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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 163 records · Page 9

Low cost, high concentration ratio solar cell array for space applications

A miniaturized Cassegrainian-type concentrator solar array concept for space applications is described. In-orbit cell operating temperatures near 80 C are achieved with purely passive cell cooling and a net concentration ratio of 100. A multiplicity of miniaturized, rigid solar cell concentrator subassemblies are electrically interconnected in conventional fashion and mounted into rigid frames to form concentrator solar panel assemblies approximately 14-mm thick. A plurality of such interconnected panels forms a stowable and deployable solar cell blanket. It is projected that for 20% efficient silicon cells an array of 500 kW beginning-of-life output capability, including orbiter cradle structures, can be transported by a single shuttle orbiter flight into low earth orbit. In-orbit array specific performance is calculated to be approximately 100 W/sq m and 20 W/kg, including all stowage, deployment and array figure control equipment designed for a 30-year orbital life. Higher efficiency gallium arsenide and multiple band gap solar cells will improve these performance factors correspondingly.

Patterson, R. E.↗

Absorbable-Susceptor Welding of Ceramics

Susceptor becomes part of joint. Susceptor is heated to high temperature by RF energy, then melts adjacent ceramic material. Susceptor dissolves in molten ceramic. When cooled, ceramic parts form moloithic assembly. Suitable for joining complex subassemblies in heat exchangers or other ceramic process equipment for high temperatures.

Schroeder, J. E.↗

Acurex Parabolic Dish Concentrator (PDC-2)

The design approach, rationale for the selected configuration, and the development status of a cost effective point-focus solar concentrator are discussed. The low-cost concentrator reflective surface design is based on the use of a thin, backsilvered mirror glass reflector bonded to a molded structural plastic substrate. The foundation, support, and drive subassembles are described. A hybrid, two-axis, Sun tracking control system based on microprocessor technology was selected. Coarse synthetic tracking is achieved through a microcomputer-based control system to calculate Sun position for transient periods of cloud cover as well as sundown and sunrise positioning. Accurate active tracking is achieved by two-axis optical sensors. Results of the reflective panel demonstration tests investigating slope error, hail impact survivability, temperature/humidity cycling, longitudinal strength/bending stiffness, and torsional stiffness are discussed.

Overly, P.↗

Spacecraft radio frequency subsystem

The historical background for the development of the planetary (RFS) is reviewed, and the performance capabilities of the various functional subassemblies are described. The flight radio frequency subsystem is a valid component for the three spacecraft telecommunications functions of tracking, command, and telemetry. It is the radio and the signal processing equipment residing in the spacecraft that interfaces with the control & data subsystem and performs two-way communications with the Earth-based Deep Space Network. The RFS consists of all the elements for RF reception, demodulation, modulation, and transmission, including those for command detection and telemetry modulation.

Tam, M. K.↗

Advanced composite aileron for L-1011 transport aircraft: Design and analysis

Detail design of the composite aileron has been completed. The aileron design is a multi-rib configuration with single piece upper and lower covers mechanically fastened to the substructure. Covers, front, spar and ribs are fabricated with graphite/epoxy tape or fabric composite material. The design has a weight savings of 23 percent compared to the aluminum aileron. The composite aileron has 50 percent fewer fasteners and parts than the metal aileron and is predicted to be cost competitive. Structural integrity of the composite aileron was verified by structural analysis and an extensive test program. Static, failsafe, and vibration analyses have been conducted on the composite aileron using finite element models and specialized computer programs for composite material laminates. The fundamental behavior of the composite materials used in the aileron was determined by coupon tests for a variety of environmental conditions. Critical details of the design were interrogated by static and fatigue tests on full-scale subcomponents and subassemblies of the aileron.

Griffin, C. F.↗

Advanced composite aileron for L-1011 transport aircraft: Aileron manufacture

The fabrication activities of the Advanced Composite Aileron (ACA) program are discussed. These activities included detail fabrication, manufacturing development, assembly, repair and quality assurance. Five ship sets of ailerons were manufactured. The detail fabrication effort of ribs, spar and covers was accomplished on male tools to a common cure cycle. Graphite epoxy tape and fabric and syntactic epoxy materials were utilized in the fabrication. The ribs and spar were net cured and required no post cure trim. Material inconsistencies resulted in manufacturing development of the front spar during the production effort. The assembly effort was accomplished in subassembly and assembly fixtures. The manual drilling system utilized a dagger type drill in a hydraulic feed control hand drill. Coupon testing for each detail was done.

