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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 181 records · Page 10
All sourcesNASA NTRSDOE OSTI
NASA NTRS2010

Lessons Learned in Launching Ares I-X

The Ares I-X flight test, scheduled for 2009, is the first opportunity for the Constellation Program and Ares Projects to obtain important data on the in-flight loads, first stage recovery, and ground-handling characteristics of the Ares I crew launch vehicle. The flight test vehicle will incorporate a mix of flight and mockup hardware, reflecting an acceptable representation of the mass and outer mold line characteristics of the operational Ares I vehicle. It will be powered by a four-segment solid rocket motor from the Space Shuttle inventory and will include a fifth, inert spacer segment and new forward structures to make it the same shape as the Ares I first stage. The vehicle also includes mass simulators for the upper stage, Orion crew module, and launch abort system to match the outer mold line of Ares I; an active roll control system; and avionics derived from Shuttle and Atlas hardware. This suborbital mission will take the flight test vehicle from stacking in the Vehicle Assembly Building (VAB) at Kennedy Space Center (KSC) through liftoff, maximum dynamic pressure, first stage separation, and recovery. Ares I-X presented NASA with unique project management challenges. This presentation will address those unique challenges, including managing a virtual nationwide team under a constrained timeline; designing and building the launch vehicle and ground systems; working concurrently with Space Shuttle activities; and integrating technical and management functions. It also will identify key data collected and lessons learned from the flight that will be applied to future exploration missions.

Davis, Stephan R.↗
NASA NTRS2015

Polyimides Derived from Novel Asymmetric Benzophenone Dianhydrides

This invention relates to the composition and processes for preparing thermoset polyimides derived from an asymmetric dianhydride, namely 2,3,3',4'-benzophenone dianhydride (a-BTDA) with at least one diamine, and a monofunctional terminal endcaps. The monofunctional terminating groups include 4-phenylethynylphthalic anhydride ester-acid derivatives, phenylethyl trimellitic anhydride (PETA) and its ester derivatives as well as 3-phenylethynylaniline. The process of polyimide composite comprises impregnating monomer reactants of dianhydride or its ester-acid derivatives, diamine and with monofunctional reactive endcaps into glass, carbon, quartz or synthetic fibers and fabrics, and then stack up into laminates and subsequently heated to between 150-375.degree. C. either at atmosphere or under pressure to promote the curing and crosslinking of the reactive endcaps to form a network of thermoset polyimides.

Chuang, Chun-Hua↗
NASA NTRS1991

Seal testing of large diameter rocket motors

This investigative program examines leakage testing of elastomeric O-ring seals for a solid rocket casing and provides direction towards an improved nondestructive postassembly test. It also details test equipment for the Space Shuttle systems solid rocket boosters (SRB). The results are useful to designers of hardware for pressure containment vessels which use O-ring seals. Using several subscale seal and groove configuration test fixtures equipped with either two or three O-ring seals in series, seal integrity is investigated with both a pressure decay and flowmeter methods. Both types of test equipment adequately detect the practical range of expected seal leak rates of 1 to 0.0001 sccs. The flowmeter leak test equipment appears to reduce testing time substantially. Limited seal leakage testing is performed on full-sized rocket motor segment seals, a pre-Challenger short stack, providing comparison of bore seals to test specimen bore and face seals. The conclusions are that seal reliability, verified via a performance pressure test, can be affected by temperature, quantity of grease, test pressure, and seal pressure load direction. Potential seal failure scenarios including contamination, seal damage, and sealing surface damage are discussed. Recommendations are made for an improved test procedure.

Moore, N. B.↗
DOE OSTI2024

Signatures of ambient pressure superconductivity in thin film La 3 Ni 2 O 7

Recently, the bilayer nickelate La 3 Ni 2 O 7 has been discovered as a new superconductor with transition temperature T c near 80 K under high pressure. Despite extensive theoretical and experimental work to understand the nature of its superconductivity, the requirement of extreme pressure restricts the use of many experimental probes and limits its application potential. Here, in this work, we present signatures of superconductivity in La 3 Ni 2 O 7 thin films at ambient pressure, facilitated by the application of epitaxial compressive strain. The onset T c varies approximately from 26 K to 42 K, with higher T c values correlating with smaller in-plane lattice constants. We observed the co-existence of other Ruddlesden-Popper phases within the films and dependence of transport behavior with ozone annealing, suggesting that the observed low zero resistance T c of around 2 K can be attributed to stacking defects, grain boundaries, and oxygen stoichiometry. This finding initiates numerous opportunities to stabilize and study superconductivity in bilayer nickelates at ambient pressure, and to facilitate the broad understanding of the ever-growing number of high temperature and unconventional superconductors in the transition metal oxides.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
NASA NTRS2003

