) and compromising suit durability and astronaut safety. To enhance dust-blocking performance, the Artemis Suit Materials Team investigated calendaring, a continuous roll to roll mechanical finishing process in which fabric passes through heated rollers under high pressure to compress and flatten the weave, thereby reducing pore size and modifying surface texture without significantly affecting other properties. Targeted testing of calendared Teflon™ T-162 and Ortho Fabric samples provides new insight into how calendaring influences dust resistance, informing future material development and advancing EVA suit technology for long-duration lunar missions.

Dust

Microgravity Effects on Standardized Cognitive Performance Measures

The purpose of this experiment, selected to fly on the International Microgravity Laboratory (IML-2) Spacelab mission, is to determine the effects of microgravity upon the cognitive skills which are critical to successful performance of many tasks on board the Space Shuttle. Six tests from the Unified Tri-service Cognitive Performance Assessment Battery (UTC-PAB) will be administered to the Mission Specialists to fulfill the goals of this experiment. These tests are based upon current theoretical models of human performance and the hypothesized effects of microgravity. The principle objective is the identification of the effects of microgravity upon specific information processing skills affecting performance from those of fatigue and shifts in work/rest cycles. Multiple measures of both short and long term fatigue will be obtained and used as a major independent variable for the analysis of these performance data. Scientific supporting studies will determine optimum practice and performance testing schedules for the astronauts. The same tests will be used post-flight to collect data on the recovery of any cognitive performance impairment compared with pre-flight, baseline levels.

Samuel G Schiflett

The Castor 120 (TM) Motor: Development and Qualification Testing Results

This paper discusses Thiokol Corporation's static test results for the development and qualification program of the Castor 120(TM) motor. The demonstration program began with a 25,000-pound motor to demonstrate the new technologies and processes that would be used on the larger Castor 120(TM) motor. The Castor 120(TM) motor was designed to be applicable as a first stage, second stage, or strap-on motor. Static test results from the Castor 25 and two Castor 120(TM) motors are discussed in this paper. The results verified the feasibility of tailoring the propellant grain configuration and nozzle throat diameter to meet various customer requirements. The first and second motors were conditioned successfully at ambient temperature and 28 F, respectively, to demonstrate that the design could handle a wide range of environmental launch conditions. Furthermore, the second Castor 120(TM) motor demonstrated a systems tunnel and forward skirt extension to verify flight-ready stage hardware. It is anticipated that the first flight motor will be ready by the fall of 1994.

Jack G Hilden

Integrated Process-Structure-Property Simulations for Additive Manufacturing Using the Open-Source Materialite Package

The microstructure and properties of additively manufactured (AM) metals are strongly dependent on process conditions. Therefore, process-structure-property (PSP) simulations are a useful tool for exploring process parameter space, studying process variations, and quantifying uncertainty in material properties. However, integrating process-structure and structure-property simulations often involves connecting multiple software packages. Each package may use unique data structures and require substantial domain knowledge. This presentation demonstrates PSP simulation capabilities of Materialite, an open-source package developed at NASA Langley Research Center. Materialite simplifies model linkages by using a common data structure and model interface, enabling straightforward simulation across a PSP model chain. Physics-based models, including kinetic Monte Carlo and crystal plasticity, are implemented within the package. The model interface is also intended to simplify implementation of new models and enable integration with external simulation tools. Example use cases include uncertainty quantification with PSP models and GPU-accelerated powder bed fusion AM process models.

additive manufacturing

Fatigue Behavior of Laser Powder Bed Fused HAYNES 214: Effects of Different Surface Treatments

In this study, under NASA’s Rapid and Analysis Manufacturing Propulsion Technology (RAMPT) project, effects of different surface post-treatments on surface texture and fatigue behavior of L-PBF Alloy 214 were investigated. Various subtractive SPTs including abrasive flow machining (AFM), machining (M), shot peening (SP), vapormatt (VM), dry electropolishing (DE), chemical milling (CM), chemical-mechanical polishing (CMP), electro chemical (ECP) were applied to study the variations of the surface texture, microstructure and uniaxial fatigue behavior under fully reversed strain-controlled condition at four different strain amplitudes of 0.005, 0.004, 0.003, and 0.0025 mm/mm. The insights gained regarding the relationship between structural and mechanical properties for different SPTs can help establish guidelines for selecting the most effective process to enhance the performance of Laser Powder Bed Fusion (L-PBF) Alloy 214, especially for critical aerospace applications.

Post-Processing