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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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NASA NTRS1987

Improved silicon nitride for advanced heat engines

The technology base required to fabricate silicon nitride components with the strength, reliability, and reproducibility necessary for actual heat engine applications is presented. Task 2 was set up to develop test bars with high Weibull slope and greater high temperature strength, and to conduct an initial net shape component fabrication evaluation. Screening experiments were performed in Task 7 on advanced materials and processing for input to Task 2. The technical efforts performed in the second year of a 5-yr program are covered. The first iteration of Task 2 was completed as planned. Two half-replicated, fractional factorial (2 sup 5), statistically designed matrix experiments were conducted. These experiments have identified Denka 9FW Si3N4 as an alternate raw material to GTE SN502 Si3N4 for subsequent process evaluation. A detailed statistical analysis was conducted to correlate processing conditions with as-processed test bar properties. One processing condition produced a material with a 97 ksi average room temperature MOR (100 percent of goal) with 13.2 Weibull slope (83 percent of goal); another condition produced 86 ksi (6 percent over baseline) room temperature strength with a Weibull slope of 20 (125 percent of goal).

Yeh, Hun C.↗

NASA NTRS2000

Advanced Engineering Environments for Space Transportation System Development

There are significant challenges facing today's launch vehicle industry. Global competition, more complex products, geographically-distributed design teams, demands for lower cost, higher reliability and safer vehicles, and the need to incorporate the latest technologies quicker, all face the developer of a space transportation system. Within NASA, multiple technology development and demonstration projects are underway toward the objectives of safe, reliable, and affordable access to space. New information technologies offer promising opportunities to develop advanced engineering environments to meet these challenges. Significant advances in the state-of-the-art of aerospace engineering practice are envisioned in the areas of engineering design and analytical tools, cost and risk tools, collaborative engineering, and high-fidelity simulations early in the development cycle. At the Marshall Space Flight Center, work has begun on development of an advanced engineering environment specifically to support the design, modeling, and analysis of space transportation systems. This paper will give an overview of the challenges of developing space transportation systems in today's environment and subsequently discuss the advanced engineering environment and its anticipated benefits.

Thomas, L. Dale↗

NASA NTRS2010

Advanced Flip Chips in Extreme Temperature Environments

The use of underfill materials is necessary with flip-chip interconnect technology to redistribute stresses due to mismatching coefficients of thermal expansion (CTEs) between dissimilar materials in the overall assembly. Underfills are formulated using organic polymers and possibly inorganic filler materials. There are a few ways to apply the underfills with flip-chip technology. Traditional capillary-flow underfill materials now possess high flow speed and reduced time to cure, but they still require additional processing steps beyond the typical surface-mount technology (SMT) assembly process. Studies were conducted using underfills in a temperature range of -190 to 85 C, which resulted in an increase of reliability by one to two orders of magnitude. Thermal shock of the flip-chip test articles was designed to induce failures at the interconnect sites (-40 to 100 C). The study on the reliability of flip chips using underfills in the extreme temperature region is of significant value for space applications. This technology is considered as an enabling technology for future space missions. Flip-chip interconnect technology is an advanced electrical interconnection approach where the silicon die or chip is electrically connected, face down, to the substrate by reflowing solder bumps on area-array metallized terminals on the die to matching footprints of solder-wettable pads on the chosen substrate. This advanced flip-chip interconnect technology will significantly improve the performance of high-speed systems, productivity enhancement over manual wire bonding, self-alignment during die joining, low lead inductances, and reduced need for attachment of precious metals. The use of commercially developed no-flow fluxing underfills provides a means of reducing the processing steps employed in the traditional capillary flow methods to enhance SMT compatibility. Reliability of flip chips may be significantly increased by matching/tailoring the CTEs of the substrate material and the silicon die or chip, and also the underfill materials. Advanced packaging interconnects technology such as flip-chip interconnect test boards have been subjected to various extreme temperature ranges that cover military specifications and extreme Mars and asteroid environments. The eventual goal of each process step and the entire process is to produce components with 100 percent interconnect and satisfy the reliability requirements. Underfill materials, in general, may possibly meet demanding end use requirements such as low warpage, low stress, fine pitch, high reliability, and high adhesion.

Ramesham, Rajeshuni↗

NASA NTRS2017

Self-Healing Technologies for Wiring and Surfaces in Aerospace and Deep Space Exploration Applications

Self-healing technologies have been identified as critical technology gaps for future exploration. NASA and KSC have been working in this area for multiple years with established intellectual property; however, there are many challenges that remain in this area of research. How do we mimic what the body does so naturally when we as NASA have unique requirements? We have been investigating several mechanisms for self-healing: microencapsulation with a healant core to fill in voids in the case of mechanical puncture and flowable (or sealable)systems that have inherent chemical properties that allow the materials to flow back together when cut or damaged. The microcapsules containing healant have to be durable and robust, must be able to take high temperatures to meet NASA unique requirements, provide good capillary flow of the healant, and be small in diameters to fill in damage voids in thin films or surfaces. Sealable systems have to flow in a range of temperatures and yet be lightweight and chemically resistant. The systems currently being developed are based on polyimide and polyurethane matrices and have been studied for use in high performance wiring systems, inflatable systems, and habitation structures. Self-healing or self-sealing capability would significantly reduce maintenance requirements and increase the safety and reliability performance of critical systems. Advances in these self-healing technologies and some of the unique challenges needed to be overcome in order to incorporate a self-healing mechanism into wiring or thin films systems will be addressed.

