National Aeronautics and Space Administration Marshall Space Flight Center Materials and Processes Laboratory Materials and Manufacturing Solutions for Space Science, Exploration, and Life on Earth Marshall’s Materials and Processes Laboratory has been a core capability for NASA for over Technology development for materials and manufacturing is unique fifty years. MSFC has a proven heritage and recognized expertise in in its potential reach. For example, it can build capabilities to solve materials and manufacturing that are essential to enable and sustain production challenges in exploration systems that dramatically impact space exploration. Marshall provides a “systems-wise” capability the rate of technology transition and for applied research, flight hardware development, and sustaining directly improve NASA’s ability to engineering. Our history of leadership and achievements in materi- acquire new systems. Our materials als, manufacturing, and flight experiments includes Apollo, Skylab, diagnostic and evaluation capabili- Mir, Spacelab, Shuttle (Space Shuttle Main Engine, External Tank, ties provide rapid-response problem Reusable Solid Rocket Motor, and Solid Rocket Booster), Hubble, assessment, and mitigation throughout Chandra, and the International Space Station. MSFC’s National all phases of programs. For example, Center for Advanced Manufacturing, NCAM, facilitates major M&P our unique technology development advanced manufacturing partnership activities with academia, industry capability for the Virtual Enterprise will and other local, state and federal government agencies. develop, demonstrate, and transition new or improved methods and models The Materials and Processes Laboratory has principal competencies for integrating design, manufacturing in metals, composites, ceramics, additive manufacturing, materials and supply chain management. and process modeling and simulation, space environmental effects, non-destructive evaluation, and fracture and failure analysis provide Materials and manufacturing R&D are critically important to the products ranging from materials research in space to fully integrated nation to enhance U.S. global aerospace and manufacturing com- solutions for large complex petitiveness. Through partnerships and innovative developments such systems challenges. Marshall’s as maturation of friction stir welding, the Materials and Process’s materials research, development capabilities contribute to the viability of a domestic aerospace struc- and manufacturing capabilities tures manufacturing industrial base. Subject matter experts in this area assure that NASA and National provide Marshall a direct link to critical sub-tier suppliers and issues missions have access to cutting- in the aerospace industrial base. Fundamental materials research con- edge, cost-effective engineering tributes to the domestic knowledge base and fosters innovation in the design and production options commercial sector. Marshall’s materials and manufacturing capabilities that are frugal in using design also frequently “cross-fertilize” into national priorities such as defense, margins and are verified as safe science, homeland security, energy, and civil industry and infra- and reliable. These are all critical structure. In some cases, these represent niche (but critical) national factors in both future mission research or development capabilities that would not be cost effective success and affordability. to sustain independently in private industry. Capabilities Materials Testing Nonmetallic Materials and Manufacturing > Real-life and theoretical understanding of materi- > Provides advanced materials and processes research and als at the molecular, surface, and bulk level using development in areas that include environmentally com- chemical, compatibility, dimensional, wear, and pliant cryogenic insulation and primers; ablative thermal strength testing methods. protection systems; adhesives/bonding; composite nozzle POC: Gail Gordon POC: Frank Ledbetter [email protected] > Materials are evaluated using regulatory methods, [email protected] materials; and advanced ceramic matrix composites. 256–544–2726 256–544–2673 industrial standards, and custom protocols in > Provides advanced manufacturing development in areas that ambient and extreme environments. include robotics; composites; structured light scanning; pho- togrammetry; process modeling; kinematic simulation and Damage Tolerance Assessment digital manufacturing/planning; environmentally friendly > Evaluates the ability of a structure to perform refurbishment and precision cleaning/surface preparation; reliably throughout its service life in the presence and additive manufacturing/rapid prototyping. of a defect, crack, or other form of damage. POC: Dr. Wayne Gamwell > Non-destructive Evaluation of hardware to Environmental Effects [email protected] assess the integrity of the part and to reliably > Provides valuable information on materials and processes 256–544–2592 detect characteristic flaws. related to contamination control and the space environment. POC: Dewitt Burns [email protected] > Provides unique test facilities to simulate space environ- Metallic Materials Engineering 256–544–2529 ments for evaluating materials and components to verify > Provides world-class support for materials spacecraft system designs. design, development, characterization, and constituent hardware failure analysis. Materials Selection and Control & Small Projects > Developing manufacturing techniques for > Materials and Processes Technical Information System POC: Timothy Vaughn [email protected] small- to large-scale metallic components using DRIESTPIORSEE/ SMEALTEECRTIIAOLN (MAPTIS) is the one location for acquiring, assessing, 256–544–2607 MATERIAL’S traditional and advanced processes such as USE LIFE CYCLE DEVELOPMENT archiving, and disseminating materials information to spin forming, forging, rolling, casting, powder QUALIFICATION save resources throughout a product life cycle. metallurgy, friction stir welding and vacuum POC: Dennis Griffin > Monitors environmental regulatory requirements to assist [email protected] plasma spray. 256–544–2493 customers in planning for material supply changes, toxic substance management, and end of life cycle disposal. Key Benefits > Full life-cycle design, development, testing, and > A 50 year history of materials, manufacturing and hardware integration of metallic and non-metallic structures integration expertise in complex aerospace systems. into complex systems. > We embody the state of the art in engineering practices > World-class facilities for materials science, materials and discipline, teaming with other government agencies, testing, manufacturing processes development, and industry and academia, partners to deliver the most value life cycle management. for the investment. Materials and Processes Laboratory Partnership Lead • Dr. Terri Tramel • [email protected] • 256–544–6048 Mr. Wendell Colberg, Lab Manager, 256–544–2725 Dr. Surendra Singhal, Deputy Lab Manager, 256–544–4236 National Aeronautics and Space Administration George C. Marshall Space Flight Center Huntsville, AL 35812 www.nasa.gov/marshall www.nasa.gov NP-2012-08-90-MSFC 8–477491c