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DOE OSTI2023

Methods and apparatus for additive manufacturing utilizing multifunctional composite materials, and articles made therefrom

A method of depositing a multiphase material. The method includes providing a Continuous Multifunctional Composite (CMC) phase containing at least one continuous element in a polymeric matrix, passing the CMC phase through a feeding system containing a cutting system, producing a predetermined length of the CMC phase, providing a flow a molten polymer such that the molten polymer and the CMC phase are merged into a continuous co-extrusion nozzle so as to produce a co-extruded multiphase material, and depositing the co-extruded multiphase material onto a surface. An apparatus for depositing a multiphase material. The apparatus contains a co-extrusion nozzle, a means to introduce a CMC phase and a molten polymer into the co-extrusion nozzle, such that the molten polymer and the CMC phase are co-extruded and deposited on a surface. An article containing a CMC phase containing continuous elements embedded in a polymer resin forming a multiphase structure.

Barocio, Eduardo↗

DOE OSTI2023

Methods and apparatus for additive manufacturing utilizing multifunctional composite materials, and articles made therefrom

Barocio, Eduardo↗

DOE OSTI2025

Benefits Of Automated Construction And Energy Efficiency Measures In Modular Homes

This article builds on and adds to a Buildings XV publication that introduced the Transformative Efficiency and Automation in Modular Homes (TEAMH) project. The TEAMH project sought to develop a scalable solution for producing modular homes with 20-50% energy savings and similar cost relative to site-fabricated single-family home construction. A key aspect of the project was assessing the potential for labor cost reductions through automation-assisted construction using light gauge steel (LGS). To quantify the advantages of this approach, side-by-side comparisons were made between traditional wood-framed construction and automation-assisted LGS construction. This demonstration involved constructing one wood-framed wall and several LGS test walls, accompanied by a time-and-motion study. The results indicated that automation assistance could decrease construction time and associated labor costs by as much as 46%. High-performance envelope technologies for exterior insulation and air sealing were evaluated to compare modular homes with site-built homes that meet the International Energy Conservation Code (IECC). A key technology considered was vacuum insulation panels (VIPs) with fiberglass cores. Guarded hot box testing of multiple full-scale wall assemblies containing different combinations of exterior continuous insulation systems containing phenolic foam and VIPs. Testing on various full-scale wall assemblies revealed that, with LGS construction, cavity insulation had minimal impact on exterior wall performance. Omitting cavity insulation can reduce labor and material costs while streamlining manufacturing, as its installation is labor-intensive and not easily automated due to the need for precise placement around wiring and other internal components. Guarded hot box tests of multiple LGS test walls with foam and VIP-based exterior insulation systems achieved R-values of up to 31 hr-ft2-°F/Btu. Finally, building energy modeling of multiple modular home designs indicated that the upgraded envelope assemblies can yield heating energy savings of up to 50% and cooling energy savings of up to 30% compared to IECC 2018 standards.

Shrestha, Som [ORNL] (ORCID:0000000183993797)↗

NASA NTRSDate not supplied

Vertical Lunar Regolith Conveying as a Flight Experiment in Simulated Lunar-Gravity

Regolith conveying will be an essential task for supplying regolith feedstock to In-Situ Resource Utilization (ISRU) reactor systems for regolith processing on the Moon and Mars. The Vertical Lunar Regolith Conveyor (VLRC) is a technology being developed at NASA Kennedy Space Center (KSC) as a regolith transport task for the GCD ISRU FLEET project led by NASA Glenn Research Center (GRC). Single test loop versions of the VLRC are being developed at NASA KSC as a technology demonstration for a flight experiment. The NASA Flight Opportunities program selected the VLRC for a technology demonstration opportunity on a future Blue Origin New Shepard suborbital launch vehicle to study regolith transport physics in a relevant environment in a vacuum chamber under simulated lunar gravity conditions in order to advance its technology readiness level (TRL) for future space applications. The VLRC system includes four primary subsystems to achieve the objectives of the lunar gravity (Lunar-G) flight experiment. (1) An eccentric vibratory conveyor stack to convey regolith particles consisting of three single-loop helical surface conveyors with each actuated by two vibratory motors that vibrate in unison. One of the three single-loops contains a 0.8°-3.1° inclined helical path and the other two contain a 1.6°-6.2° incline. (2) A stick-slip conveyor stack to convey regolith particles consisting of three single-loop helical surface conveyors with each actuated by the same motor to move in unison in a stick-slip motion. One of the three single-loops contains a 0.8°-3.1° inclined helical path and the other two contain a 1.6°-6.2° incline. (3) A regolith containment system to contain the regolith in each single-loop track during launch before the start of the experiment using containment caps that will be lifted in unison at the start of Lunar-G. (4) COTS cameras will record the motion of regolith and tracer particles. Post-flight analysis of the videos will be used to determine convey speeds and flow rates. The VLRC experiment will use the well-known technique of Particle Image Velocimetry (PIV) image analysis to determine the velocity of tracer particles entrained in the regolith flow. This velocity will be used to calculate the mass flow rate of the regolith being conveyed.

