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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

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NASA NTRS1984

The structural optimization of a spreader bar for twin lift helicopter operations

An optimization study was performed to develop a minimum weight spreader bar to allow two helicopters to lift the same payload. With this arrangement, the maximum payload that can be lifted is almost doubled without the expense of designing and building a new helicopter. The concept has had some limited use by civil helicopter operators using small helicopters and has been demonstrated in large scale by two CH-54's which successfully lifted a total load of 20 ton. To this point, rather heavy available beams or tower structures have been used for the spreader bar. Since the weight of the bar not only detracts from payload but also adds to the logistics problem, there are more than the usual incentives to minimize weight. Since the design requirement is for classic beam column with uniform side loads resulting from bar weight and aerodynamic drag, the design problem is particularly amenable to optimization. A study has been performed at Sikorsky to establish the minimum weight for a spreader bar sized to carry a load equal to the capacity of two Army BLACK HAWK helicopters. Toward this end, a computer program was written to analyze the spreader bar deflections and stresses and coupled to the NASA developed CONMIN optimization routines.

Dobyns, A.↗

NASA NTRS2010

Diamond Heat-Spreader for Submillimeter-Wave Frequency Multipliers

The planar GaAs Shottky diode frequency multiplier is a critical technology for the local oscillator (LO) for submillimeter- wave heterodyne receivers due to low mass, tenability, long lifetime, and room-temperature operation. The use of a W-band (75-100 GHz) power amplifier followed by a frequency multiplier is the most common for submillimeter-wave sources. Its greatest challenge is to provide enough input power to the LO for instruments onboard future planetary missions. Recently, JPL produced 800 mW at 92.5 GHz by combining four MMICs in parallel in a balanced configuration. As more power at W-band is available to the multipliers, their power-handling capability be comes more important. High operating temperatures can lead to degradation of conversion efficiency or catastrophic failure. The goal of this innovation is to reduce the thermal resistance by attaching diamond film as a heat-spreader on the backside of multipliers to improve their power-handling capability. Polycrystalline diamond is deposited by hot-filament chemical vapor deposition (CVD). This diamond film acts as a heat-spreader to both the existing 250- and 300-GHz triplers, and has a high thermal conductivity (1,000-1,200 W/mK). It is approximately 2.5 times greater than copper (401 W/mK) and 20 times greater than GaAs (46 W/mK). It is an electrical insulator (resistivity approx. equals 10(exp 15) Ohms-cm), and has a low relative dielectric constant of 5.7. Diamond heat-spreaders reduce by at least 200 C at 250 mW of input power, compared to the tripler without diamond, according to thermal simulation. This superior thermal management provides a 100-percent increase in power-handling capability. For example, with this innovation, 40-mW output power has been achieved from a 250-GHz tripler at 350-mW input power, while the previous triplers, without diamond, suffered catastrophic failures. This breakthrough provides a stepping-stone for frequency multipliers-based LO up to 3 THz. The future work for this design is to apply the high output power from both the 250 and 300 GHz to multiple chains in order to generate milliwatts at 2.3 THz. Using the first generation of results for this innovation, 40 mW of output power were produced from a 240-GHz tripler at 350-mW input power, and 27- mW output power was produced from a 300-GHz tripler at 408-mW input power. This is two times higher than the current state-of-the-art output power capability. A finite-element thermal simulation also shows that 30-microns thick diamond dropped the temperature of the anodes by at least 200 C.

Lin, Robert H.↗

NASA NTRS1983

Photovoltaic module bypass diode encapsulation

The design and processing techniques necessary to incorporate bypass diodes within the module encapsulant are presented. The Semicon PN junction diode cells were selected. Diode junction to heat spreader thermal resistance measurements, performed on a variety of mounted diode chip types and sizes, have yielded values which are consistently below 1 deg C per watt, but show some instability when thermally cycled over the temperature range from -40 to 150 deg C. Three representative experimental modules, each incorporating integral bypass diode/heat spreader assemblies of various sizes, were designed. Thermal testing of these modules enabled the formulation of a recommended heat spreader plate sizing relationship. The production cost of three encapsulated bypass diode/heat spreader assemblies were compared with similarly rated externally mounted packaged diodes. It is concluded that, when proper designed and installed, these bypass diode devices will improve the overall reliability of a terrestrial array over a 20 year design lifetime.

