A Review of Welding in Space and Related Technologies

Deployment of welding and additive manufacturing (AM) technologies in the space environment has the potential to revolutionize how orbiting platforms are designed, manufactured, and assembled. These technologies offer the option for repair of sustained damage to habitat structures on space missions, as astronauts would be able to manufacture new parts (using welding-derived AM processes suitable for use in the external space environment) and weld cracks. An added benefit is that required repairs can be achieved more economically, as new parts need not be shipped from Earth. With further maturation of in-space welding capabilities, astronauts could operate under given standards and weld damaged structures rather than rely on cargo resupply. This Technical Memorandum (TM) begins by reviewing the available literature relevant to welding in space, focusing on solidification, heat and mass transfer, and fluid flows in microgravity. This survey considers research on the effects of welding in microgravity on a material system. The various in-space welding devices that have been previously designed and tested are examined to determine their capabilities and shortcomings, with a focus on the results of their individual welding experiments. Safety measures are discussed to protect the orbiting International Space Station (ISS) and crew during welding operations. Finally, the state of the art is examined by focusing on current approaches to AM and on-orbit welding that are being developed by several companies in conjunction with NASA

Methods for Decarbonized Aeroengine Combustor Design

There exists an urgent need to decarbonize the civil transportation sector in order to address global warming concerns and its effects. Alternate and sustainable fuel types for combustion systems must be pursued to mitigate the dependency on fossil fuels for power generation. Possible alternative options for aeroengine combustion and propulsion include batteries or hydrogen fuel for fuel-cells or thermal-powered gas turbines. More specifically, thermal-powered aeroengines with premixed flame regimes can promise ultra-low emissions. Future aeroengine combustors operating in highly swirled premixed mode with hydrogen/air mixtures are central to this paper. Prior to the implementation and design of such systems, premixed combustion conditions must be correlated with gas turbine engine performance parameters. This thesis aims to address the gap by introducing a procedure to calculate relevant combustor operating conditions for the retrofit of aircraft engines in premixed mode with hydrogen/air mixture. The pursued method, a combustor performance map, leads to six key requirements: (1) the thermal power for the engine, (2) the mass conservation into the combustor, (3) the momentum conservation into the combustor, (4) the combustor energy budget, (5) the compressor-combustor-turbine power balance, and (6) a coupling relationship. The six requirements are obtained based on the derivation from fundamental conservation laws which are uniquely applied to pertain to a premixed combustor architecture. Whereas hydrogen fuel is considered, any fuel for premixed combustion system can be determined with the present method. To obtain the performance map, thermodynamics-based turbomachinery performance and chemical kinetics data are utilized to populate the governing conservation equations. As these two data sets provide combustor boundary conditions as well as hydrogen flame characteristics, the overall goal is to identify realistic operating points where all five requirements coincide. The results from the performance map analysis are complemented with computational fluid dynamics for validation purposes. The novel combustor performance map alongside the corresponding fluid dynamics simulations provide baseline methods for the development of future hydrogen premixed combustion systems

Characterization of Machine Variability and Progressive Heat Treatment in Selective Laser Melting of Inconel 718

The absence of an economy of scale in spaceflight hardware makes additive manufacturing an immensely attractive option for propulsion components. As additive manufacturing techniques are increasingly adopted by government and industry to produce propulsion hardware in human-rated systems, significant development efforts are needed to establish these methods as reliable alternatives to conventional subtractive manufacturing. One of the critical challenges facing powder bed fusion techniques in this application is variability between machines used to perform builds. Even with implementation of robust process controls, it is possible for two machines operating at identical parameters with equivalent base materials to produce specimens with slightly different material properties. The machine variability study presented here evaluates 60 specimens of identical geometry built using the same parameters. 30 samples were produced on machine 1 (M1) and the other 30 samples were built on machine 2 (M2). Each of the 30-sample sets were further subdivided into three subsets (with 10 specimens in each subset) to assess the effect of progressive heat treatment on machine variability. The three categories for post-processing were: stress relief, stress relief followed by hot isostatic press (HIP), and stress relief followed by HIP followed by heat treatment per AMS 5664. Each specimen (a round, smooth tensile) was mechanically tested per ASTM E8. Two formal statistical techniques, hypothesis testing for equivalency of means and one-way analysis of variance (ANOVA), were applied to characterize the impact of machine variability and heat treatment on six material properties: tensile stress, yield stress, modulus of elasticity, fracture elongation, and reduction of area. This work represents the type of development effort that is critical as NASA, academia, and the industrial base work collaboratively to establish a path to certification for additively manufactured parts. For future flight programs, NASA and its commercial partners will procure parts from vendors who will use a diverse range of machines to produce parts and, as such, it is essential that the AM community develop a sound understanding of the degree to which machine variability impacts material properties

NASA's Centennial Challenge for 3D-Printed Habitat: Phase II Outcomes and Phase III Competition Overview

