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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

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NASA NTRS1989

Thrust chamber material technology program

This report covers work performed at Pratt & Whitney on development of copper-based materials for long-life, reusable, regeneratively cooled rocket engine thrust chambers. The program approached the goal of enhanced cyclic life through the application of rapid solidification to alloy development, to introduce fine dispersions to strengthen and stabilize the alloys at elevated temperatures. After screening of alloy systems, copper-based alloys containing Cr, Co, Hf, Ag, Ti, and Zr were processed by rapid-solidification atomization in bulk quantities. Those bulk alloys showing the most promise were characterized by tensile testing, thermal conductivity testing, and elevated-temperature, low-cycle fatigue (LFC) testing. Characterization indicated that Cu- 1.1 percent Hf exhibited the greatest potential as an improved-life thrust chamber material, exhibiting LCF life about four times that of NASA-Z. Other alloys (Cu- 0.6 percent Zr, and Cu- 0.6 percent Zr- 1.0 percent Cr) exhibited promise for use in this application, but needed more development work to balance properties.

Andrus, J. S.↗

NASA NTRSDate not supplied

NASA Hypersonic Technology Project (HTP) Sic/Sic Research for Hypersonic Airframe Hot Structures

NASA, DoD, and industry have a vision for reusable hypersonic vehicles (Mach > 5). The realization of this vision will require high-specific-strength, high-temperature, reusable structures. In the sub-sonic and super-sonic flight regimes, high-specific-strength structures can be obtained via the use of aluminum, titanium, and composite materials. In the high-temperature environments associated with hypersonic flight, high specific strength is obtained via refractory-composite materials. NASA Langley Research Center has multiple efforts focused on evaluating refractory-composites for use as airframe hot structures for reusable hypersonic vehicles. Current efforts span the entire building-block approach, including coupon, element, subcomponent, and component manufacturing and testing. The coupon level work includes progressive damage testing and analysis, restrained thermal growth testing, stressed oxidation testing, and evaluation of laminate properties for several layup architectures. Element testing includes evaluation of over-temperature capability and co-processed bonding, fastener development, and analysis and testing of beaded (corrugated) panels. Subcomponent level work includes a solid rocket motor booster fin and a portion of a control surface, and component level work includes a control surface static test article. The current presentation will provide an update of work being performed at NASA, which is expected to transition refractory-composite materials to reusable hypersonic vehicles.

Hot structures↗

NASA NTRS1972

Structural active cooling applications for the Space Shuttle.

Analytic and experimental studies have been conducted to evaluate a number of active cooling approaches to structural thermal protection for the Space Shuttle. The primary emphasis was directed toward the thermal protection system. Trade study results are presented for various heat shield material and TPS arrangements. Both metallic and reusable surface insulation (RSI) concepts were considered. Active systems heat sinks consisted of hydrogen, phase change materials, and expendable water. If consideration is given only to controlling the surface temperature, passive TPS was found to provide the most efficient system. Use of active cooling which incorporates some interior temperature control made the thermally less efficient RSI system more attractive.

Masek, R. V.↗

NASA NTRS1980

Protective clothing textile research for space activities in the 1980's

Textile and clothing specifications for space activities are discussed, emphasizing a chronological and utilitarian role. New fabrication techniques led to the Mercury Space Suit, a constant-wear hybrid of the omni-environmental full pressure suit used by high-flying pilots of the 1950s. The Gemini program (1964-1966) provided the first specifically designed protective clothing assembly for both intra- and extravehicular operations. The G4C, used for EV (extravehicular) activities, protected the astronaut against solar radiation, heat loss, and meteoroid penetration. The clothing for the Apollo program (1968-1975) mirrored a greater concern for fire safety with Durette (a halogenated polyamide) and PBI (polybenzimadazole) widely used for intravehicular garments. With the advent of the Shuttle program, cabin pressure and composition were changed from 6 psi, 100% oxygen to 9-14 psi, 23.4% oxygen, 76.6% N2. As a result, 'off-the-shelf' materials were used without compromising fire safety. Reusability was stressed, as textile costs and durability were now important selection criteria noting that existing textile materials will probably be adequate for the next 20 years of space operations and research. A portable lunar survival shelter made of textiles is being developed; and a preliminary design for an EV 'tunnel suit system' (an access tunnel and homoform work station) is already in existence.