Shepard, N. J., Jr.↗

NASA NTRS2011

Robotic-Movement Payload Lifter and Manipulator

A payload lifter/manipulator module includes a rotatable joint supporting spreader arms angularly spaced with respect to one another. A rigid arm is fixedly coupled to the joint and extends out therefrom to a tip. A tension arm has a first end and a second end with the first end being fixedly coupled to the tip of the rigid arm. The tension arm incorporates pivots along the length thereof. Each pivot can be engaged by or disengaged from the outboard end of a spreader arm based on a position of the spreader arm. A hoist, positioned remotely with respect to the module and coupled to the second end of the tension arm, controls the position of the spreader arms to thereby control the position of the rigid arm's tip. Payload lifter/manipulator assemblies can be constructed with one or more of the modules.

Doggett, William R.↗

NASA NTRS2012

Composite with In Situ Plenums

A document describes a high-performance thermal distribution panel (TDP) concept using high-conductivity (greater than 800 W/mK) macro composite skin with in situ heat pipes. The processing technologies proposed to build such a panel result in a one-piece, inseparable assembly with high conductance in both the X and Y planes. The TDP configuration can also be used to produce panels with high structural stiffness. The one-piece construction of the TDP eliminates the thermal interface between the cooling plenums and the heat spreader base, and obviates the need for bulky mounting flanges and thick heat spreaders used on baseline designs. The conductivity of the TDP can be configured to exceed 800 W/mK with a mass density below 2.5 grams per cubic centimeter. This material can provide efficient conductive heat transfer between the in situ heat plenums, permitting the use of thinner panel thicknesses. The plenums may be used as heat pipes, loop heat pipes, or liquid cooling channels. The panel technology used in the TDP is a macro-composite comprised of aluminum-encapsulated annealed pyrolytic graphite (APG). APG is highly aligned crystalline graphite with an in-plane thermal conductivity of 1,700 W/mK. APG has low shear strength and does not constrain the encapsulating material. The proposed concept has no thermal interfaces between the heat pipes and the spreader plate, further improving the overall conductance of the system. The in situ plenums can also be used for liquid cooling applications. The process can be used to fabricate structural panels by adding a second thin sheet.

Montesano, Mark↗

NASA NTRS2014

Structural Assembly for Cold Plate Cooling

A device including a structural member having a heat spreader and an electronic device mounted directly to a first surface of the heat spreader of the structural member. The device also includes a cold plate mounted directly to the first surface of the heat spreader of the structural member.

Zaffetti, Mark A.↗

NASA NTRSDate not supplied

Structural Architectures for Self-Erecting Lunar Towers

The load carrying performance for deployable lunar tower architectures utilizing thin-ply composite booms are parametrically evaluated in this paper. These self-erecting towers support a communications and sensor platform on the lunar surface. The primary design consists of the Corrugated Rollable Tubular Boom (COROTUB) acting as the primary mast of the tower which supports the payload tip mass. Guy wires connecting the boom tip to spreader bars attached at the base deployer serve to correct any lateral eccentricities and provide dimensional stability. The analysis compares the maximum tip mass that this primary design can carry relative to a reference design that does not contain any guy wires or spreader bars. The results provide insights into whether the additional system mass and complexity associated with the cable-stayed design is worth the increased payload mass that can be supported. By setting the design limiting condition to a nominal maximum allowable deflection, the analysis reveals that primary design outperforms reference design for the majority of the design space. This outcome is found to be the case when the spreader bar length relative to the tower height exceeds7 a critical value. The analysis is extended to lunar towers with Collapsible Tubular Mast (CTM) booms, and similar trends are observed.

Jacob G Daye↗

NASA NTRSDate not supplied

Structural Architectures for Self-Erecting Lunar Towers

The load carrying performance for deployable lunar tower architectures utilizing thin-ply composite booms are parametrically evaluated in this paper. These self-erecting towers support a communications and sensor platform on the lunar surface. The primary design consists of the Corrugated Rollable Tubular Boom (COROTUB) acting as the primary mast of the tower which supports the payload tip mass. Guy wires connecting the boom tip to spreader bars attached at the base deployer serve to correct any lateral eccentricities and provide dimensional stability. The analysis compares the maximum tip mass that this primary design can carry relative to a reference design that does not contain any guy wires or spreader bars. The results provide insights into whether the additional system mass and complexity associated with the cable-stayed design is worth the increased payload mass that can be supported. By setting the design limiting condition to a nominal maximum allowable deflection, the analysis reveals that primary design outperforms reference design for the majority of the design space. This outcome is found to be the case when the spreader bar length relative to the tower height exceeds a critical value. The analysis is extended to lunar towers with Collapsible Tubular Mast (CTM) booms, and similar trends are observed.

