Characterization of Simulated Low Earth Orbit Space Environment Effects on Acid-spun Carbon Nanotube Yarns

The purpose of this study is to quantify the detrimental effects of atomic oxygen and ultraviolet (UV) C radiation on the mechanical properties, electrical conductivity, and piezoresistive effect of acid-spun carbon nanotube (CNT) yarns. Monotonic tensile tests with in-situ electrical resistance measurements were performed on pristine and exposed yarns to determine the effects of the atomic oxygen and UVC exposures on the yarn’s material properties. Both type of exposures were performed under vacuum to simulate space environment conditions. The CNT yarns’ mechanical properties did not change significantly after being exposed to UV radiation, but were significantly degraded by the atomic oxygen exposure. The electrical conductivity of the yarn was not significantly affected by either exposure. The piezoresistive effect did not significantly change due to atomic oxygen exposure, but was significantly enhanced as a result of the UV exposure. Scanning electron microscopy revealed significant erosion due to atomic oxygen exposure, but the UV exposure did not significantly change the appearance of the yarn’s external surface. Raman spectroscopy showed that both exposure types induced significant structural disorder in the surface level CNTs. Focused ion beam milling of a UVC exposed yarn revealed that the depth of the induced disorder was very shallow

Horizontally Issuing Diffusion Flames Characterized by OH-PLIF and Visualizations

Planar laser induced fluorescence and flame visualizations characterized the effect of buoyancy on the behavior of the combustion zone of diffusion jet flames which issued from horizontally-oriented tubes into ambient air. The study focused on the mixing characteristics of propane and ethylene at Reynolds numbers ranging from 300 to 1500 in the near field of the jet (up to X/D=9) and Froude numbers ranging as low as 0.36, based on cold-flow gas properties and conditions. Performing the study with a variety of fuel tube diameters enabled independent control of Froude and Reynolds numbers. The PLIF visualizations revealed the presence of the hydroxyl radical in the mixing layer for all cases. The hydroxyl concentrations were consistently higher in the upper portion of the mixing layer, indicative of more vigorous mixing in this region. The visualizations also revealed the evolution of polycyclic aromatic hydrocarbons which were initially spatially segregated from the portion of the reaction zone containing the hydroxyl radical. The polycyclic aromatic hydrocarbons initiate in fuel-rich regions nearer to the jet core than the hydroxyl radical, though the two regions eventually combine well downstream of the tube exit. Both the hydroxyl radical and the polycyclic aromatic hydrocarbons were more prominent on the upper side of the jet flame. Both propane and ethylene fuels led to qualitatively similar features of the flow field, indicating the important role played by the buoyancy-influenced fluid dynamics of the combustion products. The resulting cross sectional PLIF images were used to produce a three-dimensional representation of the reaction zone, indicating the jet spread and trajectory. The data was empirically correlated and found to collapse when based on the Froude number consistent with the density and temperature of a fully-reacted stoichiometric mixture. Complementary visualizations provided additional insight into the trajectory of the jet flame and revealed features of the reaction zone farther from the tube exit

Aerospike Rockets for Increased Space Launch Capability

The US Department of Defense DOD increasingly depends on space assets for everyday operations. Precision navigation communications and intelligence, surveillance, and reconnaissance satellites are highly leveraged space assets. The launch vehicles that place these satellites in orbit are a major limitation of current space systems. If higher-performing launch vehicles were available, many satellites could accommodate additional capabilities, whether in terms of more sensor channels, types of payloads, electrical power, or propellant for orbital maneuvering and station keeping. Space assets are typically designed to conform to a particular launch vehicle s limitations e.g., engineers might design a satellite to be carried by a Delta IV-2 medium launch vehicle. Essentially, this choice of vehicle fixes the maximum mass of the satellite and, thus, its capabilities. If a launcher capable of placing more mass in the desired orbit were available at similar cost, the satellite s design could allow for additional capability. Furthermore, some payloads are too heavy for present-day launch vehicles to place into a particular orbit. A better-performing launcher would enable us to put those payloads into the desired orbits, permitting new missions and capabilities

Case Study: Cooling Channels for Material Testing Applications Using Laser Powder Bed Fusion

Additive Manufacturing continues to gain a reputation as a key technology that will have a major impact on all aspects of mechanical engineering. The United States Air Force’s (USAF) Air Force Institute of Technology (AFIT), based in Dayton, Ohio, has expanded its AM-focused education and R&D capabilities with the purchase of a Laser Powder Bed Fusion system from Germany’s Concept Laser

All-Metallic Phase Change Thermal Management Systems for Transient Spacecraft Loads

