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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 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
NASA NTRS2021

Practical SiC JFET-R Analog Integrated Circuit Design for Extreme Environment Applications

Silicon carbide (SiC) junction field effect transistor and SiC resistor (SiC JFET-R) integrated circuits(ICs) have uniquely demonstrated prolonged operation above 450 °C that promises significant operational improvements to a variety of NASA missions. However, the SiC epiwafers used to fabricate these ICs suffer from epi-growth process immaturity that imparts large and systematic spreads in JFET threshold voltages as a function of the device distance from the center on the wafer. Furthermore, the unprecedently wide range of intended application operating temperatures (in many cases over 600 °C wide) imparts as much as 5-fold change in JFET bias currents. This Technical Memorandum documents methods by which both temperature and radius associated JFET electrical parameter variances can be adequately eliminated, or even exploited in JFET-R circuit designs. Full analog circuit examples, including operational amplifiers, and SPICE simulations across experimentally documented SiC JFET parameter extremes are given to illustrate the efficacy of these methods. The reader may use the examples in this memorandum as either an end point, to get a desired analog signal conditioning design into hardware implemented in SiC JFET-R ICs, or as a basis point from which to derive further improvement.

Michael J Krasowski↗
NASA NTRSDate not supplied

Advancement of Extreme Environment Additively Manufactured Alloys for Next Generation Space Propulsion Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into propulsion development and flight applications. NASA matured commonly used aerospace alloys from various alloy families (Nickel, Copper, Stainless and Steel, Aluminum, and Titanium-based) through detailed AM process and heat treatment characterization, in addition to mechanical and thermophysical testing. While these alloys are actively used in many propulsion applications, there is a need for ongoing AM optimized alloys using integrated computational materials engineering (ICME) and process development for high performance applications. The applications targeted are liquid rocket engines; advanced propulsion systems; and in-space propulsion with high heat fluxes, high pressure, and/or that use propellants that can degrade alloys (e.g., hydrogen). This paper highlights the characterization and physical properties of the more common AM alloys using laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Additionally, this paper discusses some of the ongoing novel alloy development and maturation using AM for use in these harsh environments, such as GRCop-42, GRCop-84, NASA HR-1, GRX-810, and C-103. The results from these processes demonstrated that AM could enable rapid development and ongoing efforts for optimized alloys using ICME, yielding higher performances. These alloys have undergone modeling, fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing campaigns. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL) through high duty-cycle testing. A background and overview of these novel AM-enabled alloys and AM processing developments including metallurgical and mechanical property studies is presented here. The latest advancement in the parallel component development and hot-fire testing and future developments for these alloys is also discussed.

Additive Manufacturing↗
NASA NTRSDate not supplied

Advancement of Extreme Environment Additively Manufactured Alloys for Next Generation Space Propulsion Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into propulsion development and flight applications. NASA matured commonly used aerospace alloys from various alloy families (Nickel, Copper, Stainless and Steel, Aluminum, and Titanium-based) through detailed AM process and heat treatment characterization, in addition to mechanical and thermophysical testing. While these alloys are actively used in many propulsion applications, there is a need for ongoing AM optimized alloys using integrated computational materials engineering (ICME) and process development for high performance applications. The applications targeted are liquid rocket engines; advanced propulsion systems; and in-space propulsion with high heat fluxes, high pressure, and/or that use propellants that can degrade alloys (e.g., hydrogen). This paper highlights the characterization and physical properties of the more common AM alloys using laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Additionally, this paper discusses some of the ongoing novel alloy development and maturation using AM for use in these harsh environments, such as GRCop42, GRCop-84, NASA HR-1, GRX-810, and C-103. The results from these processes demonstrated that AM could enable rapid development and ongoing efforts for optimized alloys using ICME, yielding higher performances. These alloys have undergone modeling, fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing campaigns. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL) through high duty-cycle testing. A background and overview of these novel AM-enabled alloys and AM processing developments including metallurgical and mechanical property studies is presented here. The latest advancement in the parallel component development and hot-fire testing and future developments for these alloys is also discussed.