Jacob G Daye↗

NASA NTRS2015

Tension Stiffened and Tendon Actuated Manipulator

A tension stiffened and tendon actuated manipulator is provided performing robotic-like movements when acquiring a payload. The manipulator design can be adapted for use in-space, lunar or other planetary installations as it is readily configurable for acquiring and precisely manipulating a payload in both a zero-g environment and in an environment with a gravity field. The manipulator includes a plurality of link arms, a hinge connecting adjacent link arms together to allow the adjacent link arms to rotate relative to each other and a cable actuation and tensioning system provided between adjacent link arms. The cable actuation and tensioning system includes a spreader arm and a plurality of driven and non-driven elements attached to the link arms and the spreader arm. At least one cable is routed around the driven and non-driven elements for actuating the hinge.

Doggett, William R.↗

NASA NTRS2017

Solidification and Morphological Evolution of Al-Si Eutectics in Convector-Diffusive Conditions

The Al-Si material system is an important and has been studied for over half century with a focus on industrial applications in high strength and high conductivity alloys. A great deal of researches have been focused on controlling the morphology and hence performance through the addition of small impurities and by processing conditions. Most of the structure-property correlations are based on the post solidified micromorphology and growth conditions. This material system is unique and has been explored for heat spreader, controlling coefficient of expansion by adjusting composition of silicon and in designing composites. The Al-Si system is very interesting system for understanding the dendritic (Al-rich side) eutectic transition. Recently this system has been of great interest because of its applications in designing heat spreader, low temperature flux to grow SiC large substrates and in controlling the coefficient of expansion of Al-based alloys. We have performed extensive experiments to understand eutectic transition and to understand the morphological evolution in presence of impurities. We will discuss the results of dendritic transition into faceted long grains in convector-diffusive conditions. In this presentation we will present morphological transition in presence of carbon impurity and development of novel morphology.

Singh, N. B.↗

NASA NTRS2019

Hinge for Use in a Tension Stiffened and Tendon Actuated Manipulator

Doggett, William R.↗

NASA NTRSDate not supplied

Design Development of a Stable, Lightweight, Tall and Self-Deploying Lunar Tower

Deployable composite booms with spaceflight heritage are being investigated at the National Aeronautics and Space Administration (NASA) Langley Research Center (LaRC) and the Massachusetts Institute of Technology (MIT) Space Resources Workshop for their potential to be vertically deployed in the lunar gravity field, in support of the NASA Artemis campaign. This paper reports new design development results—after the original presentation at the NASA 2020 BIG Idea Challenge—for a 16.5-meter-tall, compact, self-deploying composite tower intended to support the exploration of lunar permanently shadowed regions by nearby robotic assets or humans. Possible applications include vertical solar arrays and the provision of elevated lines-of-sight to science or engineering payloads, in support of nearby targets operating in areas of interest that may be hard to reach. Useful elevated payloads include radio repeaters, remote sensing and imaging, navigation and power beaming systems. However, while these lightweight rollable booms have an excellent height to mass ratio, they typically exhibit axial curvature upon deployment resulting in appreciable lateral dead-load deflection of the tip mass relative to the tower base. This static deflection increases with tower height and tip mass, not only constraining the value delivered by the tower but also endangering its integrity. To develop a competitive, lightweight deployable composite boom tower, a capability to correct static deflections during and after deployment will be required. In this paper, a deployable guy wire stability system will be presented for the MIT / LaRC self-erecting composite boom lunar tower that provides real time measurements, maintains tension both actively (during deployment) and passively (post-deployment), and can serve as a reconfigurable platform to test and trade alternative stability system configurations, such as with added spreaders inspired by sailing boat masts. Using a calibrated photogrammetry system, the natural lateral deflection of the boom tip relative to the boom base at different deployed heights was recorded for different configurations. With real-time force measurements it was found that tensioned guy wires can significantly reduce the static tip deflection of a deployable composite boom under dead load and can dampen a dynamic oscillation in under a minute. It was also found that control authority is greatest where it is needed most, i.e., for the lever arm closest to being opposite the direction of deflection. For a tower height of at least 11 m and spreader length of at least 60 cm, a solution of differential tension in all three arms exists and, in principle, provides sufficient control authority to correct or significantly reduce boom tip deflections. Notably, natural deflections occur almost entirely normal to the seams of the boom cross-section, but the natural boom tip lateral deflection under dead load upon deployment was approximately 5% of boom deployed length, exceeding the manufacturing acceptance specification of 1%. Ongoing and future work includes the further investigation towards mitigating manufacture-caused lateral deflection, trading of alternative guy wire system designs, as well as the design development of a second-generation tower incorporating a more capable boom design with the learnings from the proof-of-concept system presented here.

