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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

Having a Come-Apart: Lessons Learned from Additively Manufactured Hardware Failures

NASA has been engaged with additively manufactured (AM) process and component development since the 2000’s. AM offers various technical advantages, such as enhanced hardware design complexity, part consolidation, and processing of novel alloys in addition to programmatic advantages for reduction in processing time and cost. The focus of much of the AM development at NASA has been to mature the various processes, characterize material properties, develop standards, produce demonstrator parts, and integrate AM hardware in liquid rocket engines. These aspects have been demonstrated through process and design iterations using a methodical characterization, test-fail-fix cycles, as well as application and dissemination of lessons learned. In addition to these fundamental demonstrations of the AM process and hardware development, alloys that provide performance advantages in the high temperature and high-pressure environments have been matured for use in rocket engines. These environments are challenging for any alloy and any design, and the AM process is required to fully meet the intended design requirements. The importance of proper AM process was made evident in the failure of a Laser Powder Bed Fusion (L-PBF) copper-alloy combustion chamber during a hot-fire test due to a degraded material quality resulted from an AM process issue. The hot-fire test aimed to demonstrate high duty cycle under a risk-tolerant development project, where consequences of component failure would be minimal. However, the unintentional component failure emphasized the necessity of robust material characterization and rigorous process control procedures for the safe use of AM components in critical applications. In part, such concerns motivate the AM certification approach that NASA has recently adopted in NASA-STD-6030 “Additive Manufacturing Requirements for Spaceflight Systems”. This presentation provides an overview of the previously mentioned failure, a discussion on the evaluation of the failed chamber and supplemental chambers produced at the same time, a representative material samples that included intentional build witness lines, and a summary of the key results and recommendations from the evaluations. NASA continues to approach AM processes and designs with a level of risk and acceptance of failures that is appropriate for the project objectives, with the overall goal of safe implementation of AM technology and transferring AM technology into commercial space applications. The objective of this presentation is to provide awareness to the community working critical and non-critical AM components and the lessons learned on proper implementation of AM.

Additive Manufacturing↗

NASA NTRS2016

The Effect of Laser Scan Strategy on Distortion and Residual Stresses of Arches Made With Selective Laser Melting

The NASA Marshall Space Flight Center (MSFC) is developing Additive Manufacturing (AM) - both in-space AM for on-demand parts, tools, or structures, and on-earth AM for rapid, reduced-cost, small volume production of complex space-flight hardware. Selective Laser Melting (SLM) is an on-earth AM technology that MSFC is using to build Alloy 718 rocket engine components. An understanding of the SLM-718 material properties is required to design, build, and qualify these components for space flight. Residual stresses and are of particular interest for this AM process, since SLM is a series of approximately 100 micron-wide welds, where highly non-linear heating and cooling, severe thermal gradients and repeated thermal cycling can result in high residual stresses within the component. These stresses may cause degraded material properties, and warp or distort the geometry of the SLM component. The distortions can render the component out-of-tolerance when inspected, and even interrupt or halt the build process if the warped material prevents the SLM machine from operating properly. The component must be scrapped and re-designed, which is time consuming and costly. If residual stresses are better understood, and can be predicted, these effects can be mitigated early in the component's design. the compressive residual stresses in the z-direction were highest in the chess sample, followed by island then continuous. This may be due to the binding nature of the segments

Bagg, Stacey D.↗

NASA NTRS1972

Transient mass transfer at the rotating disk electrode.

Transient mass transfer at the rotating disk has been investigated theoretically and experimentally for cathodic reduction of ferricyanide in the redox system ferricyanide-ferrocyanide with potassium hydroxide supporting electrolyte. It has been shown that overpotential-time predictions for the rotating disk are fitted very well for decay (current interruption) but poorly for build-up following switching on of constant current. As an explanation for this behavior, attention is directed to the inadequacy of the assumption that a radially independent concentration profile exists at the disk surface just at the start of galvanostatic current passage.