ISRU↗

NASA NTRS1977

Gravitational radiation from binary systems in alternative metric theories of gravity - Dipole radiation and the binary pulsar

The generation of gravitational radiation in several currently viable metric theories of gravitation (Brans-Dicke, Rosen, Ni, and Lightman-Lee) is analyzed, and it is shown that these theories predict the emission of dipole gravitational radiation from systems containing gravitationally bound objects. In the binary system PSR 1913 + 16, this radiation results in a secular change in the orbital period of the system with a nominal magnitude of 3 parts in 100,000 per year. The size of the effect is proportional to the reduced mass of the system, to the square of the difference in (self-gravitational energy)/(mass) between the two components of the system, and to a parameter, xi, whose value varies from theory to theory. In general relativity xi equals 0, in Rosen's (1973) theory xi equals -20/3, and in Ni's (1973) theory xi equals -400/3. The current upper limit on such a secular period change is one part in 1 million per year. It is shown that further observations of the binary system that tighten this limit and that establish the masses of the components and the identity of the companion may provide a crucial test of otherwise viable alternatives to general relativity.

Will, C. M.↗

NASA NTRS1993

Applications of computer algebra to distributed parameter systems

In the analysis of vibrations of continuous elastic systems, one often encounters complicated transcendental equations with roots directly related to the system's natural frequencies. Typically, these equations contain system parameters whose values must be specified before a numerical solution can be obtained. The present paper presents a method whereby the fundamental frequency can be obtained in analytical form to any desired degree of accuracy. The method is based upon truncation of rapidly converging series involving inverse powers of the system natural frequencies. A straightforward method to developing these series and summing them in closed form is presented. It is demonstrated how Computer Algebra can be exploited to perform the intricate analytical procedures which otherwise would render the technique difficult to apply in practice. We illustrate the method by developing two analytical approximations to the fundamental frequency of a vibrating cantilever carrying a rigid tip body. The results are compared to the numerical solution of the exact (transcendental) frequency equation over a range of system parameters.

Storch, Joel A.↗

NASA NTRS2000

Lunar Dust Contamination Effects on Lunar Base Thermal Control Systems

Many studies have been conducted to develop a thermal control system that can operate under the extreme thermal environments found on the lunar surface. While these proposed heat rejection systems use different methods to reject heat, each system contains a similar component, a thermal radiator system. These studies have always considered pristine thermal control system components and have overlooked the possible deleterious effects of lunar dust contamination. Since lunar dust has a high emissivity and absorptivity (greater than 0.9) and is opaque, dust accumulation on a surface should radically alter its optical properties and therefore alter its thermal response compared to ideal conditions. In addition, the non-specular nature of the dust particles will alter the performance of systems that employ specular surfaces to enhance heat rejection. To date, few studies have examined the effect of dust deposition on the normal control system components. These studies only focused on a single heat rejection or photovoltaic system. These studies did show that lunar dust accumulations alter the optical properties of any lunar base hardware, which in turn affects component temperatures, and heat rejection. Therefore, a new study was conducted to determine the effect of lunar dust contamination on heat rejection systems. For this study, a previously developed dust deposition model was incorporated into the Thermal Synthesizer System (TSS) model. This modeling scheme incorporates the original method of predicting dust accumulation due to vehicle landings by assuming that the thin dust layer can be treated as a semitransparent surface slightly above and in thermal contact with the pristine surface. The results of this study showed that even small amounts of dust deposits can radically alter the performance of the heat rejection systems. Furthermore. this study indicates that heat rejection systems be either located far from any landing sites or be protected from dust producing mechanisms.

