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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 NTRS1996

PICA Forebody Heatshield Qualification for the Stardust Discovery Class Mission

This paper presents the qualification of the light weight Phenolic Impregnated Carbon Ablators (PICA) as the forebody heatshield for the Stardust Discovery Class Mission. The Stardust spacecraft will be launched in early 1999 and fly by Comet Wild-2 to collect cometary and interstellar dust and return them back to earth in the Sample Return Capsule (SRC). This earth re-entry will be the fastest to date, at 12.6 km/s, and therefore requires a heatshield that can withstand very high heating rates and stagnation pressures, as well as provide the necessary insulation to the vehicle structure. The PICA material was developed as part of the Lightweight Ceramic Ablators program at NASA Ames Research Center, and was baselined as the forebody heatshield because of its low density and superior ablation and thermal performance at severe aerothermodynamic conditions. Under a Small Business Innovative Research (SBIR) program with NASA Ames, Fiber Materials, Inc. developed a process to manufacture a single-piece PICA heatshield for the forebody of the SRC, along with witness material for the fabrication of the test models. The test models were fabricated and instrumented by the staff of Lockheed Martin Astronautics in Denver, Colorado. Full body preliminary aerothermal CFD calculations were performed at NASA Ames to determine the heating and stagnation pressure conditions. The Heat shield sizing was also performed at NASA Ames by using a new material response code that accounts for the highly porous characteristics of the PICA material. The ablation and thermal performance of PICA was qualified in the NASA Ames Interaction Heating Arc Jet Facility. A total of 24 models and four test conditions were used to qualify PICA at the predicted peak heat flux, heat load, shear, and stagnation pressure conditions. Surface and in-depth temperatures were measured using optical pyrometers and thermocouples. Surface recession was measured by using a template and a height gage. Several models were tested to evaluate repair procedures, and two models were cold soaked in liquid nitrogen, prior th testing, to investigate the effect of the cold space environment on the performance of the material. In addition, material cored from a demonstration single-piece heatshield was tested to verify that the PICA process can be successfully completed on a large, complex heatshield shape.

Tran, Huy K.↗

NASA NTRS2010

Design of 8-ft-Diameter Barrel Test Article Attachment Rings for Shell Buckling Knockdown Factor Project

The Shell Buckling Knockdown Factor (SBKF) project includes the testing of sub-scale cylinders to validate new shell buckling knockdown factors for use in the design of the Ares-I and Ares-V launch vehicles. Test article cylinders represent various barrel segments of the Ares-I and Ares-V vehicles, and also include checkout test articles. Testing will be conducted at Marshall Space Flight Center (MSFC) for test articles having an eight-foot diameter outer mold line (OML) and having lengths that range from three to ten feet long. Both ends of the test articles will be connected to the test apparatus using attachment rings. Three multiple-piece and one single-piece design for the attachment rings were developed and analyzed. The single-piece design was chosen and will be fabricated from either steel or aluminum (Al) depending on the required safety factors (SF) for test hardware. This report summarizes the design and analysis of these attachment ring concepts.

Lovejoy, Andrew E.↗

NASA NTRS2015

Spin Forming Aluminum Crew Module (CM) Metallic Aft Pressure Vessel Bulkhead (APVBH) - Phase II

The principal focus of this project was to assist the Multi-Purpose Crew Vehicle (MPCV) Program in developing a spin forming fabrication process for manufacture of the Orion crew module (CM) aft pressure vessel bulkhead. The spin forming process will enable a single piece aluminum (Al) alloy 2219 aft bulkhead resulting in the elimination of the current multiple piece welded construction, simplify CM fabrication, and lead to an enhanced design. Phase I (NASA TM-2014-218163 (1)) of this assessment explored spin forming the single-piece CM forward pressure vessel bulkhead. The Orion MPCV Program and Lockheed Martin (LM) recently made two critical decisions relative to the NESC Phase I work scope: (1) LM selected the spin forming process to manufacture a single-piece aft bulkhead for the Orion CM, and (2) the aft bulkhead will be manufactured from Al 2219. Based on the Program's new emphasis related to the spin forming process, the NESC was asked to conduct a Phase II assessment to assist in the LM manufacture of the aft bulkhead and to conduct a feasibility study into spin forming the Orion CM cone. This activity was approved on June 19, 2013. Dr. Robert Piascik, NASA Technical Fellow for Materials at the Langley Research Center (LaRC), was selected to lead this assessment. The project plan was approved by the NASA Engineering and Safety Center (NESC) Review Board (NRB) on July 18, 2013. The primary stakeholders for this assessment were the NASA and LM MPCV Program offices. Additional benefactors are commercial launch providers developing CM concepts.