Additive Manufacturing↗
DOE OSTI2025

An innovative radial gradient material design using hot isostatic pressing for applications in extreme environments

Functionally graded materials (FGMs) are highly advanced continuous or discontinuous structures whose structural and material properties vary along a singular geometric dimension either in the axial or radial direction. Here, the radial gradient FGM design makes for an optimal structural design to incorporate a bi-metallic structure with a copper-based high entropy alloy (Cu-HEA) with good mechanical properties and high irradiation resistance, and Chromium (Cr) with great corrosion resistance. This study focuses on the experimental design of a metal powder loading mechanism to fabricate a bi-metallic radial gradient structure using Cu-HEA and 99.9 % pure Cr metal powders. The powder loading strategy uses custom-designed concentric cylindrical dividers to separate the individual compositions. Two benchtop trial runs were performed for design optimization. The optimized design was then implemented to eventually load the HEA and Cr powders for consolidation via powder metallurgy hot isostatic pressing (PM-HIP). The electron microscopy analysis reveals the successful fabrication of the radial gradient structure with the chemical mapping analysis, demonstrating the gradual composition shift from the HEA at the center to the pure-Cr at the periphery via a three-step gradient.

High Entropy Alloys (HEAs)↗
DOE OSTI2024

Near-net shaping of high-density, complex, spatially-tailored ceramics for extreme environments

The purpose of this subcontract is for LLNL to collaborate with the Subcontractor (UCSB) in the areas of binder jet additive manufacturing (BJAM), hot pressing (HP), finite element modeling (FEM), and multi-material sintering studies. LLNL wants to further develop its hot pressing, AM, and modeling capabilities through LLNL’s Early Career Faculty Program. This work will focus on developing a method to hot press complex-shaped ceramic parts through the co-deposition of a structural/functional ceramic and sacrificial mold material in one assembly via multi-material binder jet printing. The method aims to produce dense, near-net shaped parts with applications relevant to a wide variety of fields including aerospace, defense, and energy.

36 MATERIALS SCIENCE↗
NASA NTRS1967

Metal flame spray coating protects electrical cables in extreme environment

Metal flame spray coating prevents EMF measurement error in sheathed instrumentation cables which are externally attached to cylinders which were cooled on the inside, but exposed to gamma radiation on the outside. The coating provides a thermoconductive path for radiation induced high temperatures within the cables.

Brady, R. D.↗
NASA NTRS1981

Microbial ecology of extreme environments: Antarctic dry valley yeasts and growth in substrate limited habitats

The multiple stresses temperature, moisture, and for chemoheterotrophs, sources of carbon and energy of the Dry Valley Antarctica soils allow at best depauperate communities, low in species diversity and population density. The nature of community structure, the operation of biogeochemical cycles, the evolution and mechanisms of adaptation to this habitat are of interest in informing speculations upon life on other planets as well as in modeling the limits of gene life. Yeasts of the Cryptococcus vishniacil complex (Basidiobiastomycetes) are investigated, as the only known indigenes of the most hostile, lichen free, parts of the Dry Valleys. Methods were developed for isolating these yeasts (methods which do not exclude the recovery of other microbiota). The definition of the complex was refined and the importance of nitrogen sources was established as well as substrate competition in fitness to the Dry Valley habitats.

Vishniac, H. S.↗
NASA NTRS1982

Microbial ecology of extreme environments: Antarctic dry valley yeasts and growth in substrate-limited habitats

The success of the Antarctic Dry Valley yeasts presumeably results from adaptations to multiple stresses, to low temperatures and substrate-limitation as well as prolonged resting periods enforced by low water availability. Previous investigations have suggested that the crucial stress is substrate limitation. Specific adaptations may be pinpointed by comparing the physiology of the Cryptococcus vishniacii complex, the yeasts of the Tyrol Valley, with their congeners from other habitats. Progress was made in methods of isolation and definition of ecological niches, in the design of experiments in competition for limited substrate, and in establishing the relationships of the Cryptococcus vishniacii complex with other yeasts. In the course of investigating relationships, a new method for 25SrRNA homology was developed. For the first time it appears that 25SrRNA homology may reflect parallel or convergent evolution.

