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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 NTRSDate not supplied

Large Scale and Multi-Alloy Rocket Engine Component Development using Various Metal Additive Manufacturing Techniques

The NASA Marshall Space Flight Center (MSFC) has been involved with various forms of metallic additive manufacturing (AM) for use in liquid rocket engine component design, development, and testing since 2010. These AM techniques have been demonstrated to significantly reduce hardware cost, shorten fabrication schedules, increase reliability by reducing the number of joints, and improve hardware performance by allowing fabrication of designs not feasible by conventional means. The focus at the NASA MSFC for these metal additive manufacturing techniques include laser powder-bed fusion (L-PBF), blown powder directed energy deposition (DED), arc-based deposition, and Laser Wire Direct Closeout (LWDC). A variety of components have been evaluated and tested including thrust chamber injectors, injector components such as faceplates, regeneratively-cooled combustion chambers, regeneratively-cooled nozzles, gas generator and preburner hardware, and augmented spark igniters. To support these component applications in harsh environments, NASA has advanced a variety of “standard” additive manufacturing alloys such as those in the superalloy-family and also evolved new alloys including GRCop-84, GRCop-42, NASA HR-1, and JBK-75. The purpose of this presentation is to discuss the various component programs at the NASA MSFC using AM to develop, fabricate, and test combustion devices hardware and the evolution of the new additive alloys. One of these projects that will be highlighted is Rapid Analysis and Manufacturing Propulsion Technology (RAMPT), which includes new process development for large scale AM components, multi-metallic AM components, including unique component designs using additive manufacturing. Additional information will be provided on the development of other components, hot-fire testing, post-processing of AM techniques including surface enhancements (polishing) techniques, material and process characterization, future development programs, and dissemination of data to industry partners.

Additive Manufacturing↗
NASA NTRSDate not supplied

Large Scale and Multi-Alloy Rocket Engine Component Development using Various Metal Additive Manufacturing Techniques

The NASA Marshall Space Flight Center (MSFC) has been involved with various forms of metallic additive manufacturing (AM) for use in liquid rocket engine component design, development, and testing since 2010. These AM techniques have been demonstrated to significantly reduce hardware cost, shorten fabrication schedules, increase reliability by reducing the number of joints, and improve hardware performance by allowing fabrication of designs not feasible by conventional means. The focus at the NASA MSFC for these metal additive manufacturing techniques include laser powder-bed fusion (L-PBF), blown powder directed energy deposition (DED), arc-based deposition, and Laser Wire Direct Closeout (LWDC). A variety of components have been evaluated and tested including thrust chamber injectors, injector components such as faceplates, regeneratively-cooled combustion chambers, regeneratively-cooled nozzles, gas generator and preburner hardware, and augmented spark igniters. To support these component applications in harsh environments, NASA has advanced a variety of “standard” additive manufacturing alloys such as those in the superalloy-family and also evolved new alloys including GRCop-84, GRCop-42, NASA HR-1, and JBK-75. The purpose of this presentation is to discuss the various component programs at the NASA MSFC using AM to develop, fabricate, and test combustion devices hardware and the evolution of the new additive alloys. One of these projects that will be highlighted is Rapid Analysis and Manufacturing Propulsion Technology (RAMPT), which includes new process development for large scale AM components, multi-metallic AM components, including unique component designs using additive manufacturing. Additional information will be provided on the development of other components, hot-fire testing, post-processing of AM techniques including surface enhancements (polishing) techniques, material and process characterization, future development programs, and dissemination of data to industry partners.

