SEARCH · Search NASA
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.
Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.
Space science - solar radiation, flame reaction kinetics, stratospheric planetary observatory, information systems, and space biology
Thermoplastic composites have experienced renewed enthusiasm within the U.S. aerospace industry, due in part to opportunities for rapidly manufacturing large structures. Unlike the lengthy cure cycles required by thermosets, the thermoplastic matrix prepreg requires only heat and pressure to consolidate consecutive layers of material; with sufficient inter-ply contact time to develop a strong interface. The manufacturing requirements for thermoplastics provide manufacturing flexibility and of particular interest are in-situ consolidation processes; i.e consolidation during layup on a tool. In-situ consolidation removes the time-consuming and costly secondary processing step of autoclave or press consolidation. Process variables which contribute to laminate quality include temperature, heat transfer, inter-ply contact time, and consolidation pressure. Most of the work to date related to in-situ consolidation has been in conjunction with automated fiber placement (AFP), where prepreg tows are consolidated when placed on the tool. Considering this process for a braided structure adds complexity relative to AFP due to the rapid lay-down rate of the braider and simultaneous placement of a multiple prepreg tows. Processes considered for consolidation during AFP could not be applied to a braided part. Alternatively, a fully braided preform could be consolidated on the tool using well established thermoplastic welding techniques. The goal of this effort was to evaluate the effectiveness of induction welding to consolidate braided carbon fiber/thermoplastic composite tubes up to eight plies in thickness. The manufacturing process, thermal characterization, and initial mechanical property data of the consolidated tubes are reported.
Nanotechnology based thermoelectric materials are considered attractive for developing highly efficient thermoelectric devices. Nano-structured thermoelectric materials are predicted to offer higher ZT over bulk materials by reducing thermal conductivity and increasing electrical conductivity. Consolidation of nano-structured powders into dense materials without losing nanostructure is essential towards practical device development. Using the gas atomization process, amorphous nano-structured powders were produced. Shockwave consolidation is accomplished by surrounding the nanopowder-containing tube with explosives and then detonating. The resulting shock wave causes rapid fusing of the powders without the melt and subsequent grain growth. We have been successful in generating consolidated nano-structured bismuth telluride alloy powders by using the shockwave technique. Using these consolidated materials, several types of thermoelectric power generating devices have been developed. Shockwave consolidation is anticipated to generate large quantities of nanostructred materials expeditiously and cost effectively. In this paper, the technique of shockwave consolidation will be presented followed by Seebeck Coefficient and thermal conductivity measurements of consolidated materials. Preliminary results indicate a substantial increase in electrical conductivity due to shockwave consolidation technique.
Systems and methods for producing a dense, well bonded solid material from a powder may include consolidating the powder utilizing any suitable consolidation method, such as explosive shockwave consolidation. The systems and methods may also include a post-processing thermal treatment that exploits a mismatch between the coefficients of thermal expansion between the consolidated material and the container. Due to the mismatch in the coefficients, internal pressure on the consolidated material during the heat treatment may be increased.
The Networks Consolidation Program (NCP) goals were defined to include the planning, designing, and implementing of a single network of ground tracking stations. The proposed consolidated network is to make use of facilities that are now included in the Goddard Ground Spaceflight Tracking and Data Network as well as the existing JPL Deep Space Network. These facilities are to be combined and modified to provide a consolidated network capable of supporting the set of planetary and Highly Elliptical Earth Orbiter missions that are planned for the Tracking and Data Relay Satellite System era. The history of activities and events that led to the decision to consolidate the NASA ground tracking and data networks are traced. A summary of the management and planning activities that have taken place at the Jet Propulsion Laboratory, Goddard Space Flight Center, and at the NASA Headquarters Office of Space Tracking and Data Systems, with respect to the NCP, from the time of decision in October 1979 to the present, are discussed.
A single consolidated network of ground tracking stations to replace the present two ground-based spacecraft tracking networks is proposed. The proposed consolidated network uses facilities that are now included in the Ground Spaceflight Tracking and Data Network (GSTDN), operated by Goddard Space Flight (GSFC), as well as the existing Deep Space Network (DSN), operated by Jet Propulsion Laboratory (JPL). These facilities are combined and modified to provide a consolidated network managed and operated by JPL and capable of supporting the set of planetary and Highly Elliptical Earth Orbiter (HEEO) missions planned for the Tracking and Data Relay Satellite System (TDRSS) era. The consolidated network is planned to be operational after the TDRSS becomes operational. It will continue to support planetary missions that are now supported by the DSN and also provide support to a broad class of other spacecraft missions which are not compatible with or which, for other reasons, cannot be supported by the TDRSS.