Dunning, E. G.↗

Fabrication of bonded graphite/polyimide structures for advanced aerospace applications

The tooling concepts and manufacturing techniques developed to produce subelements and full-scale bonded test articles for two of the NASA Composites for Advanced Transportation Systems are examined as part of the structural development of graphite/polyimide composite material systems for the Space Shuttle Orbiter and other space transportation systems. The subassembly and the assembly bonding of the test articles were accomplished using self-tooling and low-cost aluminum tooling concepts in order to eliminate the need for complex and expensive tools. Processing procedures and tooling approaches were developed which permit controlled pressure application on specific bonding planes. Two test articles were fabricated using these techniques, an acoustic panel and a quarter segment of the Space Shuttle aft body flap.

Frost, R. K.↗

Progress report on the infrared astronomical satellite cryogenic system

The main cryogen tank is sized to hold 70 kg of superfluid helium with 12 percent ullage at a temperature of 1.8 K. The insulation system surrounds the main cryogen tank with four blankets of multilayer insulation spaced by means of three vapor-cooled shields. It is noted that the multilayer insulation is 6.4 micron double-aluminized Mylar separated by polyester net. The main shell provides the primary structural integrity of the system. In orbit the main shell is cooled to 170 K using insulation blankets on one side and second surface paint on the opposite side. The aperture cover subassembly is the vacuum seal for the main shell during operation on the ground. It is also a gas condensation trap before and during cooldown of the main cryogen tank during launch hold. It contains 6 kg of supercritical helium, which permits 14 days on orbit with a 48-hour launch pad hold.

Urbach, A. R.↗

Precise thermal control test demonstration on simulated space telescope main ring

A simulated section of the main ring of the Space Telescope, (ST) the part that holds the primary mirror, was manufactured and tested for thermal stability characteristics in a complex structural assembly. The other telescope subassemblies are also mounted on the main ring, which is constructed of a titanium alloy. The entire ring is wrapped in heater elements around the outside diameter to reduce the external temperature gradient effects by two orders of magnitude. A thermal vacuum test was performed using a stainless steel alloy tailored to represent the titanium ring's thermal characteristics. The tests examined the thermal performance and controllability of the test ring, the effects of a 24-hr slew manuever that produced worst-case environment changes, hot and cold simulation of predicted ST orbital thermal environments, and the effects of heater failure. Pointing and thermal control features were verified, but a heater failure on the 'on' side was found to quickly lead to exceeding the thermal design limits.

Bettini, R. G.↗

STEP flight experiments Large Deployable Reflector (LDR) telescope

Flight testing plans for a large deployable infrared reflector telescope to be tested on a space platform are discussed. Subsystem parts, subassemblies, and whole assemblies are discussed. Assurance of operational deployability, rigidization, alignment, and serviceability will be sought.

Runge, F. C.↗

Nimbus-Earth radiation budget instrument analysis

The Wide Field Of View (WFOV) Earth Flux Channels of the Nimbus Earth Radiation Budget (ERB) instrument are studied with the objective of improving the understanding and confidence in the data. Laboratory tests on flight space Earth flux subassemblies followed by a set of in flight verification procedures are examined to see if the laboratory derived correction factors produced consistent results. Intercomparisons between the WFOV data and integrated scanner data as well as other truth are used in these verificaton procedures. The main source of errors are temperature and temperature gradient related offsets. The findings led to construction of a model for the short wave WFOV channel which use instrument temperatures and temperature differences to predict or establish offsets which need to be applied to data reduction algorithms for maximum final data product accuracy.

