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Without improvements in valve technologies, propellant and commodity losses will likely make long-duration space missions (e.g., to Mars) infeasible. Cryogenic valve leakage is often a result of misalignment and the seat seal not being perpendicular relative to the poppet. Conventional valve designs attempt to control alignment through tight tolerances across several mechanical interfaces, bolted or welded joints, machined part surfaces, etc. However, because such tight tolerances are difficult to maintain, leakage remains an issue. Traditional poppets are not self-aligning, and thus require large forces to “crush” the poppet and seat together in order to overcome misalignment and create a tight seal. In contrast, NASA’s poppet valve self-aligns the poppet to the valve seat to minimize leakage. Once the poppet and seat are precisely self-aligned, careful seat crush is provided. Owing to this unique design, the invention substantially reduces the energy required to make a tight seal – reducing size, weight, and power requirements relative to traditional valves. Testing at MSFC showed that NASA’s poppet reduces leakage rates of traditional aerospace cryogenic valves (~1000 SCIM) by three orders of magnitude, resulting in leakage rates suitable for long-duration space missions (~1 SCIM). NASA’s self-aligning poppet was originally targeted for aerospace cryogenic valve systems, especially for long-duration manned space missions – making the invention an attractive solution for aerospace valve vendors. The invention may also find use in the petrochemical or other industries that require sealing to prevent critical or hazardous chemicals from leaking into the environment. Generally, the invention may be suitable for any application requiring low-leak and/or long duration storage of expensive or limited resource commodities (e.g., cryogenic gases, natural gas, nuclear engines, etc).

Ultrasonic Stir Welding is a solid state stir welding process, meaning that the weld work piece does not melt during the welding process. The process uses a stir rod to stir the plasticized abutting surfaces of two pieces of metallic alloy that forms the weld joint. Heating is done using a specially designed induction coil. The control system has the capability to pulse the high-power ultrasonic (HPU) energy of the stir rod on and off at different rates from 1-second pulses to 60-millisecond pulses. This pulsing capability allows the stir rod to act as a mechanical device (moving and stirring plasticized nugget material) when the HPU energy is off, and allowing the energized stir rod to transfer HPU energy into the weld nugget (to reduce forces, increase stir rod life, etc.) when the HPU energy is on. The process can be used to join high-melting-temperature alloys such as titanium, Inconel, and steel.

The NASA solid-state ultracapacitor technology is based on the novel materials design and processes used to make the IBLC-type ultracapacitor. The IBLC concept is known to provide outstanding capacitance behavior but has been difficult to reproduce. NASA has developed a careful process to produce dielectric ink materials to be used in printed electronic applications with reproducibility. An individual cell is created by building electrodes on each side of the dielectric layer, and complete modules can be constructed by stacking multiple cells. Closely related NASA innovations on dielectric and conductive ink (electrode) formulations are key to the ultracapacitor construct, and are included in the technology package. Target performance criteria of this technology include the following: - Use of standard materials and processing methods - Robust solid-state device with no liquid electrolytes - High-energy densitytarget energy densities of 60 J/cc at a minimum operating voltage of 50 V - High dielectric breakdown strength (>250 V) - Excellent pulse-power performance; rapid discharge and charge - Reliable performance under repeated cycling (>500,000 cycles) Additional development work is underway to build and test complete capacitor modules and to further improve material properties and performance.

FSC is a passive technology that can operate in different modes to control vibration: Harmonic absorber mode: The fluid can be leveraged to act like a classic harmonic absorber to control low-frequency vibrations. This mode leverages already existing system mass to decouple a structural resonance from a discrete frequency forcing function or to provide a highly damped dead zone for responses across a frequency range. Shell mode: The FSC device can couple itself into the shell mode and act as an additional spring in a series, making the entire system appear dynamically softer and reducing the frequency of the shell mode. This ability to control the mode without having to make changes to the primary structure enables the primary structure to retain its load-carrying capability. Tuned mass damper mode: A small modification to a geometric feature allows the device to act like an optimized, classic tuned mass damper.

NASA's technique simplifies the seat installation process by requiring less installation equipment, eliminating the need for unnecessary apparatus such as fasteners and retainers. Multiple seals can be installed simultaneously, saving both time and money. NASA has tested the long-term performance of a solenoid actuated valve with a seat that was fitted using the new installation technique. The valve was fabricated and tested to determine high-cycle and internal leakage performance for an inductive pulsed plasma thruster (IPPT) application for in-space propulsion. The valve demonstrated the capability to throttle the gas flow rate while maintaining low leakage rates of less than 10-3 standard cubic centimeters per second (sccss) of helium (He) at the beginning of the valves lifetime. The IPPT solenoid actuated valve test successfully reached 1 million cycles with desirable leakage performance, which is beyond traditional solenoid valve applications requirements. Future design iterations can further enhance the valve's life span and performance. The seat seal installation method is most applicable to small valve instruments that have a small orifice of 0.5 inches or less.

