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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

Component Reliability Testing of Long-Life Sorption Cryocoolers

This paper summarizes ongoing experiments characterizing the ability of critical sorption cryocooler components to achieve highly reliable operation for long-life space missions. Test data obtained over the past several years at JPL are entirely consistent with achieving ten year life for sorption compressors, electrical heaters, container materials, valves, and various sorbent materials suitable for driving 8 to 180 K refrigeration stages. Test results for various compressor systems are reported. Planned future tests necessary to gain a detailed understanding of the sensitivity of cooler performance and component life to operating constraints, design configurations, and fabrication, assembly and handling techniques, are also discussed.

operating constraints fabrication design testing↗

Space aging of solid rocket materials

Solid rocket propellant and rocket motor components were aged in a vented container on the interior of the LDEF. This paper will present the results of aging the Improved Performance Space Motor-II/Payload Assist Module-Delta II (IPSM-II/PAM-DII) space motor components. Ballistic and mechanical properties of the space aged main propellant, igniter propellant, and ignition system were compared with similar data from preflight and ground aged samples. Mechanical properties of the composite materials and bonded joints used in the motor case, insulation, liner, nozzle, exit cone, and skirt were similarly evaluated. The space aging results will be compared to data collected in a ground based vacuum aging program on similar components. The operation of the vacuum actuated venting valve and pressure actuated resealing of the container will also be addressed. The materials tested showed no significant changes due to space aging. These results indicate that properly designed solid rocket motors can be expected to perform reliably after extended periods of exposure to a space environment.

Dean M Lester↗

Burning Plastics Investigated in Space for Unique US/Russian Cooperative Project

It is well known that fires in the low-gravity environment of Earth-orbiting spacecraft are different from fires on Earth. The flames lack the familiar upward plume, which is the result of gravitational buoyancy. These flames, however, are strongly influenced by minor airflow currents. A recent study conducted in low gravity (microgravity) on the Russian orbital station Mir used burning plastic rods mounted in a small chamber with a controllable fan to expose the flame to airflows of different velocities. In this unique project, a Russian scientific agency, the Keldysh Research Center, furnished the apparatus and directed the Mir tests, while the NASA Glenn Research Center at Lewis Field provided the test materials and the project management. Reference testing and calibrations in ground laboratories were conducted jointly by researchers at Keldysh and at the NASA Johnson Space Center's White Sands Test Facility. Multiple samples of three different plastics were burned in the tests: Delrin, a common material for valve bodies; PMMA, a plastic "glass"; and polyethylene, a familiar material for containers and films. Each burned with a unique spherical or egg-shaped flame that spread over the rod. The effect of varying the airflow was dramatic. At the highest airflow attainable in the combustion chamber, nearly 10 cm/sec (a typical ventilation breeze), the flames were bright and strong. As airflow velocity decreased, the flames became shorter but wider. In addition, the flames became less bright, and for PMMA and polyethylene, they showed two colors, a bright part decreasing in volume and a nearly invisible remainder (see the photographs). Finally, at a very low velocity, the flames extinguished. For the plastics tested, this minimum velocity was very low, around 0.3 to 0.5 cm/sec. This finding confirms that at least a slight airflow is required to maintain a flame in microgravity for these types of materials.

Friedman, Robert↗

Manufacturing and NDE of Large Composite Aerospace Structures at MSFC

NASA's vision for transportation to orbit calls for new vehicles built with new materials technology. The goals of this new launch system development are to improve safety, dramatically reduce cost to orbit, and improve vehicle turn around time. Planned Space Shuttle upgrades include new reusable liquid propellant boosters to replace the solid propellant boosters. These boosters are to have wings and return to the launch site for a horizontal landing on an airport runway. New single and two stages to orbit concepts are being investigated. To reduce weight and improve performance composite materials are proposed for fuel and oxidizer tanks, fuel feedlines, valve bodies, aerostructures, turbomachinery components. For large composite structures new methods of fabrication are being proposed and developed. Containment of cryogenic fuel or oxidizer requires emphases on composite material densification and chemical compatibility. Ceramic matrix and fiber composites for hot rotating turbomachinery have been developed with new fabrication processes. The new requirements on the materials for launcher components are requiring development of new manufacturing and inspection methods. This talk will examine new and proposed manufacturing methods to fabricate the revolutionary components. New NDE methods under consideration include alternative X-ray methods, X-ray laminagraphy, advanced CT, Thermography, new ultrasonic methods, and imbedded sensors. The sizes, complexity, use environment, and contamination restrictions will challenge the inspection process. In flight self-diagnosis and rapid depot inspection are also goals of the NDE development.