Keller, John R.↗

NASA NTRS2013

Self-Healing Nanocomposites for Reusable Composite Cryotanks

Composite cryotanks, or composite overwrapped pressure vessels (COPVs), offer advantages over currently used aluminum-lithium cryotanks, particularly with respect to weight savings. Future NASA missions are expected to use COPVs in spaceflight propellant tanks to store fuels, oxidizers, and other liquids for launch and space exploration vehicles. However, reliability, reparability, and reusability of the COPVs are still being addressed, especially in cryogenic temperature applications; this has limited the adoption of COPVs in reusable vehicle designs. The major problem with composites is the inherent brittleness of the epoxy matrix, which is prone to microcrack formation, either from exposure to cryogenic conditions or from impact from different sources. If not prevented, the microcracks increase gas permeation and leakage. Accordingly, materials innovations are needed to mitigate microcrack damage, and prevent damage in the first place, in composite cryotanks. The self-healing technology being developed is capable of healing the microcracks through the use of a novel engineered nanocomposite, where a uniquely designed nanoparticle additive is incorporated into the epoxy matrix. In particular, this results in an enhancement in the burst pressure after cryogenic cycling of the nanocomposite COPVs, relative to the control COPVs. Incorporating a novel, self-healing, epoxy-based resin into the manufacture of COPVs allows repeatable self-healing of microcracks to be performed through the simple application of a low-temperature heat source. This permits COPVs to be reparable and reusable with a high degree of reliability, as microcracks will be remediated. The unique phase-separated morphology that was imparted during COPV manufacture allows for multiple self-healing cycles. Unlike single-target approaches where one material property is often improved at the expense of another, robustness has been introduced to a COPV by a combination of a modified resin and nanoparticle additives. Unique nanoparticles were used that have been surface-functionalized to be compatible with the resin. Both organic and inorganic components toughen the matrix and result in a more impact-resistant COPV. In one resin system containing an inorganic nanomaterial additive, a significant improvement in burst performance was observed after the COPV was cryo-impact-damaged and then self-healed, with a greater than 10% improvement in burst pressure after the self-healing process was performed. Initial cross-sectional analysis via microscopy showed good resin infiltration of the carbon fibers and without voids. To further enhance the capability between the nanomaterial additives and the resin, a surface modification was successfully performed. A second specialty epoxy resin was prepared using a surface modified nanomaterial additive, and COPVs were fabricated. Steps were taken to improve the mechanical properties of the COPVs by using a low-viscosity resin system that contained a different curing agent. This lower viscosity improves the processing of the COPV, and preliminary results show that the burst pressure of these new vessels is 20 to 25% higher than that of the original. The self-healing concept demonstrated in this research and development effort represents a platform technology, and the self-healing property is neither restricted to the particular epoxy system used here, nor to the COPV application. Self-healing is a direct result of a unique phase separated morphology created via the resin and is aided by the nanoparticles. The self-healing function can be introduced to other customer-specific resin systems in coating, bulk, or composite applications provided that the unique phase separated morphology can be enabled in those systems.

Eberly, Daniel↗

NASA NTRS1996

System for creating at a site, remote from a sterile environment, a parenteral solution

The present invention relates to a container, system, and method for creating parenteral solutions at a site, remote from sterile environments. The system includes a flexible container that is empty except for a prepackaged amount of a solute that is housed in the interior of the container. The container includes at least one port and a sterilizing filter in communication with an interior of the port. The container is so constructed and arranged that a fluid flow path is created from the port through the filter and into the interior of the container. A sterile water source including means for establishing fluid flow from the sterile water source into the port is provided. Accordingly, sterile water can flow from the sterile water source through the filter into the container where it is mixed with the solute to create a parenteral solution that can then be infused into a patient. A method and container are also provided.