Regenerative Fuel Cell Test Rig at Glenn Research Center

The regenerative fuel cell development effort at Glenn Research Center (GRC) involves the integration of a dedicated fuel cell and electrolyzer into an energy storage system test rig. The test rig consists of a fuel cell stack, an electrolysis stack, cooling pumps, a water transfer pump, gas recirculation pumps, phase separators, storage tanks for oxygen (O2) and hydrogen (H2), heat exchangers, isolation valves, pressure regulators, interconnecting tubing, nitrogen purge provisions, and instrumentation for control and monitoring purposes. The regenerative fuel cell (RFC) thus formed is a completely closed system which is capable of autonomous cyclic operation. The test rig provides direct current (DC) load and DC power supply to simulate power consumption and solar power input. In addition, chillers are used as the heat sink to dissipate the waste heat from the electrochemical stack operation. Various vents and nitrogen (N2) sources are included in case inert purging is necessary to safe the RFC test rig.

Chang, Bei-Jiann↗
NASA NTRS2005

On the Interaction and Coalescence if Spherical Blast Waves

The scaling and similarity laws concerning the propagation of isolated spherical blast waves are briefly reviewed. Both point source explosions and high pressure gas explosions are considered. Test data on blast overpressure from the interaction and coalescence of spherical blast waves emanating from explosives in the form of shaped charges of different strength placed in the vicinity of a solid propellant stack are presented. These data are discussed with regard to the scaling laws concerning the decay of blast overpressure. The results point out the possibility of detecting source explosions from far-field pressure measurements.

Kandula, Max↗
NASA NTRS1992

The NASA Langley laminar-flow-control experiment on a swept, supercritical airfoil: Evaluation of initial perforated configuration

The initial evaluation of a large-chord, swept, supercritical airfoil incorporating an active laminar-flow-control (LFC) suction system with a perforated upper surface is documented in a chronological manner, and the deficiencies in the suction capability of the perforated panels as designed are described. The experiment was conducted in the Langley 8-Foot Transonic Pressure Tunnel. Also included is an evaluation of the influence of the proximity of the tunnel liner to the upper surface of the airfoil pressure distribution.

Harris, Charles D.↗
NASA NTRS2011

On Orbit ISS Oxygen Generation System Operation Status

The International Space Station (ISS) United States Orbital Segment (USOS) Oxygen Generation System (OGS) has accumulated almost a year of operation at varied oxygen production rates within the US Laboratory Module (LAB) since it was first activated in July 2007. It was operated intermittently through 2009 and 2010, due to filter clogging and acid accumulation in the recirculation loop. Since the installation of a deionizing bed in the recirculation loop in May of 2011 the OGA has been operated continuously. Filters in the recirculation loop have clogged and have been replaced. Hydrogen sensors have drifted apart, and a power failure may have condensed water on a hydrogen sensor. A pump delta pressure sensor failed, and a replacement new spare pump failed to start. Finally, the voltage across the cell stack increased out of tolerance due to cation contamination, and the cell stack was replaced. This paper will discuss the operating experience and characteristics of the OGS, as well as operational issues and their resolution.