Radnofsky, M. I.↗

NASA NTRS1972

Study of structural active cooling and heat sink systems for space shuttle

This technology investigation was conducted to evaluate the feasibility of a number of thermal protection systems (TPS) concepts which are alternate candidates to the space shuttle baseline TPS. Four independent tasks were performed. Task 1 consisted of an in-depth evaluation of active structural cooling of the space shuttle orbiter. In Task 2, heat sink concepts for the booster were studied to identify and postulate solutions for design problems unique to heat sink TPS. Task 3 consisted of a feasibility demonstration test of a phase change material (PCM) incorporated into a reusable surface insulation (RSI) thermal protection system for the shuttle orbiter. In Task 4 the feasibility of heat pipes for stagnation region cooling was studied for the booster and the orbiter. Designs were developed for the orbiter leading edge and used in trade studies of leading edge concepts. At the time this program was initiated, a 2-stage fully reusable shuttle system was envisioned; therefore, the majority of the tasks were focused on the fully reusable system environments. Subsequently, a number of alternate shuttle system approaches, with potential for reduced shuttle system development funding requirements, were proposed. Where practicable, appropriate shifts in emphasis and task scoping were made to reflect these changes.

Source record↗

NASA NTRS1975

High-Temperature, Low-Cycle Fatigue of Copper-Base Alloys for Rocket Nozzles. Part 1: Data Summary for Materials Tested in Prior Programs

A more detailed analysis of the results obtained in 188 previously reported low-cycle fatigue tests of various candidate materials for regeneratively-cooled, reusable rocket nozzle liners was reported. Plots of load range versus cycles were reported for each test along with a stress-strain hysteresis loop near half-life. In addition, a summary table was provided to compare N5 (cycles to a five percent load range drop) and Nf (cycles to complete specimen separation) values for each test.

Conway, J. B.↗

NASA NTRS1981

Reusable captive blind fastener

A one piece reusable fastener capable of joining materials together from one side (blind backside) comprises a screw driven pin ending in a wedge-shaped expander cone. The cone cooperates within a slotted collar end which has a number of tangs on a cylindrical body. The fastener is set by inserting it through aligned holes in the workpieces to be joined. Turning the pin in one direction draws the cone into the collar, deforming the tangs radially outward to mate with tapered back-tapered hold in the workpiece, thus fastening the two pieces together. Reversing the direction of the pin withdraws the cone from the collar, and allows the tangs to resume their contracted configuration without withdrawing the fastener from the insertion hole. The fastener is capable of joining materials together from only one side with substantial strength in tension and shear over many resue attachment cycles, with no special operations on the main assembly parts other than the tapering of the back end of the insertion hole.

Peterson, S. A.↗

NASA NTRS1983

NASA priority technologies

Significant research areas deserving of attention within the NASA Space Research and Technology program are discussed, noting that the program is pursed to strengthen the U.S. technology base, improve low-cost access to space, and to aid in the expanded use of space, including a space station. Study areas being pursued include new Orbiter thermal protection system materials, developing longer-life reusable engines, and providing the technology for orbital transfer vehicle propulsion and aeroassisted braking. Attention is also being given to CFD techniques for entry body and rocket engine design, verifying the feasibility of advanced sensor concepts, defining the technology for large deployable RF antennas, and improving on-board data management systems. Of particular concern is to establish technologies which will enhance and extend a permanent manned presence in space.

Sadin, S. R.↗

NASA NTRS1998

Health Monitoring of Composite Material Structures Using a Vibrometry Technique

Non-destructive evaluation (NDE) methods for quantifying and locating damage are essential for inspecting structures to ensure safety and reliability. Transmittance function monitoring is a potentially new NDE technique being tested as a tool to detect, quantify, and locate damage on flexible structures. The technique has a large spatial range that is practical for detecting damage on large composite material structures such as a reusable launch vehicle. The Transmittance Function (TF) theory is based on structural dynamics principles that define how vibration at one point in a structure is related to a force at another point. This relationship is called the Frequency Response Function (FRF). A Transmittance Function (TF) is derived as the ratio of FRFs, and can detect damage because the FRFs change due to damage. If one excitation is used for the testing, the force does not need to be measured to compute the TF. In the damage detection procedure, the structure is subjected to wide-band vibration and TFs are computed between different accelerometers to detect changes in the structure, presumably due to damage. In the first year of the project the TF method was tested on a bolted panel, a curved panel, and beams, all made of fiberglass. It was shown that damage could be detected using low frequency vibration, 250 to 1,250 Hz. The technique is sensitive to damage, but it requires storage of historical or pre-damage TFs for the healthy structure. This would become a large data storage requirement for large structures. Thus one objective for the second year of the project was to eliminate the need to store historical data. The second year report gives details of how storage of historical data was eliminated. Further results of testing panel structures are also given.