Additive Manufacturing↗
NASA NTRSDate not supplied

Component Applications using Metal Additive Manufacturing Techniques and Materials for Rocket Propulsion

The NASA Marshall Space Flight Center (MSFC) has been involved with various forms of metallic additive manufacturing for use in liquid rocket engine component design, development, and testing since 2010. These AM techniques have been demonstrated to significantly reduce hardware cost, shorten fabrication schedules, increase reliability by reducing the number of joints, and improve hardware performance by allowing fabrication of designs not feasible by conventional means. The focus at the NASA MSFC for these metal additive manufacturing techniques include laser powder-bed fusion (L-PBF), blown powder directed energy deposition (DED) and arc-based deposition. A variety of components have been evaluated and tested including thrust chamber injectors, injector components such as faceplates, regeneratively-cooled combustion chambers, regeneratively-cooled nozzles, gas generator and preburner hardware, and augmented spark igniters. To support these component applications in harsh environments, NASA has advanced a variety of “standard” additive manufacturing alloys such as those in the superalloy-family and also evolved new alloys including GRCop-84, GRCop-42, NASA HR-1, and JBK-75. The purpose of this presentation is to discuss the various programs at the NASA MSFC using AM to develop, fabricate, and test combustion devices hardware and the evolution of the new additive alloys. Additional information will be provided on the development of multi-metallic additive manufacturing, post-processing of AM techniques including surface enhancements (polishing) techniques, material and process characterization, future development programs, and dissemination of data to industry partners.

Additive Manufacturing↗
NASA NTRS2023

Reactive Additive Manufacturing for Fourth Industrial Revolution Exploration Systems (Ramfire) Aluminum 6061-Ram2 Nozzle Testing

The NASA Marshall Space Flight Center (MSFC) has applied various forms of metallic additive manufacturing (AM) in liquid rocket engine component design, development, and testing since 2010. These AM techniques reduce hardware cost, shorten fabrication schedules, increase reliability by reducing the number of joints, and improve hardware performance by allowing unconventional design. The RAMFIRE project, funded under Space Technology Mission Directorate (STMD) Game Changing Development (GCD) Program, has furthered the use of novel AM liquid rocket nozzles in collaboration with Elementum 3D. The project advanced novel large-scale AM aluminum material technology for significant weight savings in rocket engines and launch vehicles. Previously, aluminum alloys were difficult to weld and print using additive manufacturing. Elementum 3D’s patented Aluminum 6061-RAM2 alloy allows for aluminum alloys to be printed using various AM techniques and at various scales. The alloy can be leveraged for welding wire, showing drastic improvements in aluminum weldability. The RAMFIRE project focuses on five key areas: 1) Laser Powder Directed Energy Deposition (LP-DED) AL6061-RAM2 feedstock specification and verification, 2) LP-DED process development and validation, 3) LP-DED printed AL6061-RAM2 microstructural and mechanical property characterization, 4) Hot-fire test a 7k-lbf thrust class regeneratively cooled nozzle, 5) Print large scale regeneratively cooled nozzle. Hot-fire testing demonstrates potential of advanced space technologies to NASA and potential users by providing the relevant environments to advance TRL levels to the 5/6 range.

Al6061-RAM2↗
NASA NTRS2017

Lessons Learned from OSIRIS-Rex Autonomous Navigation Using Natural Feature Tracking

The Origins, Spectral Interpretation, Resource Identification, Security-Regolith Explorer (Osiris-REx) spacecraft is scheduled to launch in September, 2016 to embark on an asteroid sample return mission. It is expected to rendezvous with the asteroid, Bennu, navigate to the surface, collect a sample (July 20), and return the sample to Earth (September 23). The original mission design called for using one of two Flash Lidar units to provide autonomous navigation to the surface. Following Preliminary design and initial development of the Lidars, reliability issues with the hardware and test program prompted the project to begin development of an alternative navigation technique to be used as a backup to the Lidar. At the critical design review, Natural Feature Tracking (NFT) was added to the mission. NFT is an onboard optical navigation system that compares observed images to a set of asteroid terrain models which are rendered in real-time from a catalog stored in memory on the flight computer. Onboard knowledge of the spacecraft state is then updated by a Kalman filter using the measured residuals between the rendered reference images and the actual observed images. The asteroid terrain models used by NFT are built from a shape model generated from observations collected during earlier phases of the mission and include both terrain shape and albedo information about the asteroid surface. As a result, the success of NFT is highly dependent on selecting a set of topographic features that can be both identified during descent as well as reliably rendered using the shape model data available. During development, the OSIRIS-REx team faced significant challenges in developing a process conducive to robust operation. This was especially true for terrain models to be used as the spacecraft gets close to the asteroid and higher fidelity models are required for reliable image correlation. This paper will present some of the challenges and lessons learned from the development of the NFT system which includes not just the flight hardware and software but the development of the terrain models used to generate the onboard rendered images.

