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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 199 records · Page 11

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NASA NTRS2006

Modular, Intelligent Power Systems for Space Exploration

NASA's new Space Exploration Initiative demands that vehicles, habitats, and rovers achieve unprecedented levels of reliability, safety, effectiveness, and affordability. Modular and intelligent electrical power systems are critical to achieving those goals. Modular electrical power systems naturally increase reliability and safety through built-in fault tolerance. These modular systems also enable standardization across a multitude of systems, thereby greatly increasing affordability of the programs. Various technologies being developed to support this new paradigm for space power systems will be presented. Examples include the use of digital control in power electronics to enable better performance and advanced modularity functions such as distributed, master-less control and series input power conversion. Also, digital control and robust communication enables new levels of power system control, stability, fault detection, and health management. Summary results from recent development efforts are presented along with expected future technology development needs required to support NASA's ambitious space exploration goals.

Button, Robert↗

NASA NTRS2017

Exploring Concepts of Operations for On-Demand Passenger Air Transportation

In recent years, a surge of interest in "flying cars" for city commutes has led to rapid development of new technologies to help make them and similar on-demand mobility platforms a reality. To this end, this paper provides analyses of the stakeholders involved, their proposed operational concepts, and the hazards and regulations that must be addressed. Three system architectures emerged from the analyses, ranging from conventional air taxi to revolutionary fully autonomous aircraft operations, each with vehicle safety functions allocated differently between humans and machines. Advancements for enabling technologies such as distributed electric propulsion and artificial intelligence have had major investments and initial experimental success, but may be some years away from being deployed for on-demand passenger air transportation at scale.

Nneji, Victoria Chibuogu↗

NASA NTRS2004

Aircraft Fuel Cell Power Systems

In recent years, fuel cells have been explored for use in aircraft. While the weight and size of fuel cells allows only the smallest of aircraft to use fuel cells for their primary engines, fuel cells have showed promise for use as auxiliary power units (APUs), which power aircraft accessories and serve as an electrical backup in case of an engine failure. Fuel cell MUS are both more efficient and emit fewer pollutants. However, sea-level fuel cells need modifications to be properly used in aircraft applications. At high altitudes, the ambient air has a much lower pressure than at sea level, which makes it much more difficult to get air into the fuel cell to react and produce electricity. Compressors can be used to pressurize the air, but this leads to added weight, volume, and power usage, all of which are undesirable things. Another problem is that fuel cells require hydrogen to create electricity, and ever since the Hindenburg burst into flames, aircraft carrying large quantities of hydrogen have not been in high demand. However, jet fuel is a hydrocarbon, so it is possible to reform it into hydrogen. Since jet fuel is already used to power conventional APUs, it is very convenient to use this to generate the hydrogen for fuel-cell-based APUs. Fuel cells also tend to get large and heavy when used for applications that require a large amount of power. Reducing the size and weight becomes especially beneficial when it comes to fuel cells for aircraft. My goal this summer is to work on several aspects of Aircraft Fuel Cell Power System project. My first goal is to perform checks on a newly built injector rig designed to test different catalysts to determine the best setup for reforming Jet-A fuel into hydrogen. These checks include testing various thermocouples, transmitters, and transducers, as well making sure that the rig was actually built to the design specifications. These checks will help to ensure that the rig will operate properly and give correct results when it is finally ready for testing. Another of my goals is to test new membranes for use in proton-exchange membrane fuel cells, in the hope that these membranes can increase the electricity that is produced by he1 cells. Producing more electricity means that fewer fuel cells are needed, thus reducing the weight and volume of an APU based on fuel cells, making such an APU much more viable.