Nanis, L.↗

NASA NTRS1988

Internal temperature gradient of alloy semiconductor melts from interrupted growth experiments

Interrupted growth experiments on Hg(0.8)Cd(0.2)Se alloys were performed in an attempt to estimate the actual internal temperature gradient in the melt during directional solidification. The results have been analyzed in terms of a theoretical model which assumes an axial composition profile characteristic of diffusion controlled solute redistribution during growth. A comparison of the calculated and measured values suggests a reduction in the applied (empty furnace) temperature gradient by about a factor of three. Values of the interface segregation coefficient (k) determined from the phase diagram, predict values of solute concentration build up in the solid during growth interruptions which are inconsistent with measured results. It appears that the k values used tend to underestimate the actual k values for higher alloy compositions and overestimate k for the lower alloy compositions.

Andrews, R. N.↗

NASA NTRS1999

Backup Attitude Control Algorithms for the MAP Spacecraft

The Microwave Anisotropy Probe (MAP) is a follow-on to the Differential Microwave Radiometer (DMR) instrument on the Cosmic Background Explorer (COBE) spacecraft. The MAP spacecraft will perform its mission, studying the early origins of the universe, in a Lissajous orbit around the Earth-Sun L(sub 2) Lagrange point. Due to limited mass, power, and financial resources, a traditional reliability concept involving fully redundant components was not feasible. This paper will discuss the redundancy philosophy used on MAP, describe the hardware redundancy selected (and why), and present backup modes and algorithms that were designed in lieu of additional attitude control hardware redundancy to improve the odds of mission success. Three of these modes have been implemented in the spacecraft flight software. The first onboard mode allows the MAP Kalman filter to be used with digital sun sensor (DSS) derived rates, in case of the failure of one of MAP's two two-axis inertial reference units. Similarly, the second onboard mode allows a star tracker only mode, using attitude and derived rate from one or both of MAP's star trackers for onboard attitude determination and control. The last backup mode onboard allows a sun-line angle offset to be commanded that will allow solar radiation pressure to be used for momentum management and orbit stationkeeping. In addition to the backup modes implemented on the spacecraft, two backup algorithms have been developed in the event of less likely contingencies. One of these is an algorithm for implementing an alternative scan pattern to MAP's nominal dual-spin science mode using only one or two reaction wheels and thrusters. Finally, an algorithm has been developed that uses thruster one shots while in science mode for momentum management. This algorithm has been developed in case system momentum builds up faster than anticipated, to allow adequate momentum management while minimizing interruptions to science. In this paper, each mode and algorithm will be discussed, and simulation results presented.

ODonnell, James R., Jr.↗

NASA NTRS1976

Inductively coupled TI-MPD spacecraft electric propulsion

A nuclear electric propulsion concept using a thermionic reactor inductively coupled to a magnetoplasma-dynamic (MPD) accelerator is described and the results of preliminary analyses are presented. In this system, the thermionic generating unit operates continuously at a power level of approximately 0.4 MW, while the MPD thruster operates intermittently at higher voltages and power levels. Energy storage is provided by building up a large current in an inductor. Periodically, the charging current is interrupted and the energy stored in the magnetic field of the inductor is utilized for a short duration thrust pulse. A typical thrust pulse is characterized by a power level of 1 to 4 MWe, a duration of 1 msec, and a duty cycle of approximately 20%. Results of the preliminary analysis show that approximately 85 to 90% of the power available from the thermionic converter array can be delivered to the MPD thruster for a nominal 400 kWe system with an inductive unit suitable for a flight vehicle. Optimized values of the total specific mass of the system including the thermionic reactor, the inductor, and the MPD thruster are estimated in the range of 23 to 24 kg/kWe.

Britt, E. J.↗

NASA NTRS1991

Development and testing of a 180-volt dc electronic circuit breaker with a 335-ampere carry and 1200-ampere interrupt rating

NASA Lewis Research Center and associated contractors have conducted a program to assess the potential requirements for a high-current switch to conceptually design a switch using the best existing technology, and to build and demonstrate a breadboard which meets the requirements. The result is the high current remote bus isolator (HRBI). The HRBI is rated at 180 V dc, 335 A continuous with a 1200 A interrupt rating. It also incorporates remote-control and protective features called for by the Space Station Freedom PMAD dc test bed design. Two breadboard 335 A circuit breakers were built and tested that demonstrate a promising concept of paralleled current-limiting modules. The units incorporated all control and protective features required by advanced aerospace power systems. Component stresses in each unit were determined by design, and are consistent with a life of many thousands of fault operations.