Hoffman, Eric K.↗

DOE OSTI2024

Heliostats with Adjustable Shape for High Concentration throughout the Day

Our motivation is to develop more efficient heliostats that can provide commercially viable solar thermal power at temperatures > 800°C. Such high temperatures will enable high-temperature industrial processes, as well as electrical generation after sunset with high efficiency. The importance of this research is that such heliostats have the potential to substantially expand the global use of solar energy, by adding solar thermal power as a major component. Thermal solar currently accounts for only 1% of all solar power (with PV being the rest), with heliostat fields providing just 0.25%. Our goals have been 1) to demonstrate a technical improvement for heliostats that can enable fields of them to more efficiently power receivers and reactors, and 2) to show a path to low-cost mass production. Our solution uses new opto-mechanical technology to correct a fundamental deficiency of present heliostats that limits their concentration, namely that they have fixed shape. Most of today’s heliostat research does not address this, but is directed simply toward cost reduction in an effort to make heliostats commercially viable. We are motivated to explore also improving heliostat efficiency, which can be done by continually changing their shape to maximize the concentration of sunlight throughout the day. This is not a new concept, but it has never been implemented in a practical, cost-effective way that approaches the theoretical limit to concentration while also improving mechanical performance; this is our goal. Our major accomplishments have been: 1) We have realized the planned design, construction, and test of a prototype heliostat that achieves the required shape changes in an 8 m2 single-piece glass mirror. The mirror is attached to a steel support frame that is automatically mechanically twisted by the heliostat drives that orient the mirror to direct sunlight to the tower-mounted receiver. Closed-loop tracking is done using a new beamsplitter camera that exploits the target-oriented mount configuration. Field tests of the heliostat show that the light is reflected through the day to always form a disc image of the sun, as needed to obtain the highest concentration. 2) We have developed the design for a field of 431 heliostats to deliver annual average of 1 MW of thermal power at 3,000 sun concentration, matched to a high-temperature ≥ 1000°C chemical reactor. 3) We have also developed, beyond the original stated goals of the project, a new concept for closed-loop tracking and shape-sensing for all the heliostats in the above field, using just 6 cameras around the concentrated reactor focus. Our research adds to the understanding of solar thermal energy by its demonstration of the technical effectiveness of a higher performing heliostat, and by its concept for a new powerful method for real-time tracking and shape sensing in the field, as described above. We have studied the economic feasibility of fields of our twisting heliostats to provide high- temperature heat at a price competitive with that of burning gas, to satisfy the DOE’s studied zero-emissions scenario, where the gas price has to include the cost of carbon capture. The project has the potential to greatly benefit the public if it helps limit global warming by 1) reducing carbon emission from industrial heating, which is currently a major contributor to the 40-billion-ton annual increase in atmospheric CO 2 . 2) Ultimately, the technology could prove to be the least expensive method to power direct air capture of CO 2 on the very large scale needed to remove the 1 trillion-ton excess of CO 2 already in the atmosphere.

14 SOLAR ENERGY↗

NASA NTRS1980

Integral storage-bulb and microwave cavity for masers

Mechanically-stable integral storage-bulb/microwave cavity made out of single piece of fused quartz improves frequency stability. Single-piece construction eliminates joints, making cavity dimensionally and hence frequency-stable. Fused quartz is used because of its low thermal expansion coefficient.