Selective Laser Melting (SLM) is a powder bed fusion additive manufacturing process used increasingly in the aerospace industry to reduce the cost, weight, and fabrication time for complex propulsion components. SLM stands poised to revolutionize propulsion manufacturing, but there are a number of technical questions that must be addressed in order to achieve rapid, efficient fabrication and ensure adequate performance of parts manufactured using this process in safety-critical flight applications. Previous optimization studies for SLM using the Concept Laser M1 and M2 machines at NASA Marshall Space Flight Center have centered on machine default parameters. The objective of this work is to characterize the impact of higher throughput parameters (a previously unexplored region of the manufacturing operating envelope for this application) on material consolidation. In phase I of this work, density blocks were analyzed to explore the relationship between build parameters (laser power, scan speed, hatch spacing, and layer thickness) and material consolidation (assessed in terms of as-built density and porosity). Phase II additionally considers the impact of post-processing, specifically hot isostatic pressing and heat treatment, as well as deposition pattern on material consolidation in the same higher energy parameter regime considered in the phase I work. Density and microstructure represent the "first-gate" metrics for determining the adequacy of the SLM process in this parameter range and, as a critical initial indicator of material quality, will factor into a follow-on DOE that assesses the impact of these parameters on mechanical properties. This work will contribute to creating a knowledge base (understanding material behavior in all ranges of the AM equipment operating envelope) that is critical to transitioning AM from the custom low rate production sphere it currently occupies to the world of mass high rate production, where parts are fabricated at a rapid rate with confidence that they will meet or exceed all stringent functional requirements for spaceflight hardware. These studies will also provide important data on the sensitivity of material consolidation to process parameters that will inform the design and development of future flight articles using SLM.
Stitched composites (composite parts stitched in a dry preform state that are infused with resin and cured to a final shape) offer a variety of benefits for modern aircraft structures. In this document one means of stitching dry fabric preforms in a state of temporary vacuum consolidation is discussed. This vacuum consolidation allows for the completion of stitching procedures while the dry preform thickness is temporarily reduced to a thickness reflective of its final cured thickness. Here, a temporary vacuum consolidation process enabling stitching of preforms of unconsolidated nominal thickness greater than the maximum allowable stitching thickness for the Integrated Structural Assembly of Advanced Composite (ISAAC) system is explored as a use case for such processes. Temporary vacuum consolidation processes may lead to simplified manufacturing processes or desirable composite material properties in the future.
Consolidated Heat Pipe (CHP) is a new technology that enables direct thermal power delivery to the hot-end of a Stirling engine using a heat pipe--a two phase passive heat transfer device. CHP was developed after the efforts of the Kilopower Using Stirling TechnologY (KRUSTY) test where a heat pipe was used to deliver thermal power from a fission-basedreactor to a Stirling engine to produce 1 kWe of useable electrical power in 2018. Large thermal losses were noted during the KRUSTY test where a temperature drop of 145 °C was measured between the heat pipe’s condenser and the engine’s hot-end. The Consolidated Heat Pipe was designed to address and mitigate this temperature loss. CHP was designed, built and tested at the Glenn Research Center (GRC). The initial test was performed in ambient air conditions, and the results were presented in “Consolidation of a Sodium Heat Pipe and Stirling Engine for Fission Surface Power” at the Thermal Fluids Analysis Workshop in 2023. Researchers at GRC have tested this technology again in a vacuum environment in 2024. Results show that the heat pipe and the hot-end of the Stirling engine are isothermal with a minimal temperature differential of approximately 2.5 °C in varying operational states. The Consolidated Heat Pipe technology has proven to be an efficient way of delivering thermal power directly to Stirling engines.
The use of innovative cost effective material forms and processes is being considered for fabrication of future primary aircraft structures. Processes that have been identified as meeting these goals are textile preforms that use resin transfer molding (RTM) and consolidation forming. The Novel Composites for Wing and Fuselage Applications (NCWFA) program has as its objective the integration of innovative design concepts with cost effective fabrication processes to develop damage-tolerant structures that can perform at a design ultimate strain level of 6000 micro-inch/inch. In this on-going effort, design trade studies were conducted to arrive at advanced wing designs that integrate new material forms with innovative structural concepts and cost effective fabrication methods. The focus has been on minimizing part count (mechanical fasteners, clips, number of stiffeners, etc.), by using cost effective textile reinforcement concepts that provide improved damage tolerance and out-of-plane load capability, low-cost resin transfer molding processing, and thermoplastic forming concepts. The fabrication of representative Y spars by consolidation methods will be described. The Y spars were fabricated using AS4 (6K)/PEEK 150g commingled angle interlock 0/90-degree woven preforms with +45-degree commingled plies stitched using high strength Toray carbon thread and processed by autoclave consolidation.