Whitaker, Ann↗

Apparatus For Tests Of Embrittlement By Hydrogen

Test apparatus exposes disk specimens to hydrogen in controlled, repeatable way simulating conditions in use. Disk specimen constitutes thin wall between pressure and vacuum chambers. Test proceeds until hydrogen weakens disk enough that it ruptures. Aluminum impact plate absorbs debris from ruptured disk. Apparatus replicates aspects of service environments relevant to embrittlement by hydrogen in such equipment as storage tanks, valves, and fluid-handling components containing hydrogen at high absolute or gauge pressure. Hydrogen inside permeates stressed material and produces gradient of concentration as hydrogen diffuses through material to low-pressure side.

Christianson, Rollin C.↗

Sorption vacuum trap

Modified sorption trap for use in high vacuum systems contains provisions for online regeneration of sorbent material. Trap is so constructed that it has a number of encapsulated resistance heaters and a valving and pumping device for removing gases from heated sorbing material. Excessive downtime is eliminated with this trap.

Barrington, A. E.↗

Oxygen chemisorption cryogenic refrigerator

The present invention relates to a chemisorption compressor cryogenic refrigerator which employs oxygen to provide cooling at 60 to 100 K. The invention includes dual vessels containing an oxygen absorbent material, alternately heated and cooled to provide a continuous flow of high pressure oxygen, multiple heat exchangers for precooling the oxygen, a Joule-Thomson expansion valve system for expanding the oxygen to partially liquefy it and a liquid oxygen pressure vessel. The primary novelty is that, while it was believed that once oxygen combined with an element or compound the reaction could not reverse to release gaseous oxygen, in this case oxygen will indeed react in a reversible fashion with certain materials and will do so at temperatures and pressures which make it practical for incorporation into a cryogenic refrigeration system.

Jones, Jack A.↗

NASA Tech Briefs, April 2012

Topics include: Computational Ghost Imaging for Remote Sensing; Digital Architecture for a Trace Gas Sensor Platform; Dispersed Fringe Sensing Analysis - DFSA; Indium Tin Oxide Resistor-Based Nitric Oxide Microsensors; Gas Composition Sensing Using Carbon Nanotube Arrays; Sensor for Boundary Shear Stress in Fluid Flow; Model-Based Method for Sensor Validation; Qualification of Engineering Camera for Long-Duration Deep Space Missions; Remotely Powered Reconfigurable Receiver for Extreme Environment Sensing Platforms; Bump Bonding Using Metal-Coated Carbon Nanotubes; In Situ Mosaic Brightness Correction; Simplex GPS and InSAR Inversion Software; Virtual Machine Language 2.1; Multi-Scale Three-Dimensional Variational Data Assimilation System for Coastal Ocean Prediction; Pandora Operation and Analysis Software; Fabrication of a Cryogenic Bias Filter for Ultrasensitive Focal Plane; Processing of Nanosensors Using a Sacrificial Template Approach; High-Temperature Shape Memory Polymers; Modular Flooring System; Non-Toxic, Low-Freezing, Drop-In Replacement Heat Transfer Fluids; Materials That Enhance Efficiency and Radiation Resistance of Solar Cells; Low-Cost, Rugged High-Vacuum System; Static Gas-Charging Plug; Floating Oil-Spill Containment Device; Stemless Ball Valve; Improving Balance Function Using Low Levels of Electrical Stimulation of the Balance Organs; Oxygen-Methane Thruster; Lunar Navigation Determination System - LaNDS; Launch Method for Kites in Low-Wind or No-Wind Conditions; Supercritical CO2 Cleaning System for Planetary Protection and Contamination Control Applications; Design and Performance of a Wideband Radio Telescope; Finite Element Models for Electron Beam Freeform Fabrication Process Autonomous Information Unit for Fine-Grain Data Access Control and Information Protection in a Net-Centric System; Vehicle Detection for RCTA/ANS (Autonomous Navigation System); Image Mapping and Visual Attention on the Sensory Ego-Sphere; HyDE Framework for Stochastic and Hybrid Model-Based Diagnosis; and IMAGESEER - IMAGEs for Education and Research.