Vishniac, H. S.↗
NASA NTRS1994

Planetary stations and Abyssal Benthic Laboratories: An overview of parallel approaches for long-term investigation in extreme environments

In spite of the apparent great differences between deep ocean and space environment, significant similarities can be recognized when considering the possible solutions and technologies enabling the development of remote automatic stations supporting the execution of scientific activities. In this sense it is believed that mutual benefits shall be derived from the exchange of experiences and results between people and organizations involved in research and engineering activities for hostile environments, such as space, deep sea, and polar areas. A significant example of possible technology transfer and common systematic approach is given, which describes in some detail how the solutions and the enabling technologies identified for an Abyssal Benthic Laboratory can be applied for the case of a lunar or planetary station.

Dipippo, S.↗
NASA NTRS1999

Psychological Adaptation to Extreme Environments: Effects of Team Composition on Individual Adaptation

This study is part of an ongoing program of research examining the psychological effects of isolation and confinement on individual adaptation, productivity and group relations in Antarctic winter personnel. This environment is used as an analogue for long-duration space mission scenarios, such as a space station sojourn, or a mission to Mars. Earlier results from this and other environments have demonstrated that: (1) most changes in psychological well-being are event-related and of relatively short duration; and (2) the greatest problem facing most individuals is interpersonal conflict. Content analysis of responses to open-ended questions has identified the numerous enjoyable aspects of Antarctic living, and confirmed that many of the problems reported were interpersonal in nature, and that problems varied significantly by station. Current work is exploring the effects of team assignment on the self-reported psychological changes and self-evaluations of members of isolated teams. This work includes identifying the dimensions by which subjects determine how well they are functioning. These dimensions (e.g., work, social life, internal emotional state) appear to play an important role in how subjects evaluate many aspects of life in isolation.

Wood, J.↗
NASA NTRS2000

Life in Extreme Environments Research #2

The goal of this project was to collect suspended particles and microbes for spectral analysis from deep water around hydrothermal vent study sites on the Juan de Fuca Ridge. To accomplish this, the McLane WTS 6-24-47 Sampler (McLane Research Laboratories, Falmouth, MA) was used. The WTS sampler is a programmable unit which is able to collect individual samples across twenty-four 47mm diameter filters at predetermined intervals and duration. Although only one successful deployment was needed, a maximum of three 3 deployments were possible (deployment opportunities were limited by the number of battery packs available). The initial behavior of the WTS and the ship's schedule both indicated that three deployments would be possible. However, it was revealed upon recovery after the first deployment that the WTS failed as it was preparing to collect its first sample.

Fisher, Charles R.↗
NASA NTRS2001

Composites: Processing and Fabrication Methodologies of Nonoxide Ceramic Composites. Processing HfB2 Composites for Use in Extreme Environments

HfB2 and ZrB2 composites containing SiC are known to have good thermal shock and configurational stability at elevated temperatures. These are promising ultra-high temperature ceramics (UHTCs) for use on the sharp leading edges of next generation space vehicles. Sharp leading edges on these vehicles will need to: withstand repeated exposures to temperatures > 2200 C in oxidizing environments; have good thermal shock and ablation resistance; and withstand the mechanical stress of launch and reentry. The HfB2/SiC composite is currently undergoing processing improvements in an effort to better the performance of a material that has been studied for approx. 35 years. The potential for HfB2/SiC composites to meet the requirements of hypersonic flight depends on controlling processing techniques. This presentation will focus on understanding processing steps now being undertaken to optimize the material properties of HfB2/SiC composites at NASA Ames Research Center. Correlation between processing techniques and microstructure will be shown. Preliminary oxidation studies will also be discussed.

Gusman, Michael I.↗