Navigation↗
NASA NTRS1989

Robotic sampling system for an unmanned Mars mission

A major robotics opportunity for NASA will be the Mars Rover/Sample Return Mission which could be launched as early as the 1990s. The exploratory portion of this mission will include two autonomous subsystems: the rover vehicle and a sample handling system. The sample handling system is the key to the process of collecting Martian soils. This system could include a core drill, a general-purpose manipulator, tools, containers, a return canister, certification hardware and a labeling system. Integrated into a functional package, the sample handling system is analogous to a complex robotic workcell. Discussed here are the different components of the system, their interfaces, forseeable problem areas and many options based on the scientific goals of the mission. The various interfaces in the sample handling process (component to component and handling system to rover) will be a major engineering effort. Two critical evaluation criteria that will be imposed on the system are flexibility and reliability. It needs to be flexible enough to adapt to different scenarios and environments and acquire the most desirable specimens for return to Earth. Scientists may decide to change the distribution and ratio of core samples to rock samples in the canister. The long distance and duration of this planetary mission places a reliability burden on the hardware. The communication time delay between Earth and Mars minimizes operator interaction (teleoperation, supervisory modes) with the sample handler. An intelligent system will be required to plan the actions, make sample choices, interpret sensor inputs, and query unknown surroundings. A combination of autonomous functions and supervised movements will be integrated into the sample handling system.

Chun, Wendell↗
NASA NTRS1991

Architecture for Survivable System Processing (ASSP)

The Architecture for Survivable System Processing (ASSP) Program is a multi-phase effort to implement Department of Defense (DOD) and commercially developed high-tech hardware, software, and architectures for reliable space avionics and ground based systems. System configuration options provide processing capabilities to address Time Dependent Processing (TDP), Object Dependent Processing (ODP), and Mission Dependent Processing (MDP) requirements through Open System Architecture (OSA) alternatives that allow for the enhancement, incorporation, and capitalization of a broad range of development assets. High technology developments in hardware, software, and networking models, address technology challenges of long processor life times, fault tolerance, reliability, throughput, memories, radiation hardening, size, weight, power (SWAP) and security. Hardware and software design, development, and implementation focus on the interconnectivity/interoperability of an open system architecture and is being developed to apply new technology into practical OSA components. To insure for widely acceptable architecture capable of interfacing with various commercial and military components, this program provides for regular interactions with standardization working groups (e.g.) the International Standards Organization (ISO), American National Standards Institute (ANSI), Society of Automotive Engineers (SAE), and Institute of Electrical and Electronic Engineers (IEEE). Selection of a viable open architecture is based on the widely accepted standards that implement the ISO/OSI Reference Model.

Wood, Richard J.↗
NASA NTRS2011

Microcoil Spring Interconnects for Ceramic Grid Array Integrated Circuits

As integrated circuit miniaturization trends continue, they drive the need for smaller higher input/output (I/O) packages. Hermetically sealed ceramic area array parts are the package of choice by the space community for high reliability space flight electronic hardware. Unfortunately, the coefficient of thermal expansion mismatch between the ceramic area array package and the epoxy glass printed wiring board limits the life of the interconnecting solder joint. This work presents the results of an investigation by Marshall Space Flight Center into a method to increase the life of this second level interconnection by the use of compliant microcoil springs. The design of the spring and its attachment process are presented along with thermal cycling results of microcoil springs (MCS) compared with state-of-the-art ball and column interconnections. Vibration testing has been conducted on MCS and high lead column parts. Radio frequency simulation and measurements have been made and the MCS has been modeled and a stress analysis performed. Thermal cycling and vibration testing have shown MCS interconnects to be significantly more reliable than solder columns. Also, MCS interconnects are less prone to handling damage than solder columns. Future work that includes shock testing, incorporation into a digital signal processor board, and process evaluation of expansion from a 400 I/O device to a device with over 1,100 I/O is identified.

