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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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Rocket engine evaluation of erosion and char as functions of fabric orientation for silica reinforced nozzle materials
NASA's future missions will be more demanding. They require materials to be mass efficient, robust, multi-functional, scalable and able to be integrated with other subsystems to enable innovative missions to accomplish future science missions. Thermal protection systems and materials (TPSM) are critical for the robotic and human exploration of the solar system when it involves entry. TPSM is a single string system with no back-up. Mass efficiency and robustness are required. Integration of TPSM with the aeroshell is both a challenge and an opportunity. Since 2010, NASA's Space Technology Mission Directorate has invested in innovative new materials and systems across a spectrum of game changing technologies. In this keynote address, we plan to highlight and present our successful approaches utilized in developing four different materials and system technologies that use innovative new manufacturing techniques to meet mission needs. 3-D weaving and felt manufacturing allowed us to successfully propose new ways of addressing TPSM challenges. In the 3-D MAT project, we developed and delivered a multi-functional TPS materials solution, in under three years that is an enabler for Lunar Capable Orion Spacecraft. Under the HEEET project, we are developing a robust heat-shield that can withstand extreme entry conditions, both thermally and mechanically, for entry at Venus, Saturn or higher speed sample return missions. The improved efficiency of HEEET allows science missions entry at much reduced G'loads enabling delicate science instruments to be used. The ADEPT concept is a foldable and deployable entry system and the critical component is a multi-functional fabric that is foldable and deployable and also functions as a mechanical aeroshell and a TPS. The fourth technology we will highlight involves felt to address integration challenges of rigid ablative system such as PICA that was used on MSL. The felt technology allows us to develop a compliant TPS for easy integration. The above four technology developments have focused on mission infusion as the success criteria. These technologies are in different stages of mission infusion. These innovations have led to new mission concepts to be proposed in the future. In our keynote address we will present approaches we have employed throughout the project to create the bridge to transition from low TRL to mission infusion and to overcome the traditional TRL valley of death.
The article deals with the thermal protection system (TPS) designed to keep Space Shuttle structures at 350 F ratings over a wide range of temperatures encountered in orbit, but also during prelaunch, launch, deorbit and re-entry, landing and turnaround. The structure, function, fabrication, and bonding of various types of reusable surface insulation and composite materials are described. Test programs are developed for insulation, seals, and adhesion bonds; leak tests and acoustic fatigue tests are mentioned. Test facilities include arc jets, radiant heaters, furnaces, and heated tunnels. The certification tests to demonstrate TPS reusability, structural integrity, thermal performance, and endurance will include full-scale assembly tests and initial orbital flight tests.
Adhesive repair system for application in weightless vacuum space environment
Systems and methods for fabricating multi-functional articles comprised of additively formed gradient materials are provided. The fabrication of multi-functional articles using the additive deposition of gradient alloys represents a paradigm shift from the traditional way that metal alloys and metal/metal alloy parts are fabricated. Since a gradient alloy that transitions from one metal to a different metal cannot be fabricated through any conventional metallurgy techniques, the technique presents many applications. Moreover, the embodiments described identify a broad range of properties and applications.
A modified sedimentation process was used in the production of a functionally gradient material (FGM), NiAl/Al2O3. A simple finite element model was used to guide our design and fabrication efforts by estimating residual stress states as a function of composite structure. This approach could lead to tailored designs that enhance or avoid specific residual stress states. Thermal cycling tests were factored into the model to predict time dependent or steady-state internal temperature and stress profiles. Four-point bend tests were conducted to establish the mechanical load-displacement behavior of a single interlayer FGM at room temperature, 800 and 1000 K. Room temperature bend strength of the FGM was 3-4 times that of the base NiAl. At elevated temperatures, composite fracture occurred in a gradual, noncatastrophic mode involving NiAl retardation of a succession of cracks originating in the alumina face.