Brush, A. S.↗

NASA NTRS1976

Pulsed thermionic converter study

A nuclear electric propulsion concept using a thermionic reactor inductively coupled to a magnetoplasmadynamic accelerator (MPD arc jet) is described, and the results of preliminary analyses are presented. In this system, the MPD thruster operates intermittently at higher voltages and power levels than the thermionic generating unit. A typical thrust pulse from the MPD arc jet is characterized by power levels of 1 to 4 MWe, a duration of 1 msec, and a duty cycle of approximately 20%. The thermionic generating unit operates continuously but with a lower power level of approximately 0.4 MWe. Energy storage between thrust pulses is provided by building up a large current in an inductor using the output of the thermionic converter array. Periodically, the charging current is interrupted, and the energy stored in the magnetic field of the inductor is utilized for a short duration thrust pulse. The results of the preliminary analysis show that a coupling effectiveness of approximately 85 to 90% is feasible for a nominal 400 KWe system with an inductive unit suitable for a flight vehicle.

Source record↗

NASA NTRS2004

Online model-based diagnosis to support autonomous operation of an advanced life support system

This article describes methods for online model-based diagnosis of subsystems of the advanced life support system (ALS). The diagnosis methodology is tailored to detect, isolate, and identify faults in components of the system quickly so that fault-adaptive control techniques can be applied to maintain system operation without interruption. We describe the components of our hybrid modeling scheme and the diagnosis methodology, and then demonstrate the effectiveness of this methodology by building a detailed model of the reverse osmosis (RO) system of the water recovery system (WRS) of the ALS. This model is validated with real data collected from an experimental testbed at NASA JSC. A number of diagnosis experiments run on simulated faulty data are presented and the results are discussed.

Non-NASA Center↗

NASA NTRS1992

Generating effective project scheduling heuristics by abstraction and reconstitution

A project scheduling problem consists of a finite set of jobs, each with fixed integer duration, requiring one or more resources such as personnel or equipment, and each subject to a set of precedence relations, which specify allowable job orderings, and a set of mutual exclusion relations, which specify jobs that cannot overlap. No job can be interrupted once started. The objective is to minimize project duration. This objective arises in nearly every large construction project--from software to hardware to buildings. Because such project scheduling problems are NP-hard, they are typically solved by branch-and-bound algorithms. In these algorithms, lower-bound duration estimates (admissible heuristics) are used to improve efficiency. One way to obtain an admissible heuristic is to remove (abstract) all resources and mutual exclusion constraints and then obtain the minimal project duration for the abstracted problem; this minimal duration is the admissible heuristic. Although such abstracted problems can be solved efficiently, they yield inaccurate admissible heuristics precisely because those constraints that are central to solving the original problem are abstracted. This paper describes a method to reconstitute the abstracted constraints back into the solution to the abstracted problem while maintaining efficiency, thereby generating better admissible heuristics. Our results suggest that reconstitution can make good admissible heuristics even better.

Janakiraman, Bhaskar↗

NASA NTRS2005

Circuit Indicates that Voice-Recording Disks are Nearly Full

A remote alarm circuit provides visible and audible signals to indicate that there is little unused space left on magnetic and optical tracks on disks used to record voice signals in a group of three multichannel voice recorders. In the particular application for which the remote alarm circuit was built, the voice recorders are required to operate without interruption, but the technicians responsible for the continuous operation of the voice recorders perform most of their duties on a different floor of the building in which the voice recorders are located.