Needham, Robert↗

NASA NTRS2019

Design of Experiment for the Measurement of Aerosol Droplet Size Distribution of Temperature-Controlled Thermally Atomized Printed Electronic Inks

In-Space Manufacturing (ISM) centers around NASA’s growing need and ability to produce space technologies on demand in space. As the future of long term presence in space and deep space exploration approach, fundamental questions of our dependence on earth resupply to Low Earth Orbit (LEO) remain unanswered. ISM is leading various effort to evaluate the feasibility of producing essential spares and redundant parts on demand to enable a sustainable space-based supply chain model for part resupply. Among the parts and systems being considered, Avionics form the neural network of modern day aircraft and space vehicles providing a wealth of information ranging from Guidance, Navigation, and Control (GN&C) systems to on board Environmental Control and Life Support (ECLS) systems. Recent advances in the use of Aerosol Jet Technology to print Avionics components ranging from electrical traces on a circuit board to complex transistors and sensors raise the possibility of using such technology to reproduce or recreate electronic parts on demand with the help of custom electronics 3D printers. The challenge herein lies within the ability of such printers to generate and deposit an aerosol of electronic material utilizing processes independent of or enhanced by gravity to ensure controllably identical or improved behavior of the aerosol in an International Space Station (ISS) laboratory and on the ground. The behavior as well as the hazards and properties associated with such aerosols in a microgravity environment must be understood well in order to merit a feasible approach to utilizing them for manufacturing in space. In this report, we outline the experimental setup of a modified conventional vaping device to be used as the ideal gravity independent thermal atomization mechanism to generate aerosol. Our objective is to identify the ideal mass, density, and volume of our aerosolized droplets of ink to conclude that there exist a threshold of aerosolized ink droplet sizes that are indeed independent of the effects of gravity and remain stable after atomization. We use a Malvern Spraytec® Spray Particle Size Analyzer to perform real-time laser diffraction measurement of our ink droplets during atomization. The droplet size between conductive ink, dielectric ink and vegetable glycerin have been measured and contrasted. Furthermore, the mechanism of thermal atomization versus traditional pneumatic and ultrasonic atomization for operation in microgravity have been explored.

Wu, Chih-Hao↗

NASA NTRSDate not supplied

Orion Power Transfer: Impacts of a Battery-on-Bus Power System Architecture

The Orion Multi-Purpose Crew Vehicle (MPCV) has the capability to transfer power to a co-manifested payload (CPL) during transit from low-Earth orbit to the lunar vicinity. This paper discusses a time-phased parametric power analysis to determine the Orion power transfer capability limit. Charge and discharge curves were generated for various power transfer conditions and measured against various minimum system voltage limits. The Orion electrical power system (EPS) utilizes an unregulated bus architecture, which has important implications when the system is operating under very high load demand conditions, such as during power transfer. This analysis highlights three important effects of this architecture. First, increasing load demand decreases the maximum state of charge (SOC) the batteries can reach when charging. Second, increasing load demand also decreases the allowable battery depth of discharge. These two together can significantly reduce the effective useable capacity of the batteries. Finally, low battery voltage decreases the power generation of the solar arrays. This can lead to significantly longer recharge times or even push the system out of energy balance. These effects have important implications for mission design and vehicle operations and must be accounted for when conducting sizing and design of an unregulated spacecraft EPS.

Electrical Power System↗

NASA NTRS2004

NASA GRC High Power Electromagnetic Thruster Program

High-power electromagnetic thrusters have been proposed as primary in-space propulsion options for several bold new interplanetary and deep-space missions. As the lead center for electric propulsion, the NASA Glenn Research Center designs, develops, and tests high-power electromagnetic technologies to meet these demanding mission requirements. Two high-power thruster concepts currently under investigation by Glenn are the magnetoplasmadynamic (MPD) thruster and the Pulsed Inductive Thruster (PIT). This paper describes the MPD thruster and the test facility.

