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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 NTRS2017

Urban Biomining Meets Printable Electronics: End-To-End at Destination Biological Recycling and Reprinting

Space missions rely utterly on metallic components, from the spacecraft to electronics. Yet, metals add mass, and electronics have the additional problem of a limited lifespan. Thus, current mission architectures must compensate for replacement. In space, spent electronics are discarded; on earth, there is some recycling but current processes are toxic and environmentally hazardous. Imagine instead an end-to-end recycling of spent electronics at low mass, low cost, room temperature, and in a non-toxic manner. Here, we propose a solution that will not only enhance mission success by decreasing upmass and providing a fresh supply of electronics, but in addition has immediate applications to a serious environmental issue on the Earth. Spent electronics will be used as feedstock to make fresh electronic components, a process we will accomplish with so-called 'urban biomining' using synthetically enhanced microbes to bind metals with elemental specificity. To create new electronics, the microbes will be used as 'bioink' to print a new IC chip, using plasma jet electronics printing. The plasma jet electronics printing technology will have the potential to use martian atmospheric gas to print and to tailor the electronic and chemical properties of the materials. Our preliminary results have suggested that this process also serves as a purification step to enhance the proportion of metals in the 'bioink'. The presence of electric field and plasma can ensure printing in microgravity environment while also providing material morphology and electronic structure tunabiity and thus optimization. Here we propose to increase the TRL level of the concept by engineering microbes to dissolve the siliceous matrix in the IC, extract copper from a mixture of metals, and use the microbes as feedstock to print interconnects using mars gas simulant. To assess the ability of this concept to influence mission architecture, we will do an analysis of the infrastructure required to execute this concept on Mars, and additional opportunities it could offer mission design from the biological and printing technologies. In addition, we will do an analysis of the impact of this technology for terrestrial applications addressing in particular environmental concerns and availability of metals.

Space mission↗
NASA NTRS2016

Atmospheric Pressure Plasma Jet as a Dry Alternative to Inkjet Printing in Flexible Electronics

We have developed an atmospheric pressure plasma jet printing system that works at room temperature to 50 deg C unlike conventional aerosol assisted techniques which require a high temperature sintering step to obtain desired thin films. Multiple jets can be configured to increase throughput or to deposit multiple materials, and the jet(s) can be moved across large areas using a x-y stage. The plasma jet has been used to deposit carbon nanotubes, graphene, silver nanowires, copper nanoparticles and other materials on substrates such as paper, cotton, plastic and thin metal foils.

Printable electronics↗
NASA NTRS1982

Plasma Etching Improves Solar Cells

Etching front surfaces of screen-printed silicon photovoltaic cells with sulfur hexafluoride plasma found to increase cell performance while maintaining integrity of screen-printed silver contacts. Replacement of evaporated-metal contacts with screen-printed metal contacts proposed as one way to reduce cost of solar cells for terrestrial applications.

Bunyan, S. M.↗
NASA NTRS2003

Demonstration of Separation Control Using Glow-Discharge Plasma Actuators

Active flow control of boundary-layer separation using glow-discharge plasma actuators is studied experimentally. Separation is induced on a flat plate installed in a closed-circuit wind tunnel by a shaped insert on the opposite wall. The flow conditions represent flow over the suction surface of a modem low-pressure-turbine airfoil. The Reynolds number, based on wetted plate length and nominal exit velocity, is varied from 50,000 to 300,000, covering cruise to takeoff conditions. Low (0.2%) and high (2.5%) free-stream turbulence intensities are set using passive grids. A spanwise-oriented phased-plasma-array actuator, fabricated on a printed circuit board, is surface-flush-mounted upstream of the separation point and can provide forcing in a wide frequency range. Static surface pressure measurements and hot-wire anemometry of the base and controlled flows are performed and indicate that the glow-discharge plasma actuator is an effective device for separation control.