Reinhardt, V. S.↗

NASA NTRS1986

Multi-path peristaltic pump

The instant invention is directed to a peristaltic pump for critical laboratory or hospital applications requiring precise flow rates over an extended period of time. Within the cylindrical barrel pump housing is a single-piece, molded, elastometric, cylindrical liner with a multiplicity of flattened helical channels created therein from one end of the liner to the other. Three cylindrical rollers rotate about the center axis of the pump around the inside surface of the liner selectively compressing the liner, and hence the helical channels between the rollers and the barrel housing, creating a pumping action by forcing trapped fluid in the helical channels axially from one end of the liner to the opposite end. The novelty of the invention appears to lie in the provision of the special liner with multiple helical channels as the pumping chamber, rather than the standard single elastomeric tubing which is squeezed repeatedly by rollers to move the liquid through a typical peristaltic pump. Large, repeated deflections on the standard tubing causes a permanent set in the tubing, thus either changing the flow rate, or requiring a new section of tubing to be positioned in the pump head. Further, this configuration minimizes the amount of outflow pulsation which is characteristic of a typical single tubing peristaltic pump.

Chandler, Joseph A.↗

NASA NTRS1989

Gland With Cantilever Seal

Single-piece gland forms tight seal on probe or tube containing liquid or gas at high pressure. Gland and probe align as assembled by simple torquing procedure. Disconnected easily and reused at same site. Made from any of wide variety of materials so compatible with application. Cantilever ring at top of gland bites into wall of tube or probe, sealing it. Wall of tube or probe must be thick enough to accommodate deformation without rupturing. Maximum deformation designed in coordination with seating and deformation of boss or conical seal.

Melton, Patrick B.↗

NASA NTRS1992

Advanced technology application for combustion chamber concepts

NASA-Marshall is engaged in the development of an Advanced Main Combustion Chamber under the aegis of the Earth-to-Orbit Propulsion Technology Program. AMCC is to be a robust and highly reliable combustion-chamber prototype costing one-third as much as current designs of comparable performance; it will be associated with a reduction of fabrication time by one-half. Attention is presently given to the three component-manufacturing processes used: single-piece investment casting for the structural jacket and manifolds; vacuum plasma spraying, for the combustion liner, and an alternative, platelet-compounded liner.

Tygielski, Kathy S.↗

NASA NTRS1998

Carbon-Carbon Turbocharger Housing Unit for Intermittent Combustion Engines

An improved, lightweight, turbine housing unit for an intermittent combustion reciprocating internal combustion engine turbocharger is prepared from a lay-up or molding of carbon-carbon composite materials in a single-piece or two-piece process. When compared to conventional steel or cast iron, the use of carbon-carbon composite materials in a turbine housing unit reduces the overall weight of the engine and reduces the heat energy loss used in the turbocharging process. This reduction in heat energy loss and weight reduction provides for more efficient engine operation.

Northam, G. Burton↗

NASA NTRS1999

Process for Making Carbon-Carbon Turbocharger Housing Unit for Intermittent Combustion Engines

An improved. lightweight, turbine housing unit for an intermittent combustion reciprocating internal combustion engine turbocharger is prepared from a lay-up or molding of carbon-carbon composite materials in a single-piece or two-piece process. When compared to conventional steel or cast iron, the use of carbon-carbon composite materials in a turbine housing unit reduces the overall weight of the engine and reduces the heat energy loss used in the turbo-charging process. This reduction in heat energy loss and weight reduction provides for more efficient engine operation.

Northam, G. Burton↗

NASA NTRS2001

New Tool Creates a Big Stir

A new self-adjusting, retractable pin tool for friction stir welding is now used in the manufacturing of components for NASA Space Shuttles. Friction stir welding is a process that makes straight-line welds without bringing the parent material to a liquid state. This is accomplished through high-speed rotation, which generates frictional heat between the welding tool and the piece being welded. This heat causes the material to soften to the point of plasticity without allowing it to melt. The plasticized material is then transferred from the front edge of the welding tool to the trail edge, where it joins the pieces being welded. However, a major flaw of this method is its reliance on a single-piece pin tool. The weld is left unfinished and a hole remains where the pin was inserted. The hole must be covered with a rivet in order to preserve the integrity of the weld. The NASA-developed pin tool, however, eliminates the need for this finishing step, as its retraction allows continuous rewelding at lesser depths, until the hole is completely closed. With this NASA technology, welding of higher strength alloys, as well as non-planer and variable thickness structures can be achieved.