Source record↗

Advanced Vacuum Plasma Spray (VPS) for a Robust, Longlife and Safe Space Shuttle Main Engine (SSME)

In 1984, the Vacuum Plasma Spray Lab was built at NASA/Marshall Space Flight Center for applying durable, protective coatings to turbine blades for the space shuttle main engine (SSME) high pressure fuel turbopump. Existing turbine blades were cracking and breaking off after five hot fire tests while VPS coated turbine blades showed no wear or cracking after 40 hot fire tests. Following that, a major manufacturing problem of copper coatings peeling off the SSME Titanium Main Fuel Valve Housing was corrected with a tenacious VPS copper coating. A patented VPS process utilizing Functional Gradient Material (FGM) application was developed to build ceramic lined metallic cartridges for space furnace experiments, safely containing gallium arsenide at 1260 degrees centigrade. The VPS/FGM process was then translated to build robust, long life, liquid rocket combustion chambers for the space shuttle main engine. A 5K (5,000 Lb. thrust) thruster with the VPS/FGM protective coating experienced 220 hot firing tests in pristine condition with no wear compared to the SSME which showed blanching (surface pulverization) and cooling channel cracks in less than 30 of the same hot firing tests. After 35 of the hot firing tests, the injector face plates disintegrated. The VPS/FGM process was then applied to spraying protective thermal barrier coatings on the face plates which showed 50% cooler operating temperature, with no wear after 50 hot fire tests. Cooling channels were closed out in two weeks, compared to one year for the SSME. Working up the TRL (Technology Readiness Level) to establish the VPS/FGM process as viable technology, a 40K thruster was built and is currently being tested. Proposed is to build a J-2X size liquid rocket engine as the final step in establishing the VPS/FGM process TRL for space flight.

Holmes, Richard R.↗

NASA Tech Briefs, August 2008

Customizable Digital Receivers for Radar Two-Camera Acquisition and Tracking of a Flying Target Visual Data Analysis for Satellites A Data Type for Efficient Representation of Other Data Types Hand-Held Ultrasonic Instrument for Reading Matrix Symbols Broadband Microstrip-to-Coplanar Strip Double-Y Balun A Topographical Lidar System for Terrain-Relative Navigation Programmable Low-Voltage Circuit Breaker and Tester Electronic Switch Arrays for Managing Microbattery Arrays Topics covered include: Lower-Dark-Current, Higher-Blue-Response CMOS Imagers; Fabricating Large-Area Sheets of Single-Layer Graphene by CVD; Support for Diagnosis of Custom Computer Hardware; Providing Goal-Based Autonomy for Commanding a Spacecraft; Dynamic Method for Identifying Collected Sample Mass; Optimal Planning and Problem-Solving; Attitude-Control Algorithm for Minimizing Maneuver Execution Errors; Grants Document-Generation System; Heat-Storage Modules Containing LiNO3 3H2O and Graphite Foam; Precipitation-Strengthened, High-Temperature, High-Force Shape Memory Alloys; Improved Relief Valve Would Be Less Susceptible to Failure; Safety Modification of Cam-and-Groove Hose Coupling; Using Composite Materials in a Cryogenic Pump; Using Electronic Noses to Detect Tumors During Neurosurgery; Producing Newborn Synchronous Mammalian Cells; Smaller, Lower-Power Fast-Neutron Scintillation Detectors; Rotationally Vibrating Electric-Field Mill; Estimating Hardness from the USDC Tool-Bit Temperature Rise; Particle-Charge Spectrometer; Automated Production of Movies on a Cluster of Computers; FIDO-Class Development Rover; and Tone-Based Command of Deep Space Probes Using Ground Antennas.