Strickland, S. M.↗
NASA NTRS1966

Design reliability goal developed from small sample

Sampling distributions, constructed by Monte Carlo simulation are used in hardware development to establish a design reliability goal, to place a confidence coefficient on reliability estimates, and to determine whether sample stress/strength data demonstrate a specified reliability at a specified confidence level.

Burrows, D. L.↗
NASA NTRS2015

Multipurpose Pressure Vessel Scanner and Photon Doppler Velocimetry

Critical flight hardware typically undergoes a series of nondestructive evaluation methods to screen for defects before it is integrated into the flight system. Conventionally, pressure vessels have been inspected for flaws using a technique known as fluorescent dye penetrant, which is biased to inspector interpretation. An alternate method known as eddy current is automated and can detect small cracks better than dye penetrant. A new multipurpose pressure vessel scanner has been developed to perform internal and external eddy current scanning, laser profilometry, and thickness mapping on pressure vessels. Before this system can be implemented throughout industry, a probability of detection (POD) study needs to be performed to validate the system's eddy current crack/flaw capabilities. The POD sample set will consist of 6 flight-like metal pressure vessel liners with defects of known size. Preparation for the POD includes sample set fabrication, system operation, procedure development, and eddy current settings optimization. For this, collaborating with subject matter experts was required. This technical paper details the preparation activities leading up to the POD study currently scheduled for winter 2015/2016. Once validated, this system will be a proven innovation for increasing the safety and reliability of necessary flight hardware. Additionally, testing of frangible joint requires Photon Doppler Velocimetry (PDV) and Digital Image Correlation instrumentation. There is often noise associated with PDV data, which necessitates a frequency modulation (FM) signal-to-noise pre-test. Generally, FM radio works by varying the carrier frequency and mixing it with a fixed frequency source, creating a beat frequency which is represented by audio frequency that can be heard between about 20 to 20,000 Hz. Similarly, PDV reflects a shifted frequency (a phenomenon known as the Doppler Effect) from a moving source and mixes it with a fixed source frequency, which results in a beat frequency. However, for PDV, discerning the signal from the noise is difficult without a moving source to induce the modulation. A rotating wheel is currently being used as the moving source but its configuration is impractical and has cumbersome placement inside the current frangible joint test cell. As a way to combat this problem and verify a satisfactory signal-to-noise ratio, a reflective moving crystal piezo will be used to modulate a beat frequency, and an absorptive target will be used to block the signal in order to determine any back reflection coming from the probe and discern the true signal-to-noise ratio. The piezo will be mounted and inserted onto the test table on an extendable telescopic antenna grounded by a magnetic base in the test zone. This piezo configuration will be more compatible within the test zone and allow for easy removal of the disk following acceptable signal verification and prior to frangible joint tests.

Ellis, Tayera↗
NASA NTRS2018

Preliminary Aerodynamic Measurements from a Magnetic Suspension and Balance System in a Low-Speed Wind Tunnel

An existing Magnetic Suspension and Balance System (MSBS) has been restored to operation in a small (octagonal test section, 6-inches across flats) low-speed wind tunnel as the first phase of a project to develop new dynamic test capabilities for planetary entry capsules at supersonic speeds. The MSBS and associated wind tunnel were originally designed and built at MIT and were subsequently relocated to NASA Langley Research Center. NASA ceased operations of the system in the late 1990s and it was transferred to Old Dominion University where it had been mothballed until the present work started in 2015. All-new position sensor electronics, electromagnet power supplies, digital controller, and other hardware have been developed, leading to more efficient and reliable operation. Important features of the new hardware will be briefly described. Wind tunnel testing has commenced, focusing first on static aerodynamics of re-entry capsule shapes. Some preliminary results will be reviewed, including comparison to reference data. The proposed extension to dynamic stability testing, using a variety of free-to-pitch approaches will be described. Finally, the preliminary design of the all-new Phase II (supersonic) system will be briefly outlined.