Signal propagation through traditional silica-based optical fibers is limited to visible and near-infrared wavelengths. In contrast, non-oxide glasses such as chalcogenide and heavy metal fluoride glasses (e.g. ZBLAN) are highly transparent from near ultraviolet to mid-infrared wavelengths and have lower theoretical signal attenuation rates, resulting in the ability to transmit wideband signals over significant distances with minimal losses. Theoretical estimates for signal attenuation losses for non-oxide fibers yield values of approximately 0.001 dB/km for a transmitted wavelength of 2.55 micrometers. The theoretical loss for the state of the art fused silica is two orders of magnitude higher at 0.12 dB/km at 1.55 micrometers. However, there are a number of crystals and defects which can serve as scattering centers in non-oxide glass preforms and fibers. These include ZrF4, LaF3, AlF3, ZrO2, platinum particles from crucible reactions, carbon from organic impurities and crucible reactions and bubbles due to contraction, cavitation and gas precipitation. Using this patented preform formation technology, the fibers heated in the 0.1-T magnetic field did not show evidence of crystallization under optical microscopy or Scanning Electron Microscopy (SEM). As seen the figures below, an axial magnetic field has the effect of suppressing crystallization in ZBLAN. The experiments indicate that the combination of a vertical magnetic field and a rapid cool down from the crystallite melting temperature will ensure that no crystals are present in the preform after processing.

Plant uptake of TCE from contaminated groundwater is a well-known phenomenon. During the photosynthesis process, plants metabolize the TCE into a byproduct called trichloroacetic acid (TCAA). TCAA has been found to be a good indicator (or surrogate) molecule for the presence of TCE because it is more stable than TCE in plants. The hyperspectral estimator is being designed to detect TCAA. The method uses a white light that is directed at the surface of a plant's leaf. The interaction between the light and the leaf produces spectral signatures that are captured using a detector. A processor that will be coupled to the detector will compare these signatures to a library/database of signatures known to be indicators of the presence of TCAA (and thus TCE). The figure below on the left shows hyperspectral images captured using the method for leaves dosed with TCE over various time periods. These images are examples of response signatures that will eventually be built into the device's reference library/database. Proof-of-concept testing has shown that the hyperspectral estimator is capable of estimating the presence/absence of TCE in plant leaves with an accuracy of 80%. Efforts are now underway to further improve the accuracy of this method and to prototype the technology. The figure below on the right shows a diagram of the planned device.

EBAM technology is capable of making full-density, functional metallic components for numerous engineering applications; the technology is particularly advantageous in the aerospace, automotive, and biomedical industries where high-value, low-volume, custom-design productions are required. A key challenge in EBAM is overcoming deformation of overhangs that are the result of severe thermal gradients generated by the poor thermal conductivity of metallic powders used in the fabrication process. Conventional support structures (Figure 1a) address the deformation challenge; however, they are bonded to the component and need to be removed in post- processing using a mechanical tool. This process is laborious, time consuming, and degrades the surface quality of the product. The invented support design (Figure 1b) fabricates a support underneath an overhang by building the support up from the build plate and placing a support surface underneath an overhang with a certain gap (no contact with overhang). The technology deposits one or more layers of un-melted metallic powder in an elongate gap between an upper horizontal surface of the support structure and a lower surface of the overhang geometry. The support structure acts as a heat sink to enhance heat transfer and reduce the temperature and thermal gradients. Because the support structure is not connected to the part, the support structure can be removed freely without any post-processing step. Future work will compare experimental data with simulation results in order to validate process models as well as to study process parameter effects on the thermal characteristics of the EBAM process.

Traditional methods of determining film stress use ex-situ deflectometry techniques and require significant and costly modifications to the vacuum chamber to allow optical access to the substrate. These techniques determine film stress by measuring the change in substrate curvature resulting from stress. NASA's method infers the stress-induced substrate curvature by measuring the out-of-plane displacement of a single point on the substrate using a fiber optic displacement sensor (Figure 1). The probe gains optical access to the substrate through a normal fiber optic feed-through common in vacuum systems. In turn, this simplification leads to a significant reduction in cost, complexity, and system requirements. It also eliminates interference effects. With a measurement sensitivity of 0.05 N/m, the method is comparable in sensitivity with MOSS and could potentially rival the sensitivity of the microcantilever technique. NASA's method can be used to measure the stress during film growth for heated substrates, as well as the evolution of stress during thermal annealing processes. The technique can be used in a variety of thin film applications, with no limitation on substrate size or reflective characteristics of deposited films. The methodology has been proven with magnetron sputtering of chromium films, where it was used to adjust process gas pressure to achieve zero stress.