Hultgren, Lennart S.↗
NASA NTRS2003

Boundary-Layer Separation Control under Low-Pressure Turbine Airfoil Conditions using Glow-Discharge Plasma Actuators

Modem low-pressure turbines, in general, utilize highly loaded airfoils in an effort to improve efficiency and to lower the number of airfoils needed. Typically, the airfoil boundary layers are turbulent and fully attached at takeoff conditions, whereas a substantial fraction of the boundary layers on the airfoils may be transitional at cruise conditions due to the change of density with altitude. The strong adverse pressure gradients on the suction side of these airfoils can lead to boundary-layer separation at the latter low Reynolds number conditions. Large separation bubbles, particularly those which fail to reattach, cause a significant degradation of engine efficiency. A component efficiency drop of the order 2% may occur between takeoff and cruise conditions for large commercial transport engines and could be as large as 7% for smaller engines at higher altitude. An efficient means of of separation elimination/reduction is, therefore, crucial to improved turbine design. Because the large change in the Reynolds number from takeoff to cruise leads to a distinct change in the airfoil flow physics, a separation control strategy intended for cruise conditions will need to be carefully constructed so as to incur minimum impact/penalty at takeoff. A complicating factor, but also a potential advantage in the quest for an efficient strategy, is the intricate interplay between separation and transition for the situation at hand. Volino gives a comprehensive discussion of several recent studies on transition and separation under low-pressure-turbine conditions, among them one in the present facility. Transition may begin before or after separation, depending on the Reynolds number and other flow conditions. If the transition occurs early in the boundary layer then separation may be reduced or completely eliminated. Transition in the shear layer of a separation bubble can lead to rapid reattachment. This suggests using control mechanisms to trigger and enhance early transition. Gad-el-Hak provides a review of various techniques for flow control in general and Volino discusses recent studies on separation control under low-pressure-turbine conditions utilizing passive as well as active devices. As pointed out by Volino, passive devices optimized for separation control at low Reynolds numbers tend to increase losses at high Reynolds numbers, Active devices have the attractive feature that they can be utilized only in operational regimes where they are needed and when turned off would not affect the flow. The focus in the present paper is an experimental Separation is induced on a flat plate installed in a closed-circuit wind tunnel by a shaped insert on the opposite wall. The flow conditions represent flow over the suction surface of a modem low-pressure-turbine airfoil ('Pak-B'). The Reynolds number, based on wetted plate length and nominal exit velocity, is varied from 50,000 to 300,000, covering cruise to takeoff conditions. Low (0.2%) and high (2.5%) Gee-stream turbulence intensities are set using passive grids. A spanwise-oriented phased-plasma-array actuator, fabricated on a printed circuit board, is surface- flush-mounted upstream of the separation point and can provide forcing in a wide frequency range. Static surface pressure measurements and hot-wire anemometry of the base and controlled flows are performed and indicate that the glow-discharge plasma actuator is an effective device for separation control. of active separation control using glow discharge plasma actuators.

Hultgren, Lennart S.↗
NASA NTRS2004

Demonstration of Separation Delay with Glow-Discharge Plasma Actuators

Active flow control of boundary-layer separation using glow-discharge plasma actuators is studied experimentally. Separation is induced on a flat plate installed in a closed-circuit wind tunnel by a shaped insert on the opposite wall. The flow conditions represent flow over the suction surface of a modern low-pressure-turbine airfoil. The Reynolds number, based on wetted plate length and nominal exit velocity, is varied from 50,000 to 300,000, covering cruise to takeoff conditions. Low (0.2 percent) and high (2.5 percent) free-stream turbulence intensities are set using passive grids. A spanwise-oriented phased-plasma-array actuator, fabricated on a printed circuit board, is surface-flush-mounted upstream of the separation point and can provide forcing in a wide frequency range. Static surface pressure measurements and hot-wire anemometry of the base and controlled flows are performed and indicate that the glow-discharge plasma actuator is an effective device for separation control.

Hultgren, Lennart S.↗
NASA NTRS2015

Using Additive Manufacturing to Print a CubeSat Propulsion System

Small satellites, such as CubeSats, are increasingly being called upon to perform missions traditionally ascribed to larger satellite systems. However, the market of components and hardware for small satellites, particularly CubeSats, still falls short of providing the necessary capabilities required by ever increasing mission demands. One way to overcome this shortfall is to develop the ability to customize every build. By utilizing fabrication methods such as additive manufacturing, mission specific capabilities can be built into a system, or into the structure, that commercial off-the-shelf components may not be able to provide. A partnership between the University of Texas at El Paso, COSMIAC at the University of New Mexico, Northrop Grumman, and the NASA Glenn Research Center is looking into using additive manufacturing techniques to build a complete CubeSat, under the Small Spacecraft Technology Program. The W. M. Keck Center at the University of Texas at El Paso has previously demonstrated the ability to embed electronics and wires into the addtively manufactured structures. Using this technique, features such as antennas and propulsion systems can be included into the CubeSat structural body. Of interest to this paper, the team is investigating the ability to take a commercial micro pulsed plasma thruster and embed it into the printing process. Tests demonstrating the dielectric strength of the printed material and proof-of-concept demonstration of the printed thruster will be shown.

