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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 19 records
All sourcesNASA NTRSDOE OSTI
NASA NTRS2009

A Review of State-of-the-Art Separator Materials for Advanced Lithium-Based Batteries for Future Aerospace Missions

As NASA embarks on a renewed human presence in space, safe, human-rated, electrical energy storage and power generation technologies, which will be capable of demonstrating reliable performance in a variety of unique mission environments, will be required. To address the future performance and safety requirements for the energy storage technologies that will enhance and enable future NASA Constellation Program elements and other future aerospace missions, advanced rechargeable, lithium-ion battery technology development is being pursued with an emphasis on addressing performance technology gaps between state-of-the-art capabilities and critical future mission requirements. The material attributes and related performance of a lithium-ion cell's internal separator component are critical for achieving overall optimal performance, safety and reliability. This review provides an overview of the general types, material properties and the performance and safety characteristics of current separator materials employed in lithium-ion batteries, such as those materials that are being assessed and developed for future aerospace missions.

Bladwin, Richard S.↗
NASA NTRS1992

Resin transfer molding for advanced composite primary wing and fuselage structures

The stitching and resin transfer molding (RTM) processes developed at Douglas Aircraft Co. are successfully demonstrating significant cost reductions with good damage tolerance properties. These attributes were identified as critical to application of advanced composite materials to commercial aircraft primary structures. The RTM/stitching developments, cost analyses, and test results are discussed of the NASA Advanced Composites Technology program.

Markus, Alan↗
NASA NTRS2002

Development of a Prototype Low-Voltage Electron Beam Freeform Fabrication System

NASA's Langley Research Center and Johnson Space Center are developing a solid freeform fabrication system utilizing an electron beam energy source and wire feedstock. This system will serve as a testbed for exploring the influence of gravitational acceleration on the deposition process and will be a simplified prototype for future systems that may be deployed during long-duration space missions for assembly, fabrication, and production of structural and mechanical replacement components. Critical attributes for this system are compactness, minimal mass, efficiency in use of feedstock material, energy use efficiency, and safety. The use of a low-voltage (less than 15kV) electron beam energy source will reduce radiation so that massive shielding is not required to protect adjacent personnel. Feedstock efficiency will be optimized by use of wire, and energy use efficiency will be achieved by use of the electron beam energy source. This system will be evaluated in a microgravity environment using the NASA KC-135A aircraft.

Watson, J. K.↗
NASA NTRSDate not supplied

Contracting Quality Early in the Lifecycle Using AS9145 Data Deliverables

Development schedules and a highly dynamic supply chain are a challenge to developers of complex systems produced at low volume. Flaws in designs, parts and materials availability problems, poor manufacturability, and a lack of knowledge about critical items and key process attributes can be realized well before traditional second-party quality assurance activities begin. Supplier audits and product inspections may have little mitigating effect once these foundational problems have been realized. Their impacts can be significant lifecycle disruption, cost overruns, inability to deliver to plan, and even project cancellation. AS9145, Requirements for Advanced Product Quality Planning and Production Part Approval Process, can be used to drive quality engineering practices into early development lifecycles to significantly reduce this late-cycle risk and to reduce the cost of quality overall. Since its initial publication in 2016, it has had very limited adoption by the DoD, no adoption by NASA, and sparse adoption in the aerospace and defense supply chain. A task group within the Aerospace Industries Association's (AIA) Joint Strategic Quality Council (JSQC) identified that both acquirers and suppliers see as AS9145 as a cost-adder and are hesitant to use it as an alternative to late-stage-heavy quality assurance approaches. A lack of prior use creates large capability gaps in request-for-proposal (RFP) teams, proposal teams, suppliers’ quality management systems (QMS), and in experienced personnel executing the early lifecycle approach. To create a more realizable on-ramp for using AS9145 in the space and defense sectors, the AIA JSQC task team created five deliverable requirements descriptions (DRDs) that can be used in a contract to begin to engage both parties in early lifecycle quality engineering and quality assurance activities, that reduce exposure to late-stage cost and schedule collapse due to unidentified risks in design, supply chain, and manufacturability. These DRDs drive the parties to engage in planning and analysis discussions early on to understand what production risks can be known and how they will focus resources based on safety criticality and the key elements of design and construction. The suppliers and acquirers who will produce the data and information required by the DRD will be able to incrementally evolve their QMS and the acquirer will incrementally be able to track and understand the benefits of cost shifting from late to early development phases. A white paper describing this approach and the five recommended DRDs will be published by the AIA in late 2024 or early 2025.