Schoenenberger, Mark↗
NASA NTRS1968

Reliability

NASA methodology for improving reliability and quality of hardware and application to electric power industry

Himmel, S. C.↗
NASA NTRS1974

Utilization survey of prototype structural test article

A survey was conducted of six aerospace companies and two NASA agencies to determine how prototype structural test articles are used in flight operations. The prototype structures are airframes and similar devices which are used for testing and generally are not flown. The survey indicated the following: (1) prototype test articles are not being discarded after development testing is complete, but are used for other purposes, (2) only two cases of prototypes being refurbished and flown were identified, (3) protective devices and inspection techniques are available to prevent or minimize test article damage, (4) substitute programs from design verification are availabel in lieu of using prototype structural articles, and (5) there is a trend away from dedicated test articles. Four options based on these study results were identified to reduce test and hardware costs without compromising reliability of the flight program.

Baber, S.↗
NASA NTRS1976

Automatic fire/weather data station

Prototype unmanned integrated system collects and processes fire-index data. System is based on state-of-the-art technology, utilizes low-cost hardware, and is highly reliable.

Lum, H., Jr.↗
NASA NTRS1977

Instrumentation and data acquisition systems

A comprehensive and integrated measurement system was identified and a design and development effort initiated to meet the criteria imposed by the National Transonic Facility operating environment. Specific measurement areas receiving concentrated attention include: data acquisition, force measurement, pressure instrumentation, flow visualization techniques, model attitude and model deformation measurement, and temperature measurement. The NTF instrument complex will be centered around four 32-bit, 1-microsecond-cycle-time central processing units connected in a multipoint-distributed network configuration. The principal activities to be supported by these computers are: (1) data base management and processing; (2) research measurement data acquisition and display; (3) tunnel and model control; and (4) process monitoring and communication control. The distributed network approach was chosen to modularize the functional software into definable and implementable parts by the various groups involved in the design and to permit use of similar hardware configurations to improve reliability and maintainability.

Guarino, J. F.↗
NASA NTRS1978

Status and future prospects of using numerical methods to study complex flows at High Reynolds numbers

The calculation of flow fields past aircraft configuration at flight Reynolds numbers is considered. Progress in devising accurate and efficient numerical methods, in understanding and modeling the physics of turbulence, and in developing reliable and powerful computer hardware is discussed. Emphasis is placed on efficient solutions to the Navier-Stokes equations.

Maccormack, R. W.↗
NASA NTRS1982

Stable polyurethane coatings for electronic circuits. NASA tech briefs, fall 1982, volume 7, no. 1

One of the most severe deficiencies of polyurethanes as engineering materials for electrical applications has been their sensitivity to combined humidity and temperature environments. Gross failure by reversion of urethane connector potting materials has occurred under these conditions. This has resulted in both scrapping of expensive hardware and reduction in reliability in other instances. A basic objective of this study has been to gain a more complete understanding of the mechanisms and interactions of moisture in urethane systems to guide the development of reversion resistant materials for connector potting and conformal coating applications in high humidity environments. Basic polymer studies of molecular weight and distribution, polymer structure, and functionality were carried out to define those areas responsible for hydrolytic instability and to define polymer structural feature conducive to optimum hydrolytic stability.

Source record↗
NASA NTRS1986

Investigation of an advanced fault tolerant integrated avionics system

Presented is an advanced, fault-tolerant multiprocessor avionics architecture as could be employed in an advanced rotorcraft such as LHX. The processor structure is designed to interface with existing digital avionics systems and concepts including the Army Digital Avionics System (ADAS) cockpit/display system, navaid and communications suites, integrated sensing suite, and the Advanced Digital Optical Control System (ADOCS). The report defines mission, maintenance and safety-of-flight reliability goals as might be expected for an operational LHX aircraft. Based on use of a modular, compact (16-bit) microprocessor card family, results of a preliminary study examining simplex, dual and standby-sparing architectures is presented. Given the stated constraints, it is shown that the dual architecture is best suited to meet reliability goals with minimum hardware and software overhead. The report presents hardware and software design considerations for realizing the architecture including redundancy management requirements and techniques as well as verification and validation needs and methods.

Dunn, W. R.↗