manufacturing processes↗
NASA NTRS2015

3D Printing the Complete CubeSat

The 3D Printing the Complete CubeSat project is designed to advance the state-of-the-art in 3D printing for CubeSat applications. Printing in 3D has the potential to increase reliability, reduce design iteration time and provide greater design flexibility in the areas of radiation mitigation, communications, propulsion, and wiring, among others. This project is investigating the possibility of including propulsion systems into the design of printed CubeSat components. One such concept, an embedded micro pulsed plasma thruster (mPPT), could provide auxiliary reaction control propulsion for a spacecraft as a means to desaturate momentum wheels.

Printing CubeSat subsystems↗
NASA NTRS1979

Process Development for Automated Solar Cell and Module Production. Task 4: Automated Array Assembly

A baseline sequence for the manufacture of solar cell modules was specified. Starting with silicon wafers, the process goes through damage etching, texture etching, junction formation, plasma edge etch, aluminum back surface field formation, and screen printed metallization to produce finished solar cells. The cells were then series connected on a ribbon and bonded into a finished glass tedlar module. A number of steps required additional developmental effort to verify technical and economic feasibility. These steps include texture etching, plasma edge etch, aluminum back surface field formation, array layup and interconnect, and module edge sealing and framing.

Source record↗
NASA NTRS2024

Plasma Produced Gaseous Species for Food, Seed, and Equipment Sanitization

Researchers at KSC have shown that plasma produced gaseous species have shown greater than 5.89 log reduction of inoculated coupons and sanitization (greater than 3 log reduction) of produce and 3D printed materials, though with more variable results. The results were obtained using a recirculating plasma system, with 1 L of air, 1 mL of H 2 O, and less than 500 W of power being the only consumable commodities. The work is versatile and enabling for future missions since the air and the produced gases can be reused or recycled on board the spacecraft.

Kenneth Engeling↗
NASA NTRS2024

Additively Manufactured Plastic Plasma Spectrometer

We report results in development and testing of a low resource top hat electrostatic analyzer (ESA) for space plasma measurements. This device has been additively manufactured (3D-printed) using fused deposition modeling. The classic top hat design is composed of four plastic pieces, without any surface coatings. The three conducting electrodes are printed from carbon nanotube infused polyether ether ketone (CNT-PEEK). The fourth piece, an insulating electrode support, uses pure PEEK. This ESA is designed to detect electrons in space from 10eV up to 30 keV. We demonstrate that the printed CNT-PEEK is sufficiently electrically conductive to support the fast high voltage slewing often required for high time resolution measurements. The plastic ESA has been successfully vibrated beyond standard pre-flight levels, tested under keV electron beam illumination over a wide range of temperatures, and tested under UV illumination, simulating the solar Ly-α flux. In comparison with an identical machined aluminum ESA, our CNT-PEEK ESA provides nominal energy/angle band passes, closely matching simulation. These band passes imply minimal impact from surface charging at beam energies of 2-3 keV, although more investigation is needed. We also find that the CNT-PEEK ESA provides far superior out-of-band electron rejection and UV photon rejection compared to the machined aluminum ESA. We do not detect any problems with trapped gases or outgassing. This development offers potential for significant mass savings, implementation of otherwise unattainable geometric configurations, and dramatic simplification in manufacturing and assembly processes required for development of space plasma instruments.

Quetzal Larrick↗
NASA NTRS2014

Modular Pulsed Plasma Electric Propulsion System for Cubesats

Current capabilities of CubeSats must be improved in order to perform more ambitious missions. Electric propulsion systems will play a key role due to their large specific impulse. Compared to other propulsion alternatives, their simplicity allows an easier miniaturization and manufacturing of autonomous modules into the nano and pico-satellite platform. Pulsed Plasma Thrusters (PPTs) appear as one of the most promising technologies for the near term. The utilization of solid and non-volatile propellants, their low power requirements and their proven reliability in the large scale make them great candidates for rapid implementation. The main challenges are the integration and miniaturization of all the electronic circuitry into a printed circuit board (PCB) that can satisfy the strict requirements that CubeSats present. NASA Ames and the George Washington University have demonstrated functionality and control of three discrete Micro-Cathode Arc Thrusters (CAT) using a bench top configuration that was compatible with the ARC PhoneSat Bus. This demonstration was successfully conducted in a vaccum chamber at the ARC Environmental Test Laboratory. A new effort will integrate a low power Plasma Processing Unit and two plasma thrusters onto a single printed circuit board that will utilize less than 13 U of Bus volume. The target design will be optimized for the accommodation into the PhoneSatEDISON Demonstration of SmallSatellite Networks (EDSN) bus as it uses the same software interface application, which was demonstrated in the previous task. This paper describes the design, integration and architecture of the proposed propulsion subsystem for a planned Technology Demonstration Mission. In addition, a general review of the Pulsed Plasma technology available for CubeSats is presented in order to assess the necessary challenges to overcome further development.