Diderich, Greg S.↗
NASA NTRS1995

Effects of Yarn Crimping on Braided Composite Design Allowables

Braided composite materials are currently being evaluated for wing skin stiffeners on commercial aircraft. These carbon-fiber/epoxy materials allow for low-cost manufacturing while maintaining high strength-to-weight and stiffness-to-weight ratios. The proposed braid architecture consists of axial carbon fiber yarns and braider carbon fiber yarns making 60 deg to 70 deg angles with respect to the axial yarns. These 2-D triaxial braids are produced as long, continuous tubes, which are flattened, cut, and stacked to produce the desired part thickness and shape. When infiltrated with epoxy resin and cured under a compaction pressure, the fiber yarns become crimped, allowing for higher fiber packing. Although high fiber packing is desirable, yarn crimping (especially in the axial fiberyarns) is undesirable. Significant axial yarn crimp angles (greater than 10 deg) have been measured in braided composites. Comparable levels of crimping have been found to produce significant compressive strength reductions in laminated composites consisting of planar fiber sheets. Thus, axial yarn crimping is suspected of producing significant reductions in compressive strength allowables for braided composites. The objective of this research is to quantify the reduction in compressive strength as a function of axial yarn crimp severity. Since crimp severity can be reduced by lowering the compaction pressure during curing, the resulting compressive strengths may be used to determine optimum processing conditions. A 'cure-on-the-loom' manufacturing process was developed to produce braided composites with controlled levels of crimping. This method allowed for controlled levels of tension to be placed on the axial yarns and maintained during the curing process. With increasing tension, the crimp severity in the axial yarns was reduced. Thus, varying crimp severities were produced ranging from conventional levels (greater than 10 deg) to virtually straight axial yarns. Test results indicate that a 30% increase in compressive strength is obtainable by eliminating axial yarn crimping. Further compression testing is underway to quantify the relationship between crimp severity and compressive strength. Additional testing is planned to investigate the effect of crimping on the open-hole compressive strength, often considered a more significant design allowable.

Adams, Dan↗
DOE OSTI2024

Compositional effect on pressure-induced polymorphism in high-entropy alloys

Recently, pressure-induced polymorphic phase transitions were discovered in several fragmented high-entropy alloys (HEAs), offering a valuable opportunity to deepen our understanding of these materials. However, the chemical and physical factors that govern these transitions are still unclear. Here, in this work, we combined in situ high-pressure synchrotron X-ray diffraction, X-ray emission spectroscopy (XES), and high-resolution transmission electron microscopy (HRTEM) to systematically study the evolution of the atomic and electronic structures in the Cantor alloy and its face-centered-cubic ( fcc ) subset alloys (CoCrFeMnNi, CoCrFeNi, CoCrMnNi, CoFeMnNi, CoCrNi, CoFeNi, CoMnNi, CrFeNi, and FeMnNi). Surprisingly, diverse behavior was observed among these closely related alloys during compression and decompression, which includes irreversible, reversible fcc to hexagonal close-packed (hcp) phase transitions, or even no detectable phase transitions up to ∼40 GPa. HRTEM measurements confirmed that the fcc and hcp phases abided by the classic Shoji-Nishiyama orientation relationship during the transitions. XES data indicated that high-pressure suppresses the local magnetic moments in all the studied alloys, suggesting that magnetic states do not significantly influence the polymorphic transitions. By comparing the effects of the atomic size difference, entropy, valence electron concentration, and stacking fault energy across all the compositions studied, only the stacking fault energy shows a strong correlation with the phase transitions, indicating it plays a key role in inducing polymorphism in HEAs.

36 MATERIALS SCIENCE↗
NASA NTRS1981

Parametric study of thermal storage containing rocks or fluid filled cans for solar heating and cooling, phase 2

The test data and an analysis of the heat transfer characteristics of a solar thermal energy storage bed utilizing water filled cans and standard bricks as energy storage medium are presented. This experimental investigation was initiated to find a usable heat intensive solar thermal storage device other than rock storage and water tank. Four different sizes of soup cans were stacked in a chamber in three different arrangements-vertical, horizontal, and random. Air is used as transfer medium for charging and discharge modes at three different mass flow rates and inlet air temperature respectively. These results are analyzed and compared, which show that a vertical stacking and medium size cans with Length/Diameter (L/D) ratio close to one have better average characteristics of heat transfer and pressure drop.

Saha, H.↗
NASA NTRS2007

The Human as a System - Monitoring Spacecraft Net Habitable Volume throughout the Design Lifecycle

Spacecraft design has historically allocated specific volume and mass "not to exceed" requirements upon individual systems and their accompanying hardware (e.g., life support, avionics) early in their conceptual design in an effort to align the spacecraft with propulsion capabilities. If the spacecraft is too heavy or too wide for the launch stack - it does not get off the ground. This approach has predictably ended with the crew being allocated whatever open, pressurized volume remains. With the recent inauguration of a new human-rated spacecraft - NASA human factors personnel have found themselves in the unique position to redefine the human as a system from the very foundation of design. They seek to develop and monitor a "not to fall below" requirement for crew net habitable volume (NHV) - balanced against the "not to exceed" system volume requirements, with the spacecraft fitting the crew versus the crew having to fit inside the spacecraft.