Minuskin, Harold↗

NASA NTRS2005

Development of Software for a Lidar-Altimeter Processor

A report describes the development of software for a digital processor that operates in conjunction with a finite-impulse-response (FIR) chip in a spaceborne lidar altimeter. Processing is started by a laser-fire interrupt signal that is repeated at intervals of 25 ms. For the purpose of discriminating between returns from the ground and returns from such things as trees, buildings, and clouds, the software is required to scan digitized lidar-return data in reverse of the acquisition sequence in order to distinguish the last return pulse from within a commanded ground-return range window. The digitized waveform information within this range window is filtered through 6 matched filters, in the hardware electronics, in order to maximize the probability of finding echoes from sloped or rough terrain and minimize the probability of selecting cloud returns. From the data falling past the end of the range window, there is obtained a noise baseline that is used to calculate a threshold value for each filter. The data from each filter is analyzed by a complex weighting scheme and the filter with the greatest weight is selected. A region around the peak of the ground return pulse associated with the selected filter is placed in telemetry, as well as information on its location, height, and other characteristics. The software requires many uplinked parameters as input. Included in the report is a discussion of major software-development problems posed by the design of the FIR chip and the need for the software to complete its process within 20 ms to fit within the overall 25-ms cycle.

Rosenberg, Jacob S.↗

NASA NTRS1986

Development of an interface for an ultrareliable fault-tolerant control system and an electronic servo-control unit

The NASA Ames Research Center sponsors a research program for the investigation of Intelligent Flight Control Actuation systems. The use of artificial intelligence techniques in conjunction with algorithmic techniques for autonomous, decentralized fault management of flight-control actuation systems is explored under this program. The design, development, and operation of the interface for laboratory investigation of this program is documented. The interface, architecturally based on the Intel 8751 microcontroller, is an interrupt-driven system designed to receive a digital message from an ultrareliable fault-tolerant control system (UFTCS). The interface links the UFTCS to an electronic servo-control unit, which controls a set of hydraulic actuators. It was necessary to build a UFTCS emulator (also based on the Intel 8751) to provide signal sources for testing the equipment.

Shaver, Charles↗

NASA NTRS1980

Solar hot water system installed at Day's Lodge, Atlanta, Georgia

The solar energy hot water system installed in the Days Inns of America, Inc., Atlanta, Georgia is described. This system provides for 81 percent of the total hot water demand. There are two separate systems, each serving one building of the lodge (total of 65 suites). The entire system contains only potable city water. The 1024 square feet of Grumman Sunstream Model 332 liquid flat plate collectors and the outside piping drain whenever the collector plates approach freezing or when power is interrupted. Solar heated water from the two above ground cement lined steel tanks (1000 gallon tank) is drawn into the electric Domestic Hot Water (DHW) tanks as hot water is drawn. Electric resistance units in the DHW tanks top off the solar heated water, if needed, to reach thermostat setting.

Source record↗

NASA NTRS2012

Science Operations with the James Webb Space Telescope

The James Webb Space Telescope (JWST) will be a powerful space observatory whose four science instruments will deliver rich imaging and multiplexed spectroscopic datasets to the astronomical and planetary science communities. The ground segment for JWST, now being designed and built, will carry out JWST's science operations. The ground segment includes: (1) software that the scientific community will use to propose and specify new observations; (2) software that will schedule both science and calibration observations in a way that optimizes observing efficiency while managing the accumulation of momentum; (3) the infrastructure to regularly measure and maintain the telescope's wavefront; (4) orbit determination, ranging, and tracking; (5) communication via the Deep Space Network to command the observatory and retrieve scientific data; (6) onboard scripts that execute each observing program in an event-driven fashion, with occasional interruptions for targets of opportunity or time-critical observations; and (7) a system that processes and calibrates the data into science ready products, automatically recalibrates when calibrations improve, and archives the data for timely access by the principal investigator and later worldwide access by the scientific community. This ground system builds on experience from operating the Hubble Space Telescope, while solving challenges that are unique to the James Webb Space Telescope. In this paper, we describe the elements of the JWST ground system, how it will work operationally from the perspective of the observatory itself, and how a typical user will interact with the system to turn his/her idea into scientific discovery.