Deployable Entry Vehicles (DEVs) enable in-situ scientific exploration at destinations with atmospheres across the solar system. Because they stow in a compact form and deploy only when ready to enter the atmosphere, DEVs relax the volume constraint imposed by rigid aeroshells. This work seeks to do for a DEV what the Wright Brothers did to propel modern day aviation: develop the guidance and control (G&C) methods that will make maneuvering and precision landing of DEV a reality. The Pterodactyl project objective is to deliver an integrated G&C methodology for a DEV, based on a detailed analysis that utilizes a Multi-disciplinary, Design, Analysis and Optimization (MDAO) framework. The current state-of-the-art for blunt body entry, G&C is rooted in the precision landing of vehicles such as Mars Science Laboratory (MSL) and Apollo, which used a propulsive reaction control system (RCS) to steer. Recent research has taken a particular interest in non-propulsive control for DEVs, including direct force control (angle of attack modulation via control surfaces or mass movement) and drag modulation (discrete change in ballistic coefficient). Using the MDAO framework that includes a guidance and control model to explore multiple control concepts for a DEV will shed light on the best design approach for these vehicles. In Pterodactyl, we will complete this study for a novel DEV concept, and then we will fabricate a functional prototype to help validate the design. The project is expected to down-select to a final control architecture by the end of 2018, and complete fabrication of the prototype by the end of 2019.The DEV chosen for detailed study in this project is the Adaptable Deployable Entry and Placement Technology (ADEPT). ADEPT uses a revolutionary 3D-woven carbon fabric that is foldable, can serve as primary structure, and can survive the extreme heating environment of atmospheric entry. The specific configuration of ADEPT under investigation is called Lifting Nano-ADEPT (LNA). LNA is designed for secondary payloads missions that require precision landing either for scientific objectives at a target destination or for payload recovery at Earth.The MDAO framework being created through this research, called COBRA-Pt (Composite Beam Roll-Up Solar Array-Prototype), will combine three critical elements of the system design: a guidance algorithm with Monte Carlo, a parametric control model, and vehicle geometry details. Novel control models being studied are deployable aerodynamic surfaces as well as shape morphing. These concepts will be compared at the system level with a more traditional propulsive RCS by comparing several key performance parameters. Upon completion of the design study, a functional prototype of LNA will be fabricated that will include the integration of guidance software and relevant control actuators. We expect this study will provide critical data that could feed into the development of an Earth-based flight test of LNA. The COBRA-Pt framework will provide a modular system by which to study any DEV concept in any atmosphere.
Low pass elliptic function filter fabricated from RC network and low gain voltage amplifier
Design, fabrication, and functional testing of brushless dc motors with split winding connected in series or parallel
An experimental program was conducted to extend the Tracor Safety Gauge (patent pending) to elevated temperature service. The Safety Gauge is based on a conductive composite device which can be fabricated to function as a fatigue sensor that undergoes an irreversible resistance increase which results from cumulative strain damage. Prototype sensors were developed which appear capable of 1000 deg F operation for short periods of time (approaching one hour); however, bonding difficulties currently limit their use to about 775 deg F. The resistance change of the sensor was generally on the order of 400% or greater as the fatigue life of a titanium alloy (Ti-5Al-2.5Sn) test specimen was approached.
The results of a program for the development, fabrication and functional test of an engineering model magnetically suspended reaction wheel are described. The reaction wheel develops an angular momentum of + or - 0.5 foot-pound-second and is intended for eventual application in the attitude control of long-life interplanetary and orbiting spacecraft. A description of the wheel design and its major performance characteristics is presented. Recommendations for flight prototype development are made.
NASA's program for development of a laminar flow technology base for application to commercial transports has made significant progress since its inception in 1976. Current efforts are focused on development of practical reliable systems for the leading-edge region where the most difficult problems in applying laminar flow exist. Practical solutions to these problems will remove many concerns about the ultimate practicality of laminar flow. To address these issues, two contractors performed studies, conducted development tests, and designed and fabricated fully functional leading-edge test articles for installation on the NASA JetStar aircraft. Systems evaluation and performance testing will be conducted to thoroughly evaluate all system capabilities and characteristics. A simulated airline service flight test program will be performed to obtain the operational sensitivity, maintenance, and reliability data needed to establish that practical solutions exist for the difficult leading-edge area of a future commercial transport employing laminar flow control.