Szabo, Richard↗
NASA NTRS2010

Crystal Lattice Controlled SiGe Thermoelectric Materials with High Figure of Merit

Direct energy conversion between thermal and electrical energy, based on thermoelectric (TE) effect, has the potential to recover waste heat and convert it to provide clean electric power. The energy conversion efficiency is related to the thermoelectric figure of merit ZT expressed as ZT=S(exp 2)(sigma)T/Kappa, T is temperature, S is the Seebeck coefficient, sigma is conductance and Kappa is thermal conductivity. For a lower thermal conductivity Kappa and high power factor (S(exp 2)(sigma)), our current strategy is the development of rhombohedrally strained single crystalline SiGe materials that are highly [111]-oriented twinned. The development of a SiGe "twin lattice structure (TLS)" plays a key role in phonon scattering. The TLS increases the electrical conductivity and decreases thermal conductivity due to phonon scattering at stacking faults generated from the 60 X rotated primary twin structure. To develop high performance materials, the substrate temperature, chamber working pressure, and DC sputtering power are controlled for the aligned growth production of SiGe layer and TLS on a c-plane sapphire. Additionally, a new elevated temperature thermoelectric characterization system, that measures the thermal diffusivity and Seebeck effect nondestructively, was developed. The material properties were characterized at various temperatures and optimized process conditions were experimentally determined. The present paper encompasses the technical discussions toward the development of thermoelectric materials and the measurement techniques.

Kim, Hyun-Jung↗
NASA NTRS2023

Automated Fiber Placement Through Thickness Defect Stacking Optimization

In its 2022 commercial market outlook, Boeing forecasted an 80% increase in the global fleet through 2041 compared to 2019 pre-pandemic levels. This sharp rise in demand will drive pressure onto airframe manufacturers to ramp up production and find more efficient ways to design and manufacture airplanes. Complicating this challenge is the industry’s recent transformation from traditional metal-based airframes towards hybrid composite-metal aircraft. While composites have been used in aviation for decades, aircraft manufacturers are still struggling to design and manufacture quality parts at a high rate. Automated Fiber Placement (AFP) is one of the main manufacturing techniques used to produce large-scale composite parts. After a design has been created, a manufacturing strategy has to be developed based on the working material, part geometry, and machine capabilities. This process planning stage is essential to the AFP workflow and currently requires a high level of manual input from an experienced process planner. In an effort to automate and optimize this stage, the Computer Aided Process Planning (CAPP) module was developed. CAPP assists process planners in identifying optimal starting point location and layup strategy for each ply of a laminate. This Ply-Level Optimization (PLO) phase operates on the quantification of ply quality through predictable geometry-based defects such as gaps, overlaps, angle deviation, and steering. As you move from PLO to Laminate-Level Optimization (LLO) the design space grows exponentially, emphasizing the need for automated optimization. The work presented in this thesis expands CAPP’s functionality by comparing the planned fiber paths through the thickness of the laminate to mitigate stacked area defects and achieve an optimal laminate-level manufacturing strategy. Within CAPP, predicted gap and overlap defects are imported from Vericut Composites Programming (VCP) and then discretized to streamline the through-thickness comparison. Two objective functions are used to score different combinations of ply layup strategies based on defect stacking both globally and locally. Four combinatorial optimization algorithms were coupled with these objective functions to investigate the laminate-level manufacturing strategy design space and converge on the optimal plan. These algorithms were evaluated based on accuracy and efficiency through virtual testing on a complex tool surface. A separate LLO approach was developed to achieve near-optimal laminates in significantly less time. The end result is a software package which greatly reduces the required input from process planners, shortening the design-build cycle time and improving part quality.