Schulz, Mark J.↗

NASA NTRS2002

Effects of Thermal Exposure on Properties of Al-Li Alloys

Aluminum-Lithium (Al-Li) alloys offer significant performance benefits for aerospace structural applications due to their higher specific properties compared with conventional Al alloys. For example, the application of Al-Li alloy 2195 to the space shuffle external cryogenic fuel tank resulted in weight savings of over 7,000 lb, enabling successful deployment of International Space Station components. The composition and heat treatment of 2195 were optimized specifically for strength-toughness considerations for an expendable cryogenic tank. Time-dependent properties related to reliability, such as thermal stability, fatigue, and corrosion, will be of significant interest when materials are evaluated for a reusable cryotank structure. Literature surveys have indicated that there is limited thermal exposure data on Al-Li alloys. The effort reported here was designed to establish the effects of thermal exposure on the mechanical properties and microstructure of Al-Li alloys C458, L277, and 2195 in plate gages. Tensile, fracture toughness, and corrosion resistance were evaluated for both parent metal and friction stir welds (FSW) after exposure to temperatures as high as 300 F for up to 1000 hrs. Microstructural changes were evaluated with thermal exposure in order to correlate with the observed data trends. The ambient temperature parent metal data showed an increase in strength and reduction in elongation after exposure at lower temperatures. Strength reached a peak with intermediate temperature exposure followed by a decrease at highest exposure temperature. Friction stir welds of all alloys showed a drop in elongation with increased length of exposure. Understanding the effect of thermal exposure on the properties and microstructure of Al-Li alloys must be considered in defining service limiting temperatures and exposure times for a reusable cryotank structure.

Shah, Sandeep↗

NASA NTRS1975

Thrust chamber life prediction. Volume 1: Mechanical and physical properties of high performance rocket nozzle materials

Pertinent mechanical and physical properties of six high conductivity metals were determined. The metals included Amzirc, NARloy Z, oxygen free pure copper, electroformed copper, fine silver, and electroformed nickel. Selection of these materials was based on their possible use in high performance reusable rocket nozzles. The typical room temperature properties determined for each material included tensile ultimate strength, tensile yield strength, elongation, reduction of area, modulus of elasticity, Poisson's ratio, density, specific heat, thermal conductivity, and coefficient of thermal expansion. Typical static tensile stress-strain curves, cyclic stress-strain curves, and low-cycle fatigue life curves are shown. Properties versus temperature are presented in graphical form for temperatures from 27.6K (-410 F) to 810.9K (1000 F).

Esposito, J. J.↗

NASA NTRS2002

Chemical Fingerprinting Program for RSRM Critical Materials

This viewgraph presentation provides information on the chemical fingerprinting of RSRM (Reusable Sold Rocket Motor) components. A chemical fingerprint can be used to identify a material, to differentiate it from similar looking materials, or lead to its source. It can also identify unexpected changes to a vendor or supplier's material, and monitor aging.

McClennen, William H.↗

NASA NTRS2001

Novel Cryogenic Insulation Materials: Aerogel Composites

New insulation materials are being developed to economically and reliably insulate future reusable spacecraft cryogenic tanks over a planned lifecycle of extreme thermal challenges. These insulation materials must prevent heat loss as well as moisture and oxygen condensation on the cryogenic tanks during extended groundhold, must withstand spacecraft launch conditions, and must protect a partly full or empty reusable cryogenic tank from significant reentry heating. To perform over such an extreme temperature range, novel composites were developed from aerogels and high-temperature matrix material such as Space Shuttle tile. These materials were fabricated and tested for use both as cryogenic insulation and as high-temperature insulation. The test results given in this paper were generated during spacecraft re-entry heating simulation tests using cryogenic cooling.