Source record↗

NASA NTRS2003

Cloverleaf Vibratory Microgyroscope with Integrated Post

A modified design and fabrication sequence has been devised to improve the performance of a cloverleaf vibratory microgyroscope that includes an axial rod or post rigidly attached to the center of the cloverleaf structure. The basic concepts of cloverleaf vibratory microgyroscopes, without and with rods or posts, were described in two prior articles in NASA Tech Briefs, Vol. 21, No. 9 (September 1997): Micromachined Planar Vibratory Microgyroscopes (NPO-19713), page 68 and Planar Vibratory Microgyroscope: Alternative Configuration (NPO-19714), page 70. As described in more detail in the second-mentioned prior article, the cloverleaf-shaped structure and the rod or post are parts of a vibratory element that senses rotation via the effect of the Coriolis force upon its vibrations. Heretofore, the posts for devices of this type have been fabricated separately, then assembled manually onto the cloverleaf structures. The resulting imperfections in the assembled units have given rise to asymmetric stresses in the cloverleaf structures and, consequently, to changes in resonant frequencies of vibration and in shapes of vibration modes. These changes, in turn, have caused variations in performance among nominally identical devices. The modified design provides for the fabrication of the upper half of the post as an integral part of the cloverleaf structure; this is accomplished by reactive-ion etching of a single-piece half-post-and-cloverleaf structure from a wafer of silicon. The lower half of the post and a baseplate are also a single piece made by reactive-ion etching from a wafer of silicon. The two pieces are bonded together (see figure) by a thermal-compression metal-to-metal bonding technique to form a cloverleaf gyroscope with an integrated post structure..

Tang, Tony K.↗

NASA NTRS2012

Friction-Stir-Welded and Spin-Formed End Domes for Cryogenic Tanks

Manufacturing of single-piece end domes for cryogenic tanks employing spin forming of tailored, friction-stir-welded blanks of Al-Li alloy 2195 plate offers cost and reliability benefits. The introduction of plastic deformation into a friction stir weld is a unique feature of the proposed manufacturing route. This investigation addressed abnormal grain growth [AGG] within the friction stir weldments during postfabrication processing of a prototype dome. The phenomenon of AGG was observed during the solution heat treatment [SHT] phase of T8 tempering and is a major concern for meeting specifications. Such abrupt microstructural transitions can be detrimental to notch-sensitive mechanical properties, such as ductility and/or fracture toughness. If the issue of AGG cannot be resolved, then the acceptance of this approach as a viable manufacturing route may be in jeopardy. The innovative approach adopted in this investigation was the insertion of a stand-alone, Intermediate Annealing Treatment [IAT] between the spin forming and T8 processing operations. A simple, recovery annealing step was deemed to be the most readily-scalable solution when fabricating thin-walled, ellipsoidal domes. The research effort culminated in the development of an effective IAT, which resulted in a significant decrease in AGG following SHT. The processing philosophy adopted in designing the IAT is outlined and the microstructural reasons for success are discussed. The analytical results presented are consistent with promoting continuous grain growth during the IAT, thereby suppressing AGG during the SHT.

Hales, S. J.↗

NASA NTRS2012

Correlation of Fracture Behavior With Microstructure in Friction Stir Welded, and Spin Formed AI-Li 2195 Domes

Single-piece, spin-formed domes manufactured from friction stir welded (FSW) plates of Al-Li alloy 2195 have the potential to reduce the cost of fabricating cryogenic propellant tanks. Mechanical properties in the completed domes can be related directly to the final material condition and the microstructures developed. However, these new fabrication techniques have resulted in unexpected material challenges, such as abnormal grain growth in the weld nugget and the propensity for fracture in the adjacent thermo-mechanically affected zone (TMAZ). In this study, the microstructure and texture transformations within the TMAZ are related to fracture location in the vicinity of the weldment. The texture variations in the TMAZ are caused primarily by the varying amounts of shear deformation introduced during the FSW process. Grain morphology and microtexture characteristics are examined as a function of location in the TMAZ via electron backscatter diffraction (EBSD). A strong correlation between fracture location and the presence of texture banding in the TMAZ is observed. The fracture path tends to follow a distinct region of low Taylor Factor (TF) grains.