In this work, we explore the thermal properties of gallium as an effective phase change material for thermal management applications. Thermal storage and dissipation of gallium manufactured heat sinks were compared to conventional phase change heat sinks. The comparison revealed a 50-fold (80 K versus 1.5 K) potential reduction in temperature during the phase change process due to the high density, thermal conductivity, and latent heat of fusion. The gallium creates shallow thermal gradients when transiently heated, producing a nearly isothermal process. Computational estimates using lumped sum parameters were able to provide simple modeling to predict the results. Gallium based phase change devices offer a combination of low volume, small temperature drops across the device, simplicity of manufacture and design, and high energy storage applications

Effects of Thermal Process Parameters on Mechanical Interlayer Strength for Additively Manufactured Ultem 9085

The effects of the envelope temperature on the microstructure and mechanical strength of Ultem 9085 fused deposition modeling (FDM) components were studied. A customized build chamber was developed for a commercial 3D printer in order to control the envelope temperature during printing. Test specimens were printed in the vertical direction because their mechanical strength exhibited the greatest dependence on inter-layer adhesion and neck development. A delay was introduced between two layers in each specimen in order to create a weak region where the neck was not expected to fully develop. However, none of the specimens failed in this region. Mechanical testing revealed that neck growth was highly dependent on the envelope temperature, and the strength was shown to vary significantly (20%) based on the envelope temperature. The variability of the mechanical strength also decreased as the envelope temperature increased. Thermal imaging revealed that the cooling rate of the specimens was consistent regardless of the envelope temperature. Fracture analysis confirmed that higher envelope temperatures improved the amount of neck growth and inter-layer adhesion in the specimens. This study showed that increasing the envelope temperature created parts with higher strengths and improved consistencies

The Impact of Laser Control on The Porosity And Microstructure of Selective Laser Melted Nickel Superalloy 718

Additively manufacturing high performance metals by laser processing represents an exciting opportunity to exploit localized properties by varying input parameters throughout the process. This work explores the solidification and microstructural properties of selectively laser melted (SLM) Inconel 718 (IN718) using unique processing parameters. By employing traditional pulsed laser physics techniques, samples were manufactured with a continuous wave laser to study a potential ubiquitous approach. While the overall power density was controlled, the power, speed, and hatch spacing were varied. The porosity and grain sizes of the samples were characterized by optical and scanning electron microscopes. The influence of processing parameters showed physical differences in the final samples. Sample degradation was observed in higher power processes with porosity up 10%, likely due to increased temperatures and more intense thermal gradients

Analysis of the Application of a Triggered Isomer Heat Exchanger as a Replacement for the Combustion Chamber in an Off-The-Shelf Turbojet

The objective of this research was to evaluate the feasibility of using the triggered decay of a radioactive isomer in a solid-state heat exchanger to power a gas turbine engine. Primary performance measures were stagnation temperature increase and stagnation pressure drop across the heat exchanger. Analysis was performed using commercial software, and explored three types of heat exchanger: concentric tubes, radial fins with constant spacing, and radial fins with constant thickness. All met or exceeded performance of the baseline J-57 turbojet engine at static sea level conditions. A single configuration of heat exchanger, using concentric tubes, was evaluated at typical in-flight conditions, up to 45,000 ft and Mach 0.8. At every flight condition, the heat exchanger was capable of delivering higher turbine inlet temperatures than the engine required for full-throttle operation at that flight condition. Performance trends in heat exchanger design were evaluated as they affected this application

Design and Characterization of a Space-based Imaging Experiment Computer Unit

The space-based chromotomographic experiment (CTEx), a hyperspectral imager, is currently in development at the Air Force Institute of Technology. This paper details an investigation of hermetic enclosures to house commercial off-the-shelf (COTS) components. These enclosures will enable the use of electronics in space which may not be available in a space-qualified form for years and reduce cost/schedule constraints. This activity produced an experimentally validated thermal mathematical model supporting further trade-space refinement and operational planning aspects for this device. Results support the transition of this next-generation technology from the laboratory to a fully-realized, space-readied platform uniquely capable of generating hyperspectral data at high spectral and temporal resolutions. © 2014 American Society of Civil Engineers

Performance Impacts of Metal Additive Manufacturing of Very Small Nozzles

For small satellite electrothermal or chemical thrusters, nozzle throat diameters may be less than 1 mm. At these sizes, the effects of flow surface roughness on nozzle performance must be considered. In this research, nozzles were processed using a nickel alloy by laser powder bed fusion (LPBF), a form of additive manufacturing. Experimentally, the thrust coefficient was measured over a range of targeted throat Reynolds numbers and nozzle expansion ratios. Additional nozzles were manufactured using traditional machining practices to compare performance at similar flow conditions. An analytic model was then developed to determine that performance may not be predicted by traditional viscous loss theory. Surface features of the LPBF manufactured nozzles appear to have caused bow shock systems that overwhelm all other impacts, limiting performance of the as-printed nozzles. This imperfection was then implemented into a computational fluid dynamics (CFD) flow study, showing shock wave reflections and similar thrust losses