LaPointe, Michael R.↗

NASA NTRS2001

High-Power Electromagnetic Thruster Being Developed

LaPointe, Michael R.↗

NASA NTRS2004

High-Temperature Hybrid Rotor Support System Developed

The Army Research Laboratory Vehicle Technology Directorate and the NASA Glenn Research Center demonstrated a unique high-speed, high-temperature rotor support system in September 2003. Advanced turbomachinery is on its way to surpassing the capabilities of rolling-element bearings and conventional dampers. To meet these demands, gas turbine engines of the future will demand increased efficiency and thrust-to-weight ratio, and reduced specific fuel consumption and noise. The more-electric engine replaces oil-lubricated bearings, dampers, gears, and seals with electrical devices. One such device is the magnetic bearing. The Vehicle Technology Directorate and Glenn have demonstrated the operation of a radial magnetic bearing in combination with a hydrostatic bearing at 1000 F at 31,000 rpm (2.3 MDN1). This unique combination takes advantage of a high-temperature rub surface in the event of electrical power loss or sudden overloads. The hydrostatic bearings allow load sharing with the magnetic bearing. The magnetic-hydrostatic bearing combination eliminates wear and high contact stress from sudden acceleration of the rolling-element bearings and overheating. The magnetic bearing enables high damping, adaptive vibration control, and precise rotor positioning, diagnostics, and health monitoring. A model of the test facility used at Glenn for this technology demonstration is shown. A high-temperature heteropolar radial magnetic bearing is located at the center of gravity of the test rotor. There is a 0.022-in. radial air gap between the rotor and stator. Two rub surface hydrostatic bearings were placed on either side of the magnetic bearing. The rotor is supported by a 0.002-in. hydrostatic air film and the magnetic field. The prototype active magnetic bearing cost $24,000 to design and fabricate and a set of four high temperature, rub-surface, hydrostatic bearings cost $28,000. This work was funded by the Turbine-Based Combined Cycle program.

Montague, Gerald T.↗

NASA NTRS2018

A Risk Analysis Tool for Estimating the Risk of Electrical Failures Due to Human Induced Defects

Aerospace electrical systems are required to withstand and adequately operate in extremely harsh environments that include, for example, high radiation exposure, temperature extremes, intense vibrational stress and drastic temperature cycling. The nature of aerospace electronics also demands high reliability since, with very few exceptions, there is no chance for hardware servicing or repairs. Common risk mitigation techniques for this type of situation are to perform a Reliability Analysis of the system throughout the development cycle, and to use electrical components that are regarded as “high reliability” because of additional controls and requirements applied in their design, manufacturing and testing. Unfortunately, studies have shown that even though these techniques are used, many systems fail to meet mission requirements well before the predicted lifetimes. This paper presents the analysis of failures of electrical parts, experienced during various stages of system development, at NASA Goddard Space Flight Center, Greenbelt MD, between the years 2001 and 2013. These components were subjected to qualification, screening and testing in which the goal was to ensure that the components would survive the stresses of the mission. The analysis categorizes failures by part type and failure mechanisms. One of the results of the analysis was the realization that a surprising proportion of failures experienced during system integration and testing were caused by human error (i.e. human induced defect). Further analysis included the determination of root failure mechanisms and any influencing factors contributing to these failures. The major causes of these defects were attributed to electrostatic damage (ESD), electrical overstress (EOS), mechanical overstress (MOS), and thermal overstress (TOS). Finally, the study proposes a risk analysis tool which incorporates these major causes for the failures, termed error-producing conditions (EPCs), and a proportionality factor representing the number of each type of failure that has occurred at the facility under study. These factors are quantified and used to communicate the risk of human induced defects for the assembly, integration and testing of space hardware based on the system’s electrical parts list. The new risk identification can trigger risk-mitigating actions more effectively, based on the presence of component categories or other hazardous conditions that have a history of failure due to human error.

Majewicz, Peter J.↗

NASA NTRS2005

A Facility for Testing High-Power Electric Propulsion Systems in Space: A Design Study

Petro, Andrew J.↗

NASA NTRS1979

Demand and supply of hydrogen as chemical feedstock in USA

Projections are made for the demand and supply of hydrogen as chemical feedstock in USA. Industrial sectors considered are petroleum refining, ammonia synthesis, methanol production, isocyanate manufacture, edible oil processing, coal liquefaction, fuel cell electricity generation, and direct iron reduction. Presently, almost all the hydrogen required is produced by reforming of natural gas or petroleum fractions. Specific needs and emphases are recommended for future research and development to produce hydrogen from other sources to meet the requirements of these industrial sectors. The data and the recommendations summarized in this paper are based on the Workshop 'Supply and Demand of Hydrogen as Chemical Feedstock' held at the University of Houston on December 12-14, 1977.