deployable composite boom↗

NASA NTRS1968

Hoisting frame facilitates handling of large objects

Hoisting frame can be used with a standard 5-ton forklift to handle the large spreader bars, or other bulky pieces of equipment, much faster and more efficiently than with a boom or gantry crane. In addition forklifts of this type are more readily available.

Colpean, K. V.↗

NASA NTRS1976

Shuttle spectrum despreader

The results of the spread spectrum despreader project are reported and three principal products are designed and tested. The products are, (1) a spread spectrum despreader breadboard, (2) associated test equipment consisting of a spectrum spreader and bit reconstruction/error counter and (3) paper design of a Ku-band receiver which would incorporate the despreader as a principal subsystem. The despreader and test set are designed for maximum flexibility. A choice of unbalanced quadriphase or biphase shift keyed data modulation is available. Selectable integration time and threshold voltages on the despreader further lend true usefulness as laboratory test equipment to the delivered hardware.

Source record↗

NASA NTRS1979

Data and analysis procedures for improved aerial applications mission performance

An analysis procedure is given and cases analyzed for the effects of wing geometry on lateral transport of a variety of agricultural particles released in the wake of an agricultural airplane. The cases analyzed simulate the release of particles from a fuselage centerline-mounted dry material spreader; however, the procedure applies to particles released anywhere along the wing span. Consideration is given to the effects of taper ratio, aspect ratio, wing loading, and deflected flaps. It is noted that significant lateral transport of large particles can be achieved using high-lift devices positioned to create a strong vortex near the location of particle release.

Holmes, B. J.↗

NASA NTRS1980

Energy from wood waste - A case study

A joint study has been conducted by NASA and Army installations collocated in a dense forest in southwestern Mississippi in order to determine the technical and economic feasibility of using wood waste as a renewable energy source. The study has shown that, with proper forest management, the timber on government lands could eventually support the total energy requirements of 832 billion Btu/yr. Analysis of the current conversion technologies indicates that the direct combustion spreader stoker approach is the best demonstrated technology for this specific application. The economics of the individual powerplants reveal them as attractive alternatives to fossil fueled plants. Environmental aspects are also discussed.

Scola, R.↗

NASA NTRS1982

National geotechnical centrifuge

A high G-ton centrifuge, able to take a 2700 kg (6000 lb) payload up to 300 G, is described. The stability of dams and embankments, the bearing capacity of soil foundations, and the dynamic behavior of foundations due to vibration of machinery are examples of applications. A power rating of 6,000 kW (9,000 hp) was established for the motor. An acceptable maximum speed of 70 rpm was determined. A speed increase with a ratio of 1:3 is discussed. The isolated tension straps, the anti-spreader bar and the flexwall bucket, and safety precautions are also discussed.

Hallam, J. A.↗

NASA NTRS1982

Cassegrainian concentrator solar array exploratory development module

A miniaturized Cassegrainian concentrator solar array concept is under development to reduce the cost of multi-kW spacecraft solar arrays. A primary parabolic reflector directs incoming solar energy to a secondary, centrally mounted inverted hyperbolic reflector and down onto a solar cell mounted on an Mo heat spreader on a 0.25 mm thick Al heat fin. Each unit is 12.7 mm thick, which makes the concentrator assembly roughly as thick as a conventional panel. The output is 100 W/sq and 20 W/kg, considering 20% efficient Si cells at 100 suns. A tertiary light catcher is mounted around the cell to ameliorate optic errors. The primary reflector is electroformed Ni with protective and reflective coatings. The cells have back surface reflectors and a SiO antireflective coating. An optical efficiency of 80% is projected, and GaAs cells are being considered in an attempt to raise cell efficiencies to over 30%.

Patterson, R. E.↗