Tayon, Wesley A.↗

NASA NTRS2013

Experimental Investigation of Aeroelastic Deformation of Slender Wings at Supersonic Speeds Using a Video Model Deformation Measurement Technique

A video-based photogrammetric model deformation system was established as a dedicated optical measurement technique at supersonic speeds in the NASA Langley Research Center Unitary Plan Wind Tunnel. This system was used to measure the wing twist due to aerodynamic loads of two supersonic commercial transport airplane models with identical outer mold lines but different aeroelastic properties. One model featured wings with deflectable leading- and trailing-edge flaps and internal channels to accommodate static pressure tube instrumentation. The wings of the second model were of single-piece construction without flaps or internal channels. The testing was performed at Mach numbers from 1.6 to 2.7, unit Reynolds numbers of 1.0 million to 5.0 million, and angles of attack from -4 degrees to +10 degrees. The video model deformation system quantified the wing aeroelastic response to changes in the Mach number, Reynolds number concurrent with dynamic pressure, and angle of attack and effectively captured the differences in the wing twist characteristics between the two test articles.

Erickson, Gary E.↗

NASA NTRS2013

Investigation of Abnormal Grain Growth in a Friction Stir Welded and Spin-Formed Al-Li Alloy 2195 Crew Module

In order to improve manufacturing efficiency and reduce structural mass and costs in the production of launch vehicle structures, NASA is pursuing a wide-range of innovative, near-net shape manufacturing technologies. A technology that combines friction stir welding (FSW) and spin-forming has been applied to manufacture a single-piece crew module using Aluminum-Lithium (AL-Li) Alloy 2195. Plate size limitations for Al-Li alloy 2195 require that two plates be FSW together to produce a spin-forming blank of sufficient size to form the crew module. Subsequent forming of the FSW results in abnormal grain growth (AGG) within the weld region upon solution heat treatment (SHT), which detrimentally impacts strength, ductility, and fracture toughness. The current study seeks to identify microstructural factors that contribute to the development of AGG. Electron backscatter diffraction (EBSD) was used to correlate driving forces for AGG, such as stored energy, texture, and grain size distributions, with the propensity for AGG. Additionally, developmental annealing treatments prior to SHT are examined to reduce or eliminate the occurrence of AGG by promoting continuous, or uniform, grain growth

Tayon, Wesley A.↗

NASA NTRS2014

Flexural Fillet Geometry Optimization for Design of Force Transducers Used in Aeronautics Testing

Force transducer designs used in the ground testing aeronautics community have seen minimal change over the last few decades. With increased focus on data quality and long- term performance capabilities over the life of these instruments, it is critical to investigate new methods that improve these designs. One area of focus in the past few years at NASA has been on the design of the exural elements of traditional force balance transducers. Many of the heritage balances that have been heavily used over the last few decades have started to develop fatigue cracks. The recent focus on the exural design of traditional single-piece force balances revolves around the design of these elements such that stress concentrations are minimized, with the overall goal of increasing the fatigue life of the balance. Recent research in the area of using conic shaped llets in the highly stressed regions of traditional force balances will be discussed, with preliminary numerical and experimental data results. A case study will be presented which discusses integration of this knowledge into a new high-capacity semi-span force balance

Lynn, Keith C.↗

NASA NTRS2015

Flexural Fillet Geometry Optimization for Design of Force Transducers Used in Aeronautics Testing

Force transducer designs used in the ground testing aeronautics community have seen minimal change over the last few decades. With increased focus on data quality and long-term performance capabilities over the life of these instruments, it is critical to investigate new methods that improve these designs. One area of focus in the past few years at NASA has been on the design of the flexural elements of traditional force balance transducers. Many of the heritage balances that have been heavily used over the last few decades have started to develop fatigue cracks. The recent focus on the flexural design of traditional single-piece force balances revolves around the design of these elements such that stress concentrations are minimized, with the overall goal of increasing the fatigue life of the balance. Recent research in the area of using conic shaped fillets in the highly stressed regions of traditional force balances will be discussed, with preliminary numerical and experimental data results. A case study will be presented which discusses integration of this knowledge into a new high-capacity semi-span force balance.

Lynn, Keith C.↗