Huang, C. J.↗

NASA NTRS2016

Parallel Aircraft Trajectory Optimization with Analytic Derivatives

Trajectory optimization is an integral component for the design of aerospace vehicles, but emerging aircraft technologies have introduced new demands on trajectory analysis that current tools are not well suited to address. Designing aircraft with technologies such as hybrid electric propulsion and morphing wings requires consideration of the operational behavior as well as the physical design characteristics of the aircraft. The addition of operational variables can dramatically increase the number of design variables which motivates the use of gradient based optimization with analytic derivatives to solve the larger optimization problems. In this work we develop an aircraft trajectory analysis tool using a Legendre-Gauss-Lobatto based collocation scheme, providing analytic derivatives via the OpenMDAO multidisciplinary optimization framework. This collocation method uses an implicit time integration scheme that provides a high degree of sparsity and thus several potential options for parallelization. The performance of the new implementation was investigated via a series of single and multi-trajectory optimizations using a combination of parallel computing and constraint aggregation. The computational performance results show that in order to take full advantage of the sparsity in the problem it is vital to parallelize both the non-linear analysis evaluations and the derivative computations themselves. The constraint aggregation results showed a significant numerical challenge due to difficulty in achieving tight convergence tolerances. Overall, the results demonstrate the value of applying analytic derivatives to trajectory optimization problems and lay the foundation for future application of this collocation based method to the design of aircraft with where operational scheduling of technologies is key to achieving good performance.

aircraft↗

NASA NTRSDate not supplied

Rapid Aero Modeling for Urban Air Mobility Aircraft in Computational Experiments

Rapid Aero Modeling (RAM) applied to computational testing, RAM-C, is an approach to efficiently and automatically obtain aerodynamic models during computational investigations. RAM-C is designed to estimate models appropriate for flight dynamics studies and simulations. The approach responds to a demand for experimental efficiency and model fidelity that has increased with growing aircraft complexity and aerodynamic nonlinearities associated with hybrid and electric vertical takeoff and landing (eVTOL) aircraft. In an Urban Air Mobility (UAM) transportation system, it is expected that aircraft will embrace many features from both airplanes and rotorcraft. These vehicles present many more factors than conventional aircraft which can lead to increased computational costs and missed key factor interactions when applying traditional testing and modeling methods. RAM-C provides feedback loops around computational codes to rapidly guide testing toward aerodynamic models meeting user-defined fidelity goals. It combines and extends concepts from design of experiment theory and aircraft system identification theory that allow the user the freedom to choose, in advance of the test, a specific level of fidelity in terms of prediction error. RAM-C only collects enough data required to meet the user-specified prediction error requirements thus saving computational time and resources. The overall achievable fidelity of the final model also depends on the accuracy of the test facility, or in this case, the computational modeling approach. Previous studies to support development of the RAM-T process were conducted in wind tunnel tests to assess potential metrics, algorithms, and procedures. This paper presents results from the next steps taken and tests conducted for the development of RAM-C technology and highlights some of the unique features of RAM applied eVTOL configurations in a computational study.