Jeannette Plante↗
NASA NTRS2010

Pressure Flammability Thresholds in Oxygen of Selected Aerospace Materials

The experimental approach consisted of concentrating the testing in the flammability transition zone following the Bruceton Up-and-Down Method. For attribute data, the method has been shown to be very repeatable and most efficient. Other methods for characterization of critical levels (Karberand Probit) were also considered. The data yielded the upward limiting pressure index (ULPI), the pressure level where approx.50% of materials self-extinguish in a given environment.Parametric flammability thresholds other than oxygen concentration can be determined with the methodology proposed for evaluating the MOC when extinguishment occurs. In this case, a pressure threshold in 99.8% oxygen was determined with the methodology and found to be 0.4 to 0.9 psia for typical spacecraft materials. Correlation of flammability thresholds obtained with chemical, hot wire, and other ignition sources will be conducted to provide recommendations for using alternate ignition sources to evaluate flammability of aerospace materials.

Hirsch, David↗
NASA NTRS2004

Ground-Based VIS/NIR Reflectance Spectra of 25143 Itokawa: What Hayabusa will See and How Ground-Based Data can Augment Analyses

Planning for the arrival of the Hayabusa spacecraft at asteroid 25143 Itokawa includes consideration of the expected spectral information to be obtained using the AMICA and NIRS instruments. The rotationally-resolved spatial coverage the asteroid we have obtained with ground-based telescopic spectrophotometry in the visible and near-infrared can be utilized here to address expected spacecraft data. We use spectrophotometry to simulate the types of data that Hayabusa will receive with the NIRS and AMICA instruments, and will demonstrate them here. The NIRS will cover a wavelength range from 0.85 m, and have a dispersion per element of 250 Angstroms. Thus, we are limited in coverage of the 1.0 micrometer and 2.0 micrometer mafic silicate absorption features. The ground-based reflectance spectra of Itokawa show a large component of olivine in its surface material, and the 2.0 micrometer feature is shallow. Determining the olivine to pyroxene abundance ratio is critically dependent on the attributes of the 1.0- and 2.0 micrometer features. With a cut-off near 2,1 micrometer the longer edge of the 2.0- feature will not be obtained by NIRS. Reflectance spectra obtained using ground-based telescopes can be used to determine the regional composition around space-based spectral observations, and possibly augment the longer wavelength spectral attributes. Similarly, the shorter wavelength end of the 1.0 micrometer absorption feature will be partially lost to the NIRS. The AMICA filters mimic the ECAS filters, and have wavelength coverage overlapping with the NIRS spectral range. We demonstrate how merging photometry from AMICA will extend the spectral coverage of the NIRS. Lessons learned from earlier spacecraft to asteroids should be considered.

Vilas, Faith↗
NASA NTRS2023

Manufacturing and Mechanical Testing of TC1225/LM-PAEK and TC1200/PEEK Thermoplastic Composite Panels

Development of thermoplastic composites (TPCs) for aerospace structures is experiencing renewed enthusiasm attributed to the availability of rapid manufacturing technology, ease of joining through fusion welding processes, and the successful utilization of the material in flight critical structures. Semicrystalline thermoplastics such as polyether ether ketone (PEEK), polyether ketone ketone (PEKK), and polyphenylene sulfide (PPS) have been successfully demonstrated as thermoplastic skins, keel beams, and angle brackets for commercial aircraft. Composite specimens were fabricated from the Toray TC1225 and TC1200 unidirectional prepreg systems and tested to gain confidence with NASA in-house TPC processing as part of the Thermoplastics Development for Exploration Application (TDEA) project. TC1225 is a relatively new material system that uses T700GC fibers and low-melt polyaryl ether ketone (LM-PAEK) resin. TC1200 is the latest version of a material system that has been available for several decades with AS4 fibers and PEEK resin. Results for ultrasonic inspection, optical microscopy, acid digestion, and differential scanning calorimetry establish the quality of the panels. Mechanical test data for unnotched and notched laminate tension and compression as well as compression after impact provide data for equivalency assessment and support material selection in TDEA. Satisfactory equivalence of the TC1225 results and the National Center for Advanced Materials Performance (NCAMP) database was found. The results indicate high-quality manufacturing was achieved, and the resulting mechanical test data are in agreement with that in the literature.