An apparatus and method were developed for providing a uniform, consolidated, unidirectional, continuous, fiber-reinforced polymeric material. The apparatus comprises a supply means, a forming means, a shaping means, and a take-up means. The forming means further comprises a pre-melting chamber and a stationary bar assembly. The shaping means is a loaded cooled nip-roller apparatus. Forming takes place by heating a polymeric prepreg material to a temperature where the polymer becomes viscous and applying pressure gradients at separate locations along the prepreg material. Upon exiting the forming means, the polymeric prepreg material is malleable, consolidated, and flattened. Shaping takes place by passing the malleable, consolidated, flattened prepreg material through a shaped, matched groove in a loaded, cooled nip-roller apparatus to provide the final solid product.
The National Aeronautics and Space Administration (NASA) initiated the Hi-Rate Composites Aircraft Manufacturing (HiCAM) project in 2021 with the goal of significantly increasing composite structures manufacturing rate in the commercial aircraft industry. The technologies currently under investigation include resin infusion and automated fiber placement (AFP) of novel thermoset materials and thermoplastic composites. Thermoplastic composites offer attractive solutions to rapid manufacturing due to their ability to be formed and consolidated quickly. NASA is particularly focused on assessing composite structure manufacturing utilizing an in-situ consolidation AFP of thermoplastics (ICAT) process employing a recently developed laser heating system. Two semi-crystalline polyaryletherketone thermoplastic tape materials were characterized to ascertain the ICAT process parameters at AFP placement speeds approaching 423 mm/s. The required laser power settings were determined at Electroimpact, measuring material temperatures utilizing a forward looking infrared (FLIR) thermal imaging camera and thermocouples. The material temperature, tool temperature, and placement speed were varied for resulting consolidation quality assessment. The resulting temperature data were also utilized to calibrate thermal analysis models under development at NASA. The experimental temperature data confirmed analytical results. An overview of the HiCAM project as well as initial data from ICAT process characterizations are described.
The National Aeronautics and Space Administration (NASA) initiated the Hi-Rate Composites Aircraft Manufacturing (HiCAM) project in 2021 with the goal of significantly increasing composite structures manufacturing rate in the commercial aircraft industry. The technologies currently under investigation include resin infusion and automated fiber placement (AFP) of novel thermoset materials and thermoplastic composites. Thermoplastic composites offer attractive solutions to rapid manufacturing due to their ability to be formed and consolidated quickly. NASA is particularly focused on assessing composite structure manufacturing utilizing an in-situ consolidation AFP of thermoplastics (ICAT) process employing a recently developed laser heating system. Two semi-crystalline polyaryletherketone thermoplastic tape materials were characterized to ascertain the ICAT process parameters at AFP placement speeds approaching 423 mm/s. The required laser power settings were determined at Electroimpact, measuring material temperatures utilizing a forward looking infrared (FLIR) thermal imaging camera and thermocouples. The material temperature, tool temperature, and placement speed were varied for resulting consolidation quality assessment. The resulting temperature data were also utilized to calibrate thermal analysis models under development at NASA. The experimental temperature data confirmed analytical results. An overview of the HiCAM project as well as initial data from ICAT process characterizations are described.
The National Aeronautics and Space Administration (NASA) project Hi-Rate Composites Aircraft Manufacturing (HiCAM) aims to significantly increase commercial aircraft composite structures manufacturing rate. Thermoplastic composites offer attractive solutions to rapid manufacturing due to their ability to be formed and consolidated quickly. NASA has a particular interest in assessing composite structure manufacturing utilizing an in-situ consolidation automated fiber placement (AFP) of thermoplastics (ICAT) process employing current state-of-the-art laser heating systems. Three semi-crystalline polyaryletherketone (PAEK) thermoplastic tape materials were characterized to ascertain the ICAT process parameters. The required laser power settings were determined at Electroimpact, Inc., measuring material temperatures utilizing a forward looking infrared (FLIR) thermal imaging camera and thermocouples. The material temperature, tool temperature, and placement speed were varied for resulting consolidation quality assessment. The resulting temperature data were also utilized to calibrate thermal analysis models under development at NASA. The experimental temperature data confirmed analytical results. The quality of the resulting test panels was evaluated by both non-destructive evaluation as well as destructively by photo-microscopy. The effect on interlaminar strength was determined by short beam strength testing. Test results of carbon fiber laminates fabricated by ICAT using polyetheretherketone (PEEK), polyetherketoneketone (PEKK), and low-melt polyaryletherketone (LM-PAEK) at various placement temperatures and placement speeds are presented.