Maschhoff, R. M.↗

Advanced manufacturing development of a composite empennage component for L-1011 aircraft

This is the final report of technical work conducted during the fourth phase of a multiphase program having the objective of the design, development and flight evaluation of an advanced composite empennage component manufactured in a production environment at a cost competitive with those of its metal counterpart, and at a weight savings of at least 20 percent. The empennage component selected for this program is the vertical fin box of the L-1011 aircraft. The box structure extends from the fuselage production joint to the tip rib and includes front and rear spars. During Phase 4 of the program, production quality tooling was designed and manufactured to produce three sets of covers, ribs, spars, miscellaneous parts, and subassemblies to assemble three complete ACVF units. Recurring and nonrecurring cost data were compiled and documented in the updated producibility/design to cost plan. Nondestruct inspections, quality control tests, and quality acceptance tests were performed in accordance with the quality assurance plan and the structural integrity control plan. Records were maintained to provide traceability of material and parts throughout the manufacturing development phase. It was also determined that additional tooling would not be required to support the current and projected L-1011 production rate.

Alva, T.↗

The space shuttle orbiter remote manipulator positioning mechanism

The major subassemblies of the Manipulator Positioning Mechanism (MPM) are described and illustrated. The Space Shuttle Orbiter design provides that the MPM may be mounted on either left or right sides of the payload bay, or both sides if two are flown. This MPM is provided for the purpose of securing the remote arm in stowed position during lift-off, boost, and landing. It also provides the deploy, latch and unlatch capabilities of the Remote Manipulator System arm.

Hardee, J. H.↗

Extreme Precision Antenna Reflector Study Results

Thermal and mechanical distortion degrade the RF performance of antennas. The complexity of future communications antennas requires accurate, dimensionally stable antenna reflectors and structures built from materials other than those currently used. The advantages and disadvantages of using carbon fibers in an epoxy matrix are reviewed as well as current reflector fabrications technology and adjustment. The manufacturing sequence and coefficient of thermal expansion of carbon fiber/borosilicate glass composites is described. The construction of a parabolic reflector from this material and the assembling of both reflector and antenna are described. A 3M-aperture-diameter carbon/glass reflector that can be used as a subassembly for large reflectors is depicted. The deployment sequence for a 10.5M-aperture-diameter antenna, final reflector adjustment, and the deployment sequence for large reflectors are also illustrated.

Sharp, G. R.↗

The Rubidium-Crystal Oscillator Hybrid Development Program

The rubidium-crystal oscillator hybrid (RbXO) will make precise time available to systems that lack the power required by atomic frequency standards. The RbXO consists of two subassemblies in separate enclosures. One contains a small rubidium frequency standard (RFS) without its internal oven-controlled crystal oscillator (OCXO), plus interface circuits. The second contains a low-power OCXO, and additional interface circuits. The OCXO is on continuously. Periodically, e.g., once a week, the user system applies power to the RFS. After the few necessary for the warmup of the RFS, the interface circuits adjust the frequency of the OCXO to the RFS reference, then shut off the RFS. The OCXO enclosure is separable from the RFS enclosure so that manpacks will be able to operate with minimum size, weight, and power consumption, while having the accuracy of the RFS for the duration of a mission. A prototype RbXO's RFS has operated successfully for 4200 on-off cycles. Parallel efforts on a Phase 2 RbXO development are in progress. Two sources for the RbXO are scheduled to be available during 1986.

Vig, J. R.↗

Automatic Fastening Large Structures: a New Approach

The external tank (ET) intertank structure for the space shuttle, a 27.5 ft diameter 22.5 ft long externally stiffened mechanically fastened skin-stringer-frame structure, was a labor intensitive manual structure built on a modified Saturn tooling position. A new approach was developed based on half-section subassemblies. The heart of this manufacturing approach will be 33 ft high vertical automatic riveting system with a 28 ft rotary positioner coming on-line in mid 1985. The Automatic Riveting System incorporates many of the latest automatic riveting technologies. Key features include: vertical columns with two sets of independently operating CNC drill-riveting heads; capability of drill, insert and upset any one piece fastener up to 3/8 inch diameter including slugs without displacing the workpiece offset bucking ram with programmable rotation and deep retraction; vision system for automatic parts program re-synchronization and part edge margin control; and an automatic rivet selection/handling system.

Lumley, D. F.↗