NASA's program for development of a laminar flow technology base for application to commercial transports has made significant progress since its inception in 1976. Current efforts are focused on development of practical reliable systems for the leading-edge region where the most difficult problems in applying laminar flow exist. Practical solutions to these problems will remove many concerns about the ultimate practicality of laminar flow. To address these issues, two contractors performed studies, conducted development tests, and designed and fabricated fully functional leading-edge test articles for installation on the NASA JetStar aircraft. Systems evaluation and performance testing will be conducted to thoroughly evaluate all system capabilities and characteristics. A simulated airline service flight test program will be performed to obtain the operational sensitivity, maintenance, and reliability data needed to establish that practical solutions exist for the difficult leading-edge area of a future commercial transport employing laminar flow control.
This paper presents the results of an experimental study designed to explore both qualitatively and quantitatively the mechanism of the improved current gain in bipolar transistors with polysilicon emitter contacts. Polysilicon contacts were deposited and heat treated at different conditions. The electrical properties were measured using p-n junction test structures that are much more sensitive to the contact properties than are bipolar transistors. A simple phenomenological model was used to correlate the structural properties with electrical measurements. Possible transport mechanisms are examined and estimates are made about upper bounds on transport parameters in the principal regions of the devices. The main conclusion of this study is that the minority-carrier transport in the polycrystalline silicon is dominated by a highly disordered layer at the polysilicon-monosilicon interface characterized by very low minority-carrier mobility. The effective recombination velocity at the n(+) polysilicon-n(+) monosilicon interface was found to be a strong function of fabrication conditions. The results indicate that the recombination velocity can be much smaller than 10,000 cm/s.
Progress on optically addressing a CMOS RAM for a feasibility demonstration of free space optical interconnection is reported in this paper. The optical RAM chip has been fabricated and functional testing is in progress. Initial results seem promising. New design and SPICE simulation of optical gate cell (OGC) circuits have been carried out to correct the slow fall time of the 'weak pull down' OGC, which has been characterized experimentally. Methods of reducing the response times of the photodiodes and the associated circuits are discussed. Even with the current photodiode, it appears that an OGC can be designed with a performance that is compatible with a CMOS circuit such as the RAM.
A smoke generator system was developed for in-flight vortex flow studies on the F-18 high alpha research vehicle (HARV). The development process included conceptual design, a survey of existing systems, component testing, detailed design, fabrication, and functional flight testing. Housed in the forebody of the aircraft, the final system consists of multiple pyrotechnic smoke cartridges which can be fired simultaneously or in sequence. The smoke produced is ducted to desired locations on the aircraft surface. The smoke generator system (SGS) has been used successfully to identify vortex core and core breakdown locations as functions of flight condition. Although developed for a specific vehicle, this concept may be useful for other aerodynamic flight research which requires the visualization of local flows.
Automated remote fluid servicing will be necessary for future space missions, as future satellites will be designed for on-orbit consumable replenishment. In order to develop an on-orbit remote servicing capability, a standard interface between a tanker and the receiving satellite is needed. The objective of the Automated Fluid Interface System (AFIS) program is to design, fabricate, and functionally demonstrate compliance with all design requirements for an automated fluid interface system. A description and documentation of the Fairchild AFIS design is provided.
In order to provide high sensitivity rapid imaging at 3.3mm (90GHz) for the Green Bank Telescope - the world's largest steerable aperture - a camera is being built by the University of Pennsylvania, NASA/GSFC, and NRAO. The heart of this camera is an 8x8 close-packed, Nyquist-sampled detector array. We have designed and are fabricating a functional superconducting bolometer array system using a monolithic planar architecture. Read out by SQUID multiplexers, the superconducting transition edge sensors will provide fast, linear, sensitive response for high performance imaging. This will provide the first ever superconducting bolometer array on a facility instrument.