As part of reducing the cost of operating Deep Space planetary missions, the Jet Propulsion Laboratory (JPL) has developed and deployed a highly-accurate digital receiver capable of recovering telemetry at rates as high as 26 Msymbols/s. JPL is currently assessing the consolidation of all these functions (receiving, telemetry, ranging, doppler, and open-loop recording) into a single rack that could be remotely controlled...This paper discusses the motivation, details, and benefits of this consolidation.
Composite materials have tremendous potential in the design and manufacture of commercial aircraft due to their high strength-to-weight and stiffness-to-weight properties. However, the use of composite materials is currently limited by high cost and long manufacturing time. The National Aeronautics and Space Administration (NASA) initiated the Hi-rate Composite Aircraft Manufacturing (HiCAM) project to investigate promising composite processing technologies with a goal of vastly improving composite commercial aircraft manufacturing rate (4-6x faster than current production rates). Laser assisted automated fiber placement (AFP) of thermoplastics is a key technology that could increase speed of composite manufacturing, but the technology has not been fully developed. In-situ consolidation AFP of thermoplastics (ICAT) could reduce time and cost even further by eliminating the time and equipment required for post-consolidation. In this work, the thermal response of laser heated ICAT was investigated using forward looking infrared (FLIR) and embedded thermocouples (TCs) to better understand fusion between layers (autohesion). Detailed explanation of the algorithm to combine FLIR and TC data will be presented. In addition, the effect of robot speed on time above melting temperature was quantified.
The Consolidated Heat Pipe (CHP) is a new design in which a sodium heat pipe is welded directly to the hot end of the Stirling engine to deliver thermal power more efficiently. The new integrated interface aims to reduce the large temperature drop (about 120 °C) that was measured across the bolted clamp joint between the Stirling engine and the heat pipes during the Kilopower Reactor Using Stirling TechnologY (KRUSTY) test from 2018. Initial testing and characterization of the CHP was performed in ambient air at the NASA Glenn Research Center (GRC). In the test, the heat pipe evaporator section was heated with a tube furnace. The thermal power was then transported to the Stirling engine integrated with a linear alternator that produced electrical power. The CHP has been tested at a hot end temperature ranging from 600 °C - 800 °C and a variety of other Stirling engine parameters (cold end temperature, piston amplitude and pressure). The results show that the temperature drop between the Stirling engine and the heat pipe has been reduced to 2°C - 4 °C. An overall temperature drop of 20 °C – 60 °C was also noted within the heat pipe depending on the combination of parameters mentioned above. Overall, it has been shown that the new Consolidated Heat Pipe design significantly improved the thermal interface to the Stirling engine.
The Consolidated Heat Pipe (CHP) is a new design in which a sodium heat pipe is welded directly to the hot end of the Stirling engine to deliver thermal power more efficiently. The new integrated interface aims to reduce the large temperature drop (about 120 °C) that was measured across the bolted clamp joint between the Stirling engine and the heat pipes during the Kilopower Reactor Using Stirling TechnologY (KRUSTY) test from 20181. Initial testing and characterization of the CHP was performed in ambient air at the NASA Glenn Research Center (GRC). In the test, the heat pipe evaporator section was heated with a tube furnace. The thermal power was then transported to the Stirling engine integrated with a linear alternator that produced electrical power. The CHP has been tested at a hot end temperature ranging from 600 °C - 800 °C and a variety of other Stirling engine parameters (cold end temperature, piston amplitude and pressure). The results show that the temperature drop between the Stirling engine and the heat pipe has been reduced to 2°C - 4 °C. An overall temperature drop of 20 °C – 60 °C was also noted within the heat pipe depending on the combination of parameters mentioned above. Overall, it has been shown that the new Consolidated Heat Pipe design significantly improved the thermal interface to the Stirling engine.