Thermoplastic Composites↗
NASA NTRS2006

Manned Spacecraft Requirements for Materials and Processes

A major cause of project failure can be attributed to an emphasized focus on end products and inadequate attention to resolving development risks during the initial phases of a project. The initial phases of a project, which we will call the "study period", are critical to determining project scope and costs, and can make or break most projects. If the requirements are not defined adequately, how can the scope be adequately determined, also how can the costs of the entire project be effectively estimated, and how can the risk of project success be accurately assessed? Using the proper material specifications and standards and incorporating these specifications and standards in the design process should be considered inherently crucial to the technical success of a project as just as importantly, crucial to the cost and schedule success. This paper will intertwine several important aspects or considerations for project success: 1) Characteristics of a "Good Material Requirement"; 2) Linking material requirements to the implementation of "Design for Manufacturing"; techniques and 3) The importance of decomposing materials requirements during the study phase/development phase to mitigate project risk for the maturation of technologies before the building of hardware.

Vaughn, Timothy P.↗
NASA NTRS2008

Structural, Physical, and Compositional Analysis of Lunar Simulants and Regolith

Relative to the prior manned Apollo and unmanned robotic missions, planned Lunar initiatives are comparatively complex and longer in duration. Individual crew rotations are envisioned to span several months, and various surface systems must function in the Lunar environment for periods of years. As a consequence, an increased understanding of the surface environment is required to engineer and test the associated materials, components, and systems necessary to sustain human habitation and surface operations. The effort described here concerns the analysis of existing simulant materials, with application to Lunar return samples. The interplay between these analyses fulfills the objective of ascertaining the critical properties of regolith itself, and the parallel objective of developing suitable stimulant materials for a variety of engineering applications. Presented here are measurements of the basic physical attributes, i.e. particle size distributions and general shape factors. Also discussed are structural and chemical properties, as determined through a variety of techniques, such as optical microscopy, SEM and TEM microscopy, Mossbauer Spectroscopy, X-ray diffraction, Raman microspectroscopy, inductively coupled argon plasma emission spectroscopy and energy dispersive X-ray fluorescence mapping. A comparative description of currently available stimulant materials is discussed, with implications for more detailed analyses, as well as the requirements for continued refinement of methods for simulant production.

Greenberg, Paul↗
NASA NTRS1991

Thermal stress analysis of a silicon carbide/aluminum composite

Thermal deformations and stresses were studied in a silicon-carbide/aluminum filamentary composite at temperatures up to 370 C (700 F). Longitudinal and transverse thermal strains were measured with strain gages and a dilatometer. An elastoplastic micromechanical analysis based on a one-dimensional rule-of-mixtures model and an axisymmetric two-material composite cylinder model was performed. It was established that beyond a critical temperature thermal strains become nonlinear with decreasing longitudinal and increasing transverse thermal-expansion coefficients. This behavior was attributed to the plastic stresses in the aluminum matrix above the critical temperature. An elastoplastic analysis of both micromechanical models was performed to determine the stress distributions and thermal deformation in the fiber and matrix of the composite. While only axial stresses can be determined by the rule-of-mixtures model, the complete triaxial state of stress is established by the composite cylinder model. Theoretical predictions for the two thermal-expansion coefficients were in satisfactory agreement with experimental results.

Gdoutos, E. E.↗
NASA NTRS1991

The effects of space radiation on thin films of YBa2Cu3O(7-x)

This investigation had two objectives: (1) to determine the effects of space radiation on superconductor parameters that are most important in space applications; and (2) to determine whether this effect can be simulated with Co-60 gamma rays, the standard test method for space materials. Thin films of yttrium barium copper oxide (YBCO) were formed by coevaporation of Y, BaF2, and Cu and post-annealing in wet oxygen at 850 C for 3.5 h. The substrate used was (100) silicon with an evaporated zirconia buffer layer. The samples were characterized by four point probe electrical measurements as a function of temperature. The parameters measured were the zero resistance transition temperature T(sub c) and the room temperature resistance. The samples were then exposed to Co-60 gamma-rays in air and in pure nitrogen, and to 780 keV electrons, in air. The parameters were then remeasured. The results are summarized. The results indicate little or no degradation in the parameters measured for samples exposed up to 10 Mrads of gamma-rays in nitrogen. However, complete degradation is preliminarily attributed to the high level of ozone generated in the chamber by the gamma-ray interaction with air. It can be concluded that: (1) the electron component of space radiation does not degrade the critical temperature of the YBCO films described, at least for energies around 800 keV and doses similar to those received by surface materials on spacecraft in typical remote sensing missions; and (2) for qualifying this and other superconducting materials against the space-radiation threat the standard test method used in the aerospace industry, namely, exposure to Co-60 gamma-rays in air, may require some further investigation. As a minimum, the sample must be either in vacuum or in positive nitrogen pressure.