Scharf, Mike↗

NASA NTRSDate not supplied

NASA Capture, Containment, and Return System: Bringing Mars Samples to Earth

The Capture, Containment, and Return System (CCRS) project is NASA’s last step in bringing back Mars samples. CCRS will close a decades-long multi-mission and multi-agency effort to bring Mars surface samples back to Earth for scientific studies. CCRS will launch in 2027 on the European Earth Return Orbiter (ERO) spacecraft, which will provide communications relay for the Mars Sample Return ground missions, Perseverance rover and the Sample Retrieval Lander (SRL) (to be launched in 2028). The main mission for CCRS begins when the first-ever orbital planetary capture operation occurs with CCRS catching and securing the Orbiting Sample (OS)in low Mars orbit. From this point, the system will perform additional "firsts": it will autonomously contain the OS with heat-shrink-fit, sterilize the outside surface, and assemble the Earth entry capsule, named Earth Entry System (EES), in orbit around Mars using a gantry mechanism. At approximately 2.8 Lunar distances from Earth, or 3-days from entry into Earth’s atmosphere, CCRS will open its micrometeoroid shield and release the EES on a ballistic trajectory to Earth. The EES is designed to be a fully passive system that will enter the atmosphere and land without parachute at the Utah Test and Training Range (UTTR).

Mars mission, Sample return, Mission design↗

DOE OSTI2020

Panel Session 80: Interagency Community of Practice in Risk and Performance Assessment

This panel focused on the status of the Inter-agency Performance and Risk Assessment Community of Practice (P and RA COP). Representatives from the P and RA COP and subject matter experts discussed lessons learned and provided feedback on building the P and RA COP to support risk-informed environmental decision making. Panelists with presentations: Understanding Mechanisms to Manage Uncertainty and Risk in Waste Containment Systems (Craig Benson, University of Virginia - CRESP (USA) Scaling for Performance Assessments (Paul Black, Katie Catlett, Doug Anderson, Paul Duffy, Tom Stockton, Sam Van Sickle, John Carson); Interagency Community of Practice in Rick and Performance Assessment (Horst Monken Fernandes); Institutional Controls as a Risk Management Tool (David Esh); Superfund: Explanation of Screening and PRG's for Risk and Dose Assessment (Stuart Walker)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRS1992

Linear polarization sensitivity specifications for space-borne instruments

The radiometric accuracy of space-borne instruments such as radiometers and spectroradiometers which make measurements of the earth and other celestial objects can be compromised by the linear polarization sensitivity (LPS) induced by the optical system. Most of these optical systems contain optical elements whose reflectance or transmission is polarization dependent, such as diffraction gratings, folding and scanning mirrors, dichroic filters, and optical fibers. Optical system incorporating such elements generally display linear polarization sensitivity; different linear polarization states incident with equal radiometric power will be measured as different power levels. If the incident polarization state is unknown, the linear polarization sensitivity cannot be compensated during the data reduction. The light reflected from the earth and other planets and moons is usually partially linearly polarized, but in a random distribution. Thus, to make accurate radiometric measurements of these bodies, a radiometer or spectrometer should have a low level of linear polarization sensitivity. This paper contains a mathematical description of LPS, contains references to systems which have imposed a LPS specification, describes some of the sources of LPS, describes how to model LPS by polarization ray tracing, and discusses methods to reduce the LPS of an optical system.

Maymon, Peter W.↗

NASA NTRS1976

An automated secondary standard for calibrating liquid flowmeters

A secondary working standard of flow calibration has been developed to be used in place of a primary weight-time standard, and which can thereby effect a 75 percent reduction in calibration time while maintaining acceptable accuracies. The secondary standard uses six previously calibrated turbine-type flowmeters built into two manifold systems containing automatically switched flow valves. The pair of systems is capable of covering the flow range of 0.0004 to 19 l/s (0.007 to 300 gpm) with the uncertainty in volume flow rate not exceeding + or - 0.25 percent over the range of 0.06 to 19 l/s and not exceeding + or - 0.5 percent over the range 0.0004 to 0.06 1/s. Data reduction and plotting of results are by computer.

Hobart, H. F.↗

NASA NTRS1976

An automated secondary standard for calibrating liquid flowmeters

A secondary working standard of flow calibration has been developed to be used in place of a primary weight-time standard, and which can thereby effect a 75 percent reduction in calibration time while maintaining acceptable accuracies. The secondary standard uses six previously calibrated turbine-type flowmeters built into two manifold systems containing automatically switched flow valves. The pair of systems is capable of covering the flow range of 0.0004 to 19 1/s (0.007 to 300 gpm) with the uncertainty in volume flow rate not exceeding plus or minus 0.25 percent over the range 0.06 to 19 1/s and not exceeding plus or minus 0.5 percent over the range 0.0004 to 0.06 1/s. Data reduction and plotting of results are by computer.