PCB↗
NASA NTRS1980

High density circuit technology

Acquisition of polyimide materials for inter-metal dielectrics was obtained from three vendors, with considerable evaluation conducted on the Dupont PI2550 material. Experimental results indicate this material can be patterned using contact printing to line width far below 0.1 mils. Optimum line width is acquired using plasma etch equipment. Metal lift-off experiments on thermal evaporated films were optimized for application to sputtered deposited films. Alternate metal-lift-off experiments are proposed for future investigation. Dry processing equipment studies and future trends in VLSI fabrication techniques are on-going.

Wade, T. E.↗
NASA NTRS1984

Improved Coil for Hydrogen Dissociators

Flat coil has rigid printed circuit substrate. New coil structure minimizes RF electric field near glass walls of plasma vessel; therefore reduces direct electron bombardment of glass. Design lends itself well to high production and standardized dimensions.

Vessot, R.↗
NASA NTRS2000

Development of Metal Matrix Composites for NASA'S Advanced Propulsion Systems

The state-of-the-art development of several aluminum and copper based Metal Matrix Composites (MMC) for NASA's advanced propulsion systems will be presented. The presentation's goal is to provide an overview of NASA-Marshall Space Flight Center's planned and on-going activities in MMC for advanced liquid rocket engines such as the X-33 vehicle's Aerospike and X-34 Fastrac engine. The focus will be on lightweight and environmental compatibility with oxygen and hydrogen of key MMC materials, within each NASA's new propulsion application, that will provide a high payoff for NASA's reusable launch vehicle systems and space access vehicles. Advanced MMC processing techniques such as plasma spray, centrifugal casting, pressure infiltration casting will be discussed. Development of a novel 3D printing method for low cost production of composite preform, and functional gradient MMC to enhanced rocket engine's dimensional stability will be presented.

Lee, Jonathan A.↗
NASA NTRS2017

Marshall Space Flight Center Faculty Fellowship Program

The research projects conducted by the 2016 Faculty Fellows at NASA Marshall Space Flight Center included propulsion studies on propellant issues, and materials investigations involving plasma effects and friction stir welding. Spacecraft Systems research was conducted on wireless systems and 3D printing of avionics. Vehicle Systems studies were performed on controllers and spacecraft instruments. The Science and Technology group investigated additive construction applied to Mars and Lunar regolith, medical uses of 3D printing, and unique instrumentation, while the Test Laboratory measured pressure vessel leakage and crack growth rates.

Six, N. F.↗
NASA NTRS1989

Photovoltaic array environmental protection program

During the photovoltaic array environmental protection program, a coating material, application technique, and design approach intended to protect flexible solar array blankets during a nominal fifteen-year operating lifetime were developed. Numerous thin-film coatings for protecting the Kapton polyimide material used in the construction of the Space Station Freedom flexible solar array blanket were evaluated. The critical solar array design features and protection measures are discussed with special emphasis on the effects of solar array fabrication and flexible printed circuit manufacturing processes on coating durability. The results of the mechanical and environmental test evaluation, including oxygen plasma, neutral oxygen beam, and UV/charged-particle combined exposure, are discussed. These results led to the selection of a silicon dioxide thin-film coating to protect the solar array blanket from the low-earth-orbit atomic oxygen environment.

Bilger, Kevin M.↗
NASA NTRS1976

A high-voltage-isolated automated data acquisition system

A data acquisition system for electric-arc heated, high-temperature wind tunnel facilities has been developed; the high voltage isolation of the system exceeds 50 kV. A closed loop, optically coupled data system acquires transducer signals from high-temperature, arc-generated plasmas used for reentry testing. The data acquisition system monitors on-line tests, stores data on magnetic tape, and prints out a paper tape. The system has 400 data channels: 200 low-voltage programmable channels and 200 high-voltage sequential channels.

Cox, J.↗