Aerodynamics↗

NASA NTRSDate not supplied

Extending ISS Life Beyond 2030

The United States On-orbit Segment (USOS) of the International Space Station (ISS) was designed to meet a 15-year on-orbit life. Since the first hardware was launched in late 1998, the ISS would have reached its end of life in 2013. With the realization that the ISS would be needed well into the next decade, and beyond, a multi-disciplinary effort was undertaken to extend the ISS’ life through 2028 and to show that further extension to 2040 and beyond is not only feasible but achievable. Currently, NASA and the ISS international partners have agreed to extend its operations through 2030. This collaborative effort ensures that the ISS will continue to serve as a hub for scientific research, international cooperation, and educational endeavors for the next decade. Maintaining a continuous human presence in Low Earth Orbit (LEO) is desirable for testing new LEO, lunar, and deep-space technologies; conducting scientific research in micro-gravity for the benefit of life on Earth; and enabling a seamless transition of capabilities to one or more commercially owned and operated destinations. This paper provides an overview of the ISS life extension project with a particular focus on the analytical approach used to assess the primary structure. This analytical approach includes future operations planning, critical location screening, on-orbit dynamic load simulation, on-orbit optical property degradation studies, on-orbit thermal analyses, spectra generation, crack model idealization, fracture analyses, and post processing. Structural life results and identification of the most critical on-orbit events are presented. Also addressed are life extension approaches for other affected sub-systems, including: 1. Secondary Structure. 2. Materials. Evaluations consider environmental exposure to atomic oxygen, ionizing and gamma radiation, fluids, etc. Life limited materials, wear, and usage effects are also considered. 3. Environmental Control and Life Support Systems, including oxygen supply and generation, water recovery and management, and regenerative hardware. Evaluations are performed to determine which hardware can be run to failure and which are assessed for life extension. 4. Electrical power system. ISS is powered by eight channels of solar arrays and an electrical energy storage system providing 357 kWh power. Power generation and balance analyses are performed considering hardware degradation and increasing power demand. 5. Logistics and maintenance. Analyses are performed to determine critical spares required to maintain functionality. Consideration is given to supply chain health, obsolescence issues, onboard stowage availability, and up-mass capability. The successful life extension results have built confidence to safely operate, maintain and enhance the ISS well beyond the current decade. Extending the operational life of the ISS maintains an international presence in LEO and serves to avoid a gap in capability necessary to fulfill the exploration and research needs of NASA, international partners, and industry without interruption until a commercial space station is operational.

design life↗

NASA NTRS2005

A High-power Electric Propulsion Test Platform in Space

This paper will describe the results of the preliminary phase of a NASA design study for a facility to test high-power electric propulsion systems in space. The results of this design study are intended to provide a firm foundation for subsequent detailed design and development activities leading to the deployment of a valuable space facility. The NASA Exploration Systems Mission Directorate is sponsoring this design project. A team from the NASA Johnson Space Center, Glenn Research Center, the Marshall Space Flight Center and the International Space Station Program Office is conducting the project. The test facility is intended for a broad range of users including government, industry and universities. International participation is encouraged. The objectives for human and robotic exploration of space can be accomplished affordably, safely and effectively with high-power electric propulsion systems. But, as thruster power levels rise to the hundreds of kilowatts and up to megawatts, their testing will pose stringent and expensive demands on existing Earth-based vacuum facilities. These considerations and the human access to near-Earth space provided by the International Space Station (ISS) have led to a renewed interest in space testing. The ISS could provide an excellent platform for a space-based test facility with the continuous vacuum conditions of the natural space environment and no chamber walls to modify the open boundary conditions of the propulsion system exhaust. The test platform could take advantage of the continuous vacuum conditions of the natural space environment. Space testing would provide open boundary conditions without walls, micro-gravity and a realistic thermal environment. Testing on the ISS would allow for direct observation of the test unit, exhaust plume and space-plasma interactions. When necessary, intervention by on-board personnel and post-test inspection would be possible. The ISS can provide electrical power, a location for diagnostic instruments, data handling and thermal control. The platform will be designed to accommodate the side-by-side testing of multiple types of electric thrusters. It is intended to be a permanent facility in which different thrusters can be tested over time. ISS crews can provide maintenance for the platform and change out thruster test units as needed. The primary objective of this platform is to provide a test facility for electric propulsion devices of interest for future exploration missions. These thrusters are expected to operate in the range of hundreds of kilowatts and above. However, a platform with this capability could also accommodate testing of thrusters that require much lower power levels. Testing at the higher power levels would be accomplished by using power fiom storage devices on the platform, which would be gradually recharged by the ISS power generation system. This paper will summarize the results of the preliminary phase of the study with an explanation of the user requirements and the initial conceptual design. The concept for test operations will also be described. The NASA project team is defining the requirements but they will also reflect the inputs of the broader electric propulsion community including those at universities, commercial enterprises and other government laboratories. As a facility on the International Space Station, the design requirements are also intended to encompass the needs of international users. Testing of electric propulsion systems on the space station will help advance the development of systems needed for exploration and could also serve the needs of other customers. Propulsion systems being developed for commercial and military applications could be tested and certification testing of mature thrusters could be accomplished in the space environment.