Rigby, Jane↗

NASA NTRS1989

Advanced information processing system: Local system services

The Advanced Information Processing System (AIPS) is a multi-computer architecture composed of hardware and software building blocks that can be configured to meet a broad range of application requirements. The hardware building blocks are fault-tolerant, general-purpose computers, fault-and damage-tolerant networks (both computer and input/output), and interfaces between the networks and the computers. The software building blocks are the major software functions: local system services, input/output, system services, inter-computer system services, and the system manager. The foundation of the local system services is an operating system with the functions required for a traditional real-time multi-tasking computer, such as task scheduling, inter-task communication, memory management, interrupt handling, and time maintenance. Resting on this foundation are the redundancy management functions necessary in a redundant computer and the status reporting functions required for an operator interface. The functional requirements, functional design and detailed specifications for all the local system services are documented.

Burkhardt, Laura↗

NASA NTRS1980

Solar hot water system installed at Quality Inn, Key West, Florida

The solar energy hot water system installed in the Quality Inn, Key West, Florida, which consists of four buildings is described. Three buildings are low-rise, two-story buildings containing 100 rooms. The fourth is a four-story building with 48 rooms. The solar system was designed to provide approximately 50 percent of the energy required for the domestic hot water system. The solar system consists of approximately 1400 square feet of flat plate collector, two 500 gallon storage tanks, a circulating pump, and a controller. Operation of the system was begun in April 1978, and has continued to date with only three minor interruptions for pump repair. In the first year of operation, it was determined that the use of the solar facility resulted in forty percent fuel savings.

Source record↗

NASA NTRS2008

The EXIST Mission Concept Study

EXIST is a mission designed to find and study black holes (BHs) over a wide range of environments and masses, including: 1) BHs accreting from binary companions or dense molecular clouds throughout our Galaxy and the Local Group, 2) supermassive black holes (SMBHs) lying dormant in galaxies that reveal their existence by disrupting passing stars, and 3) SMBHs that are hidden from our view at lower energies due to obscuration by the gas that they accrete. 4) the birth of stellar mass BHs which is accompanied by long cosmic gamma-ray bursts (GRBs) which are seen several times a day and may be associated with the earliest stars to form in the Universe. EXIST will provide an order of magnitude increase in sensitivity and angular resolution as well as greater spectral resolution and bandwidth compared with earlier hard X-ray survey telescopes. With an onboard optical-infra red (IR) telescope, EXIST will measure the spectra and redshifts of GRBs and their utility as cosmological probes of the highest z universe and epoch of reionization. The mission would retain its primary goal of being the Black Hole Finder Probe in the Beyond Einstein Program. However, the new design for EXIST proposed to be studied here represents a significant advance from its previous incarnation as presented to BEPAC. The mission is now less than half the total mass, would be launched on the smallest EELV available (Atlas V-401) for a Medium Class mission, and most importantly includes a two-telescope complement that is ideally suited for the study of both obscured and very distant BHs. EXIST retains its very wide field hard X-ray imaging High Energy Telescope (HET) as the primary instrument, now with improved angular and spectral resolution, and in a more compact payload that allows occasional rapid slews for immediate optical/IR imaging and spectra of GRBs and AGN as well as enhanced hard X-ray spectra and timing with pointed observations. The mission would conduct a 2 year full sky survey in scanning mode, interrupted for several orbits per day by GRB follow-ups, followed by a combined pointing-scanning mission phase for optical/IR spectroscopy and redshifts for the large AGN sample found in the survey as well as GRBs and LSST transients. A Team of university, NASA, and industry investigators will conduct the study to determine the full sensitivity and capabilities of this new configuration for EXIST. It will build on the extensive studies of the prior design for the mission and the HET and will incorporate the optical/IR telescope (hereafter IRT) now fully developed by our ITT partner for the NextView Commercial Remote Sensing mission (early 2008 launch) with a focal plane to be developed at GSFC based in part on JWST/NIRSPEC designs. No new technology is needed for either the IRT or HET instruments. The study will pay close attention to full mission cost and present a design for the Decadal Survey Workshop to ensure this even more capable EXIST mission is once again part of the next Decadal Survey.

Fishman, Gerald J.↗