The 3D-Printed Habitat Challenge is part of NASA's Centennial Challenges Program. NASA's Centennial Challenges seek to accelerate innovation in aerospace technology development through public competitions. The 3D-Printed Habitat Challenge, launched in 2015, is part of the Centennial Challenges portfolio and focuses on habitat design and development of large-scale additive construction systems capable of fabricating structures from in situ materials and/or mission recyclables. The challenge is a partnership between NASA, Caterpillar (primary sponsor), Bechtel, Brick and Mortar Ventures, and Bradley University. Phase I of the challenge was an architectural concept competition in which participants generated conceptual renderings of habitats on Mars which could be constructed using locally available resources. Phase II asked teams to develop the printing systems and material formulations needed to translate these designs into reality. Work under the phase II competition, which concluded in August 2017 with a head to head competition at Caterpillar's Edward Demonstration Facility in Peoria, Illinois, is discussed, including the key technology development outcomes resulting from this portion of the competition. The phase III competition consists of both virtual and construction subcompetitions. Virtual construction asks teams to render high fidelity architectural models of a habitat and all the accompanying information required for construction of the pressure retaining and load bearing portions of the structure. In construction phase III, teams are asked to scale up their printing systems to produce a 1/3 scale habitat on-site at Caterpillar. The levels of the phase III construction competition (which include printing of a foundation and printing and hydrostatic testing of a habitat element) are discussed. Phase III construction also has an increased focus on autonomy, as these systems are envisioned for robotic precursor missions which would buildup infrastructure prior to the arrival of crew. Results of the phase III competition through July 2017 (which includes virtual construction level 1) are discussed. This Centennial Challenge enables an assessment of the scaleability and efficacy of various processes, material systems, and designs for planetary construction. There are also near-term terrestrial applications, from disaster response to affordable housing and infrastructure refurbishment, for these technologies

Summary Report on Phase I and Phase II Results From the 3D Printing in Zero-G Technology Demonstration Mission

In-space manufacturing seeks to develop the processes, skill sets, and certification architecture needed to provide a rapid response manufacturing capability on long-duration exploration missions. The first 3D printer on the Space Station was developed by Made in Space, Inc. and completed two rounds of operation on orbit as part of the 3D Printing in Zero-G Technology Demonstration Mission. This Technical Publication provides a comprehensive overview of the technical objections of the mission, the two phases of hardware operation conducted on orbit, and the subsequent detailed analysis of specimens produced. No engineering significant evidence of microgravity effects on material outcomes was noted. This technology demonstration mission represents the first step in developing a suite of manufacturing capabilities to meet future mission needs

Cytoskeletal Changes During Adhesion and Release: A Comparison of Human and Nonhuman Primate Platelets

The organization of cytoskeletal proteins in whole-mount adherent platelets from African green monkeys and normal human volunteers has been studied by SEM, high vacuum electron microscopy (HVEM) and conventional (120 kV) electron microscopy. We describe three distinct organizational zones, the Central Matrix, the Trabecular Zone and the Peripheral Web in spread platelets from both sources. The Central Matrix is an ill-defined superstructure of 80-100 Å filaments of short length which enshrouded the granules, dense bodies, mitochondria and elements of the open-channel and dense-tubular systems. The latter, identified through the use of peroxidase cytochemistry with the whole mounts, is an anastomosing network of elongate saccules having diameters of 600-1200 Å. The Trabecular Zone, which encircles the Central Matrix, contains 165, 80-100 and 30-50 Å filaments in an open lattice of irregular lattice spacing. The outermost region of the cells, the Peripheral Web, is comprised of 70 Å filaments organized in a honeycomb lattice with center to center spacing in the range 150-300 Å. This pattern for the spread cells is not consistently observed in cells during the early stages of adhesion; therefore, correlations of SEM and TEM observations are made for the various stages of adhesion/activation

Multi-frequency Ferromagnetic Resonance Investigation of Nickel Nanocubes Encapsulated in Diamagnetic Magnesium Oxide Matrix

Partially aligned nickel nanocubes were grown epitaxially in a diamagnetic magnesium oxide (MgO:Ni) host and studied by a continuous wave ferromagnetic resonance (FMR) spectroscopy at the X-band (9.5 GHz) from ca. 117 to 458 K and then at room temperature for multiple external magnetic fields/resonant frequencies from 9.5 to 330 GHz. In contrast to conventional magnetic susceptibility studies that provided data on the bulk magnetization, the FMR spectra revealed the presence of three different types of magnetic Ni nanocubes in the sample. Specifically, three different ferromagnetic resonances were observed in the X-band spectra: a line 1 assigned to large nickel nanocubes, a line 2 corresponding to the nanocubes exhibiting saturated magnetization even at ca. 0.3 T field, and a high field line 3 (geff ∼ 6.2) tentatively assigned to small nickel nanocubes likely having their hard magnetization axis aligned along or close to the direction of the external magnetic field. Based on the analysis of FMR data, the latter nanocubes possess an anisotropic internal magnetic field of at least ∼1.0 T in magnitude