Petro, Andrew J.↗

NASA NTRS1978

Space power for space

The total energy demanded by space missions of the future is expected to exceed past needs by orders of magnitude. The unit costs of this energy must be reduced from present levels if these missions are to be carried out at projected budget levels. The broad employment of electric propulsion and the capability to utilize novel high power sensors hinge on the availability of systems lighter by factors of ten or more than have flown to date. The NASA program aimed at providing the technological basis to meet these demands is described in this paper. Research and technology efforts in areas of energy conversion, storage and management are covered. In addition, work aimed at evolving the understanding necessary to cope with space environment interactions and at advanced concepts is described.

Mullin, J. P.↗

NASA NTRS2018

Digital Image Correlation Data Processing and Analysis Techniques to Enhance Test Data Assessment and Improve Structural Simulations

The NASA Shell Buckling Knockdown Factor Project (SBKF) was established in 2007 by the NASA Engineering and Safety Center (NESC) with the primary goal to develop new analysis-based buckling design factors (a.k.a. knockdown factors) and high-fidelity buckling simulations for selected launch-vehicle-like cylindrical shell structures. A series of tests are being conducted on large-scale metallic and composite cylindrical shells in order to provide validation data for these new factors and simulations. However, the validation of these new factors and simulations is quite demanding and requires test data that is commensurate with their fidelity. Traditional instrumentation, such as linear variable displacement transducers (LVDTs) and electrical-resistance strain gages serve a critical role in providing accurate displacement and strain measurements in these tests, but only allow for data to be recorded at a select number of point locations and are not sufficient to provide all the necessary validation data. Advanced measurement technologies can be used effectively to complement traditional instrumentation and gather additional data required to validate these structural simulations. In particular, three-dimensional digital image correlation (DIC) was implemented during SBKF cylinder testing to characterize the full-field displacement and strain behavior. Commercially available VIC-3DTM software and user-written data processing scripts were used to generate valuable data and insight into the complex buckling response of the cylinders that otherwise would be impossible to gather using traditional instrumentation. In addition, the measured data from DIC was used to verify measured test data obtained from other instrumentation, enhance test and analysis correlation, and help identify the root cause of anomalous test results that may have gone unexplained if only traditional instrumentation was used. Selected test results that demonstrate the use of DIC on the SBKF cylinders are presented and a portion of the data processing methods are described.

Gardner, Nathaniel W.↗

NASA NTRSDate not supplied

Battery Pack Shape Optimization using Transient Heat Conduction Coupled with Cell-Discharge Analysis

Battery electric systems exhibit significant time-dependence, especially when evaluated in the context of an aircraft mission profile with continually changing power demands. Additionally, when evaluating battery-powered aircraft concepts, it is important to accurately compute the temperature of the batteries and properly characterize the thermal response of the system. The temperature of the batteries has a significant impact on cell performance, in addition to safety considerations of maintaining battery temperatures below their operating limit. Because of these considerations, battery models for preliminary design and optimization of aircraft should include the capability to accurately compute the temperature distribution within the battery pack. Furthermore, battery pack designs should be as light-weight as possible to maximize the pack energy density, while also considering battery temperature limits. Here, we demonstrate a simultaneous trajectory and shape optimization of a battery pack concept, using a transient heat transfer finite element model coupled with a time-varying cell-discharge battery model to provide this capability. Including the transient finite element problem in the loop enables accurate temperatures that can be passed back to the cell discharge model, while the cell discharge model can supply the finite element model with time-varying heat boundary conditions to the finite element problem, further benefiting the fidelity of the thermal response of the batteries. We first demonstrate the coupling capability between the battery cell-discharge model and the transient finite-element heat transfer through an optimization which computes the optimal current profile for the battery pack while ensuring the battery temperatures remain below their operational limit. We then build on this optimization by adding shape optimization to the problem, which allows us to consider a composite objective function which also minimizes the mass of the battery pack, while also producing an optimal current discharge profile.

Optimization↗