Source record↗

Carbon Fiber Reinforced Carbon Composite Valve for an Internal Combustion Engine

A carbon fiber reinforced carbon composite valve for internal combustion engines and the like formed of continuous carbon fibers throughout the valve's stem and head is disclosed. The valve includes braided carbon fiber material over axially aligned unidirectional carbon fibers forming a valve stem; the braided and unidirectional carbon fibers being broomed out at one end of the valve stem forming the shape of the valve head; the valve-shaped structure being densified and rigidized with a matrix of carbon containing discontinuous carbon fibers: and the finished valve being treated to resist oxidation. Also disclosed is a carbon matrix plug containing continuous and discontinuous carbon fibers and forming a net-shape valve head acting as a mandrel over which the unidirectional and braided carbon fibers are formed according to textile processes. Also disclosed are various preform valves and processes for making finished and preform carbon fiber reinforced carbon composite valves.

Rivers, H. Kevin↗

Polymer-lined filament-wound pressure vessels for nitrogen containment

A program has been started to develop fatigue-resistant polymeric liners for a filament-wound pressure vessel to contain nitrogen gas at room temperature. First, nitrogen permeation of butyl rubber sheet coated with Saran and Parylene C was studied in flat specimens. Then four 10-cm-diam cylindrical pressure vessels were prepared with chlorobutyl rubber liners coated with the same materials. These vessels were valved off after nitrogen gas pressurization to approximately 65% (approximately 11.7 MPa or 1700 psig) of their expected failure pressure. One vessel leaked. The other three vessels showed an average pressure loss of less than 1% per month. These pressure vessels have an average performance factor of approximately 370 kPa-cu m/kg (1,500,000 in.) based on composite mass.

Hamstad, M. A.↗

Polymer-lined filament-wound pressure vessels for nitrogen containment

A program has been started to develop fatigue-resistant polymeric liners for a filament-wound pressure vessel to contain nitrogen gas at room temperature. First, nitrogen permeation of butyl rubber sheet coated with Saran and Parylene C was studied in flat specimens. Then four 10-cm-diam cylindrical pressure vessels were prepared with chlorobutyl rubber liners coated with the same materials. These vessels were valved off after nitrogen gas pressurization to approximately 65% of their expected failure pressure. One vessel leaked. The other three vessels showed an average pressure loss of less than 1% per month. These pressure vessels have an average performance factor of about 370 kPa x cu m/kg based on composite mass.

Hamstad, M. A.↗

Adiabatic Compression Sensitivity of Liquid Fuels and Monopropellants

Liquid rocket propellants can be sensitive to rapid compression. Such liquids may undergo decomposition and their handling may be accompanied with risk. Decomposition produces small gas bubbles in the liquid, which upon rapid compression may cause catastrophic explosions. The rapid compression can result from mechanical shocks applied on the tank containing the liquid or from rapid closure of the valves installed on the lines. It is desirable to determine the conditions that may promote explosive reactions. At Air Force Research Laboratory (AFRL), we constructed an apparatus and established a safe procedure for estimating the sensitivity of propellant materials towards mechanical shocks (Adiabatic Compression Tester). A sample is placed on a stainless steel U-tube, held isothermally at a temperature between 20 and 150 C then exposed to an abrupt mechanical shock of nitrogen gas at a pressure between 6.9 and 20.7 MPa (1000 to 3000 psi). The apparatus is computer interfaced and is driven with LABTECH NOTEBOOK-pro (registered) Software. In this presentation, the design of the apparatus is shown, the operating procedure is outlined, and the safety issues are addressed. The results obtained on different energetic materials are presented.