White, Susan↗

NASA NTRS1984

Selection of burn-resistant materials for oxygen-driven turbopumps

NASA goals for reusable space-based, high-performance orbit transfer vehicle propulsion systems have resulted in a need for oxygen/hydrogen engines which include lightweight, highly reliable, liquid oxygen pumps. The selection of ignition- and burn-resistant materials is a major factor in the design of a compact 75,000-rpm turbopump which can deliver 6 lbM/sec of liquid oxygen at 5,000 psia. The potential operational hazards of rubbing friction and impact of foreign particles at high velocity were investigated experimentally for a wide range of candidate materials, i.e., nickel, copper, monel, 316 Stainless Steel, Hastelloy-X, Invar-36, and silicon carbide. Test parameters included oxygen pressure and temperature up to 5,000 psia and 800 F, respectively. The effect of increasing the O2 pressure from 1000 to 5000 psi is discussed. The applicability of the candidate materials to oxygen pump design was ranked by comparing the experimental results among themselves and with an analytically determined parameter, i.e., the burn factor. Nickel and copper demonstrated superior resistance to ignition and burn in the friction rubbing and particle impact tests relative to monel, stainless steel, and nickel-iron base superalloys.

Schoenman, L.↗

NASA NTRS1983

CLEFT Process for GaAs Solar Cells

CLEFT (cleavage of lateral epitaxial films for transfer) process involves growing ultrathin gallium arsenide (GaAs solar cell on much thicker layer of same material). Growth method is completed solar cell easily separated by cleaving from much thicker substrate. Thick substrate is reusable in making additional cells, which reduces cell material cost.

Fan, J. C. C.↗

NASA NTRS1977

Evaluation of three thermal protection systems in a hypersonic high-heating-rate environment induced by an elevon deflected 30 deg

Three thermal protection systems proposed for a hypersonic research airplane were subjected to high heating rates in the Langley 8 foot, high temperature structures tunnel. Metallic heat sink (Lockalloy), reusable surface insulation, and insulator-ablator materials were each tested under similar conditions. The specimens were tested for a 10 second exposure on the windward side of an elevon deflected 30 deg. The metallic heat sink panel exhibited no damage; whereas the reusable surface insulation tiles were debonded from the panel and the insulator-ablator panel eroded through its thickness, thus exposing the aluminum structure to the Mach 7 environment.

Taylor, A. H.↗

NASA NTRS1971

Overview of composites for space shuttle structures.

The space shuttle, proposed as an earth to orbit reusable vehicle, presents a challenge to materials and design engineers to apply light-weight materials. To provide large payloads, the shuttle structure must be as light weight as possible, yet possess a high degree of structural integrity over a lifetime of multiple flights. This paper reviews the general maturity of advanced composites considered for various components of the shuttle and discusses the range of potential applications for such materials.

Cataldo, C. E.↗

NASA NTRS1997

Health Monitoring of Composite Material Structures using a Vibrometry Technique

Large composite material structures such as aircraft and Reusable Launch Vehicles (RLVS) operate in severe environments comprised of vehicle dynamic loads, aerodynamic loads, engine vibration, foreign object impact, lightning strikes, corrosion, and moisture absorption. These structures are susceptible to damage such as delamination, fiber breaking/pullout, matrix cracking, and hygrothermal strain. To ensure human safety and load-bearing integrity, these structures must be inspected to detect and locate often invisible damage and faults before becoming catastrophic. Moreover, nearly all future structures will need some type of in-service inspection technique to increase their useful life and reduce maintenance and overall costs. Possible techniques for monitoring the health and indicating damage on composite structures include: c-scan, thermography, acoustic emissions using piezoceramic actuators or fiber-optic wires with gratings, laser ultrasound, shearography, holography, x-ray, and others. These techniques have limitations in detecting damage that is beneath the surface of the structure, far away from a sensor location, or during operation of the vehicle. The objective of this project is to develop a more global method for damage detection that is based on structural dynamics principles, and can inspect for damage when the structure is subjected to vibratory loads to expose faults that may not be evident by static inspection. A Transmittance Function Monitoring (TFM) method is being developed in this project for ground-based inspection and operational health monitoring of large composite structures as a RLV. A comparison of the features of existing health monitoring approaches and the proposed TFM method is given.

Schulz, Mark J.↗