Hobart, H. F.↗

NASA NTRS1979

Countercurrent distribution of biological cells

A neutral polymer phase system consisting of 7.5 percent dextran 40/4.5 percent PEG 6, 0.11 M Na phosphate, 5 percent fetal bovine serum (FBS), pH 7.5, was developed which has a high phase droplet electrophoretic mobility and retains cell viability over many hours. In this and related systems, the drop mobility was a linear function of drop size, at least in the range 4-30 micron diameter. Applications of and electric field of 4.5 v/cm to a system containing 10 percent v/v bottom phase cleared the system more than two orders of magnitude faster than in the absence of the field. At higher bottom phase concentrations a secondary phenomenon intervened in the field driven separations which resulted in an increase in turbidity after clearing had commenced. The increase was associated with a dilution of the phase system in the chamber. The effect depended on the presence of the electric field. It may be due to electroosmotic flow of buffer through the Amicon membranes into the sample chamber and flow of phase system out into the rinse stream. Strategies to eliminate this problem are proposed.

Brooks, D. E.↗

NASA NTRS1986

Apparatus for Sizing and Rewinding Graphite Fibers

Equipment ideally suited for research and development of new sizing solutions. Designed expecially for applying thermoplastic sizing solutions to graphite tow consisting of 3,000 to 12,000 filaments per tow, but accommodates other solutions, filament counts, and materials other than graphite. Closed system containing highly volatile methylene chloride vapors. Also ventilation system directly over resin reservoir. Concept used to apply sizing compounds on fiber tows or yarn-type reinforcement materials used in composite technology. Sizing solutions consist of compounds compatible with thermosets as well as thermoplastics.

Wilson, M. L.↗

NASA NTRS1988

Materials and structures for hypersonic vehicles

Hypersonic vehicles are envisioned to require, in addition to carbon-carbon and ceramic-matrix composities for leading edges heated to above 2000 F, such 600 to 1800 F operating temperature materials as advanced Ti alloys, nickel aluminides, and metal-matrix composited; These possess the necessary low density and high strength and stiffness. The primary design drivers are maximum vehicle heating rate, total heat load, flight envelope, propulsion system type, mission life requirements and liquid hydrogen containment systems. Attention is presently given to aspects of these materials and structures requiring more intensive development.

Tenney, Darrel R.↗

NASA NTRSDate not supplied

Development of an Additively Manufactured Subscale Secondary Sealed Container for the NASA FROSTE Project

This presentation details the development of an additively manufactured (AM) subscale test article for the secondary sealed container (SSC) as part of the NASA FROSTE project. FROSTE is focused on the collection of regolith samples from shadowed regions of the Moon and the preservation of those samples at cryogenic temperatures for return to Earth. Our team was integrated into the FROSTE program to leverage innovative design approaches and additive manufacturing capabilities in support of a scalable development strategy, where the subscale configuration serves as the development path toward a full-scale SSC. Scalmalloy was selected as the primary material for all AM components due to its favorable strength-to-weight ratio, thermal conductivity, and demonstrated performance in aerospace applications. Its aluminum-based composition supports robust mechanical behavior at cryogenic temperatures while enabling efficient heat transfer and control of thermal gradients within the containment system. The SSC architecture consists of an outer container assembly that houses a phase change material (PCM) tank, which in turn contains primary containers holding the regolith. Thermal management relies on controlled conductive and radiative heat transfer, including a thermal connection assembly that interfaces the PCM tank to an external cryocooler via a thermal strap, and IMLI surrounding the PCM tank to inhibit radiative heat transfer. The outer container assembly incorporates sealing interfaces, thermal connection ports, and I/O feedthroughs, with PTFE spring seals used at critical interfaces to maintain containment integrity. The PCM tank is manufactured as a single monolithic Scalmalloy component and incorporates an integral lattice structure to minimize thermal gradients, internal channels for thermocouple routing, and interface features for thermal connection assembly integration. The tank is centrally suspended within the outer container using support rings, with G10 insulating components employed to inhibit thermal leaks. This work describes the design methodology, AM approach, and key considerations used to inform the design.

regolith↗