Ismail, Ismail M. K.↗

Evacuation of coal from hoppers/silos with low pressure pneumatic blasting systems

The need for an efficient, economical, effective and quiet device for moving coal and other difficult bulk solids was recognized. Thus came the advent of the low pressure pneumatic blasting system - a very efficient means of using a small amount of plant air (up to 125 PSI) to eliminate the most troublesome material hang-ups in storage containers. This simple device has one moving part and uses approximately 3% of the air consumed by a pneumatic vibrator on the same job. The principle of operation is very simple: air stored in the unit's reservoir is expelled directly into the material via a patented quick release valve. The number, size, and placement of the blaster units on the storage vessel is determined by a series of tests to ascertain flowability of the problem material. These tests in conjunction with the hopper or silo configuration determine specification of a low pressure pneumatic blasting system. This concept has often proven effective in solving flow problems when all other means have failed.

Fischer, J. S.↗

Apparatus for Sampling Surface Contamination

An apparatus denoted a swab device has been developed as a convenient means of acquiring samples of contaminants from surfaces and suspending the samples in liquids. (Thereafter, the liquids can be dispensed, in controlled volumes, into scientific instruments for analysis of the contaminants.) The swab device is designed so as not to introduce additional contamination and to facilitate, simplify, and systematize the dispensing of controlled volumes of liquid into analytical instruments. The swab device is a single apparatus into which are combined all the equipment and materials needed for sampling surface contamination. The swab device contains disposable components stacked together on a nondisposable dispensing head. One of the disposable components is a supply cartridge holding a sufficient volume of liquid for one complete set of samples. (The liquid could be clean water or another suitable solvent, depending on the application.) This supply of liquid is sealed by Luer valves. At the beginning of a sampling process, the user tears open a sealed bag containing the supply cartridge. A tip on the nondisposable dispensing head is engaged with a Luer valve on one end of the supply cartridge and rotated, locking the supply cartridge on the dispensing head and opening the valve. The swab tip includes a fabric swab that is wiped across the surface of interest to acquire a sample. A sealed bag containing a disposable dispensing tip is then opened, and the swab tip is pushed into the dispensing tip until seated. The dispensing head contains a piston that passes through a spring-loaded lip seal. The air volume displaced by this piston forces the liquid out of the supply cartridge, over the swab, and into the dispensing tip. The piston is manually cycled to enforce oscillation of the air volume and thereby to cause water to flow to wash contaminants from the swab and cause the resulting liquid suspension of contaminants to flow into the dispensing tip. After several cycles to ensure adequate mixing, liquid containing the suspended contaminant sample is dispensed. The disposable components are then removed from the dispensing head, which may then be reused with a fresh set of disposable components.

Wells, Mark↗

Periodically Discharging, Gas-Coalescing Filter

A proposed device would remove bubbles of gas from a stream of liquid (typically water), accumulate the gas, and periodically release the gas, in bulk, back into the stream. The device is intended for use in a flow system (1) in which there is a requirement to supply bubble-free water to a downstream subsystem and (2) that includes a sensor and valves, just upstream of the subsystem, for sensing bubbles and diverting the flow from the subsystem until the water stream is again free of bubbles. By coalescing the gas bubbles and then periodically releasing the accumulated gas, the proposed device would not contribute to net removal of gas from the liquid stream; nevertheless, it would afford an advantage by reducing the frequency with which the diverter valves would have to be activated. The device (see figure) would include an upper and a lower porous membrane made of a hydrophilic material. Both membranes would cover openings in a tube leading to an outlet. These membranes would allow water, but not gas bubbles, to pass through to the interior of the tube. Inside the tube, between the two membranes, there would be a flow restrictor that would play a role described below. Below both membranes there would be a relief valve. Water, possibly containing bubbles, would enter from the top and would pass through either the lower membrane or both membranes, depending how much gas had been accumulated thus far. When the volume of accumulated gas was sufficient to push the top surface of the liquid below the lower porous membrane, water could no longer flow through either membrane toward the outlet. This blockage would cause an increase in back pressure that would cause the relief valve to open. The opening of the relief valve would allow both the water and the bulk-accumulated gas to pass through to the outlet. Once the gas had been pushed out, water would once again flow through both membranes at a much lower pressure drop. The flow restrictor would maintain enough pressure drop to keep the relief valve open until gas had been cleared from both hydrophilic membranes.

Carter, Donald Layne↗