AFP↗
NASA NTRS1990

A passive bearing system using superconducting magnets

A passive radial bearing concept is presented using superconducting magnets which can generate a bearing pressure as high as 360 N/sq cm, comparable to a conventional active bearing system. The system consists of a number of solenoidal superconducting coils of alternating current direction. These coils are stacked axially over the bearing length and connected in series. The currents in stator and rotor coils are in the opposite directions, generating repulsive forces. This system, in comparison with an active system, has the advantage of much smaller power dissipation in the coils since the coil currents are mostly dc currents. The cooling for the superconducting coils is therefore simpler, and the coils are more stable. An optimization study seeking the maximum bearing pressure was conducted. Details of the design, pressure calculations, and results are presented.

Huang, X.↗
DOE OSTI2025

Public Reference Data for Megawatt-Scale Hydrogen Electrolysis - Simulated Wave

The U.S. Department of Energy and the National Laboratory of the Rockies (NLR) demonstrate hydrogen electrolysis, hydrogen compression and storage, and variable hydrogen fuel cell power production using megawatt-scale equipment at NLR’s Flatirons Campus as part of the Advanced Research on Integrated Energy Systems (ARIES) initiative. This dataset represents part of that effort and is intended for academic, national laboratory, industrial, and other stakeholders to plan, design, and validate models of megawatt-scale hydrogen technologies and diverse energy infrastructure nationwide. These data provide a baseline for how existing hydrogen electrolysis technologies perform when coupled with various energy technologies. Future datasets will demonstrate how existing hydrogen fuel cell technologies can provide controllable, dispatchable, and variable power output for artificial intelligence (AI) data centers and other variable loads. This dataset entry describes hydrogen production using a single, simulated wave energy conversion device. The electrolyzer is a 1.25-MW proton exchange membrane type MC250 system manufactured by Nel Hydrogen. While the unit supports up to 2.5 MW of electrolysis, NLR only has a single 1.25-MW electrolysis stack. For the wave energy, NLR used a wave energy converter model from PacWave. These devices can be equipped with accumulators and pressure relief values to smooth the power output by storing and releasing hydraulic energy. Using a peak power output of 10 MW, the model created two 25-minute profiles: one with and one without the accumulators and pressure relief valves. To down select the profile data from the native resolution of 20 Hz to 1 Hz, NLR took the mean of every 20 data points. NLR experimented with two simulated wave energy power plants: one that peaks at 10 MW, and one that peaks at 5 MW. These profiles were scaled for the physical 1.25 MW electrolyzer by multiplying the original profiles by one eighth and one quarter, respectively. The first profile matches the capacity rating of eight of the 1.25 MW electrolyzers, while the second matches four electrolyzers. Finally, NLR experimented with two settings for the electrolyzer power supply minimum and maximum current ramp rates (gain and slew): 200 and 400 amperes per second. The simulated profiles were translated from power (kilowatts) to current (amperes) using a curve fit with calibration data and sent to the electrolyzer power supply at 1-Hz frequency. These datasets report relevant hydrogen balance-of-plant and system data, all captured at 1 Hz, including hydrogen mass production measured with an Emerson Coriolis flow meter. Each .zip file represents a single wave electrolysis experiment and is formatted as follows: {technology}-{accumulator?}_{number of 1.25 MW electrolyzers connected}-{electrolyzer ramp rate in amperes/second} For instance, “wavePacWave-Noacc_4-400.zip” represents the 25 minute-long experiment using the PacWave’s wave energy converter model, equipped with no accumulator, connected to four 1.25-MW electrolyzers with their power supplies set to a maximum current ramp rate (gain and slew) of 400 A/s. Each .zip folder contains the following files: A .csv file containing raw data. An .xlsx file explaining all the fields in the raw data. A .png plot showing the time series of hydrogen production in kilograms per hour, electrolysis power consumption, and input wave power. An experiment, labeled “characterization_200.zip”, demonstrates the MC250 electrolyzer steady-state response with 30 minute load steps for a total duration of 5 hours. Finally, a .csv file is provided with all wave profiles combined into one dataset labeled "combined_wave_experiments.csv". NLR also built an AI/machine-learning predictive model based on these datasets. The model ingests the electrolyzer current command in amperes, as well as various pressures and temperatures across the system, and predicts hydrogen output in kilograms per hour. The complete model can be found at https://huggingface.co/NatLabRockies/ptmelt-hydrogen-electrolysis.

08 HYDROGEN↗