Herschitz, R.↗
NASA NTRS1990

The effects of space radiation on thin films of YBa2Cu3O(sub 7-x)

This investigation had two objectives: (1) to determine the effects of space radiation on superconductor parameters that are most important in space applications; and (2) to determine whether this effect can be simulated with Co-60 gamma rays, the standard test method for space materials. Thin films of yttrium barium copper oxide (YBCO) were formed by coevaporation of Y, BaF2, and Cu and post-annealing in wet oxygen at 850 C for 3.5 h. The substrate used was (100) silicon with an evaporated zirconia buffer layer. The samples were characterized by four point probe electrical measurements as a function of temperature. The parameters measured were the zero resistance transition temperature (T sub c) and the room temperature resistance. The samples were then exposed to Co-60 gamma-rays in air and in pure nitrogen, and to 780 keV electrons, in air. The parameters were then remeasured. The results are summarized. The results indicate little or no degradation in the parameters measured for samples exposed up to 10 Mrads of gamma-rays in nitrogen. However, complete degradation of samples exposed to 10-Mrad in air was observed. This degradation is preliminarily attributed to the high level of ozone generated in the chamber by the gamma-ray interaction with air. It can be concluded that: (1) the electron component of space radiation does not degrade the critical temperature of the YBCO films described, at least for energies around 800 keV and doses similar to those received by surface materials on spacecraft in typical remote sensing missions; and (2) for qualifying this and other superconducting materials against the space-radiation threat the standard test method in the aerospace industry, namely, exposure to Co-60 gamma-rays in air, may require some further investigation. As a minimum, the sample must be either in vacuum or in positive nitrogen pressure.

Herschitz, R.↗
NASA NTRS1973

Multidimensional analysis of fast-spectrum material replacement measurements for systematic estimation of cross section uncertainties

A series of central core and core-reflector interface sample replacement experiments for 16 materials performed in the NASA heavy-metal-reflected, fast spectrum critical assembly (NCA) were analyzed in four and 13 groups using the GAM 2 cross-section set. The individual worths obtained by TDSN and DOT multidimensional transport theory calculations showed significant differences from the experimental results. These were attributed to cross-section uncertainties in the GAM 2 cross sections. Simultaneous analysis of the measured and calculated sample worths permitted separation of the worths into capture and scattering components which systematically provided fast spectrum averaged correction factors to the magnitudes of the GAM 2 absorption and scattering cross sections. Several Los Alamos clean critical assemblies containing Oy, Ta, and Mo as well as one of the NCA compositions were reanalyzed using the corrected cross sections. In all cases the eigenvalues were significantly improved and were recomputed to within 1 percent of the experimental eigenvalue. A comparable procedure may be used for ENDF cross sections when these are available.

Klann, P. G.↗
NASA NTRS1992

The nonlinear bending response of thin-walled laminated composite cylinders

The geometrically nonlinear Donnell shell theory is applied to the problem of stable bending of thin-walled circular cylinders. Responses are computed for cylinders with a radius-to-thickness ratio of 50 and length-to-radius ratios of 1 and 5. Four laminated composite cylinders and an aluminum cylinder are considered. Critical moment estimates are presented for short cylinders for which compression-type buckling behavior is important, and for very long cylinders for which the cross-section flattening, i.e., Brazier effect, is important. A finite element analysis is used to estimate the critical end rotation in addition to establishing the range of validity of the prebuckling analysis. The radial displacement response shows that the character of the boundary layer is significantly influenced by the geometric nonlinearities. Application of a first ply failure analysis using the maximum stress criterion suggests that in nearly all instances material failure occurs before buckling. Failure of the composite cylinders can be attributed to fiber breakage. Striking similarities are seen between the prebuckling displacements of the bending problem and axial compression problem for short cylinders.

Fuchs, Hannes P.↗
NASA NTRS1985

Reduction of Moisture Effects During the Cure of Epoxy Adhesives Used in Composite Repair

The requirements for repair work on Naval aircraft composite wing skins that can be performed under depot conditions (or still worse, under field conditions) are quite restrictive. Equipment that can be used is rather limited as are the available repair space and time. The procedures must be simple enough so that they can be performed satisfactorily by personnel without special knowledge in composite materials technology. Repairs of small holes should not require more than perhaps a short predrying cycle (with heat guns) and a subsequent patch bonding using a heating blanket, held in place by applying a vacuum. However, it has been observed during simulated experimental repair work that the glue lines frequently show a high content of pores and bubbles which are attributed to evaporation of moisture during the curing cycle. (Of course, other volatile materials such as residual solvent would act similarly). The purpose of this paper is to give some detailed analysis of the problem of moisture transport as a function of repair conditions, and to discuss some preliminary work to reduce the effect of moisture by removing moisture chemically with carbodiimides before it reaches a critical level for bubble formations.

Augl, J. M.↗
NASA NTRS2010

Battery Separator Characterization and Evaluation Procedures for NASA's Advanced Lithium-Ion Batteries

To address the future performance and safety requirements for the electrical energy storage technologies that will enhance and enable future NASA manned aerospace missions, advanced rechargeable, lithium-ion battery technology development is being pursued within the scope of the NASA Exploration Technology Development Program s (ETDP's) Energy Storage Project. A critical cell-level component of a lithium-ion battery which significantly impacts both overall electrochemical performance and safety is the porous separator that is sandwiched between the two active cell electrodes. To support the selection of the optimal cell separator material(s) for the advanced battery technology and chemistries under development, laboratory characterization and screening procedures were established to assess and compare separator material-level attributes and associated separator performance characteristics.

Baldwin, Richard S.↗
NASA NTRS1992

Materials science research in microgravity

There are several important attributes of an extended duration microgravity environment that offer a new dimension in the control of the microstructure, processing, and properties of materials. First, when gravitational effects are minimized, buoyancy driven convection flows are also minimized. The flows due to density differences, brought about either by composition or temperature gradients will then be reduced or eliminated to permit a more precise control of the temperature and the composition of a melt which is critical in achieving high quality crystal growth of electronic materials or alloy structures. Secondly, body force effects such as sedimentation, hydrostatic pressure, and deformation are similarly reduced. These effects may interfere with attempts to produce uniformly dispersed or aligned second phases during melt solidification. Thirdly, operating in a microgravity environment will facilitate the containerless processing of melts to eliminate the limitations of containment for reactive melts. The noncontacting forces such as those developed from electromagnet, electrostatic, or acoustic fields can be used to position samples. With this mode of operation, contamination can be minimized to enable the study of reactive melts and to eliminate extraneous crystal nucleation so that novel crystalline structures and new glass compositions may be produced. In order to take advantage of the microgravity environment for materials research, it has become clear that reliable processing models based on a sound ground based experimental experience and an established thermophysical property data base are essential.

Perepezko, John H.↗
NASA NTRS2001

Prospects for Nuclear Electric Propulsion Using Closed-Cycle Magnetohydrodynamic Energy Conversion

Nuclear electric propulsion (NEP) has long been recognized as a major enabling technology for scientific and human exploration of the solar system, and it may conceivably form the basis of a cost-effective space transportation system suitable for space commerce. The chief technical obstacles to realizing this vision are the development of efficient, high-power (megawatt-class) electric thrusters and the development of low specific mass (less than 1 kg/kWe) power plants. Furthermore, comprehensive system analyses of multimegawatt class NEP systems are needed in order to critically assess mission capability and cost attributes. This Technical Publication addresses some of these concerns through a systematic examination of multimegawatt space power installations in which a gas-cooled nuclear reactor is used to drive a magnetohydrodynamic (MHD) generator in a closed-loop Brayton cycle. The primary motivation for considering MHD energy conversion is the ability to transfer energy out of a gas that is simply too hot for contact with any solid material. This has several intrinsic advantages including the ability to achieve high thermal efficiency and power density and the ability to reject heat at elevated temperatures. These attributes lead to a reduction in system specific mass below that obtainable with turbine-based systems, which have definite solid temperature limits for reliable operation. Here, the results of a thermodynamic cycle analysis are placed in context with a preliminary system analysis in order to converge on a design space that optimizes performance while remaining clearly within established bounds of engineering feasibility. MHD technology issues are discussed including the conceptual design of a nonequilibrium disk generator and opportunities for exploiting neutron-induced ionization mechanisms as a means of increasing electrical conductivity and enhancing performance and reliability. The results are then used to make a cursory examination of piloted Mars missions during the 2018 opportunity.

Litchford, R. J.↗