Self-healing technologies↗

NASA NTRS1979

Industrialization study, phase 2

The potentials and requirements of advanced photovoltaic technologies still in their early developmental stages were evaluated and compared to the present day single crystal silicon wafer technology and to each other. The major areas of consideration include polycrystalline and amorphous silicon, single crystal and polycrystalline gallium arsenide, and single crystal and polycrystalline cadmium sulfide. A rank ordering of the advanced technologies is provided. The various ranking schemes were based upon present-day efficiency levels, their stability and long-term reliability prospects, material availability, capital investments both at the laboratory and production level, and associated variable costs. An estimate of the timing of the possible readiness of these advanced technologies for technology development programs and industrialization is presented along with a set of recommended government actions concerning the various advanced technologies.

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NASA NTRS1979

The role of fuel cells in NASA's space power systems

The advances in fuel cell technology which have expanded the capabilities of the fuel cell from that of power generation to include energy storage also expanded its potential role in space power systems. This paper presents a brief evolutionary history of the fuel cell technology and compares this with NASA's increasing space power requirements. The role of fuel cells is put in perspective with other energy storage systems applicable for space using such criteria as type of mission, weight, reliability, costs, etc. Potential applications of space fuel cells with projected technology advances are examined.

Been, J. F.↗

NASA NTRS2001

An Approach to Establishing System Benefits for Technologies In NASA's Spaceliner Investment Area

NASA's has established long term goals for access-to-space. The third generation launch systems are to be fully reusable and operational around 2025. The goals for the third generation launch system are to significantly reduce cost and improve safety over current systems. The Advanced Space Transportation Program Office (ASTP) at the NASA's Marshall Space Flight Center in Huntsville, AL has the agency lead to develop space transportation technologies. Within ASTP, under the Spaceliner Investment Area, third generation technologies are being pursued. The Spaceliner Investment Area's primary objective is to mature vehicle technologies to enable substantial increases in the design and operating margins of third generation RLVs (current Space Shuttle is considered the first generation RLV) by incorporating advanced propulsion systems, materials, structures, thermal protection systems, power, and avionics technologies. Advancements in design tools and better characterization of the operational environment will result in reduced design and operational variabilities leading to improvements in margins. Improvements in operational efficiencies will be obtained through the introduction of integrated vehicle health management, operations and range technologies. Investments in these technologies will enable the reduction in the high operational costs associated with today's vehicles by allowing components to operate well below their design points resulting in improved component operating life, reliability, and safety which in turn reduces both maintenance and refurbishment costs. The introduction of advanced technologies may enable horizontal takeoff by significantly reducing the takeoff weight and allowing use of existing infrastructure. This would be a major step toward the goal of airline-like operation. These factors in conjunction with increased flight rates, resulting from reductions in transportation costs, will result in significant improvements of future vehicles. The real-world problem is that resources are limited and technologies need to be prioritized to assure the resources are spent on technologies that provide the highest system level benefits. Toward that end, a systems approach is being taken to determine the benefits of technologies for the Spaceliner Investment Area. Technologies identified to be enabling will be funded. However, the other technologies will be funded based on their system's benefits. Since the final launch system concept will not be decided for many years, several vehicle concepts are being evaluated to determine technology benefits. Not only performance, but also cost and operability are being assessed. This will become an annual process to assess these technologies against their goals and the benefits to various launch systems concepts. The paper describes the system process, tools and concepts used to determine the technology benefits. Preliminary results will be presented along with the current technology investments that are being made by ASTP's Spaceliner Investment Area.

Hueter, Uwe↗

NASA NTRS1995

Ka-band MMIC subarray technology program (Ka-Mist)

The broad objective of this program was to demonstrate a proof of concept insertion of Monolithic Microwave Integrated Circuit (MMIC) device technology into an innovative (tile architecture) active phased array antenna application supporting advanced EHF communication systems. Ka-band MMIC arrays have long been considered as having high potential for increasing the capability of space, aircraft, and land mobile communication systems in terms of scan performance, data rate, link margin, and flexibility while offering a significant reduction in size, weight, and power consumption. Insertion of MMIC technology into antenna systems, particularly at millimeter wave frequencies using low power and low noise amplifiers in close proximity to the radiating elements, offers a significant improvement in the array transmit efficiency, receive system noise figure, and overall array reliability. Application of active array technology also leads to the use of advanced beamforming techniques that can improve beam agility, diversity, and adaptivity to complex signal environments.

Pottenger, Warren↗

NASA NTRS2015

Advancing Lidar Sensors Technologies for Next Generation Landing Missions

Missions to solar systems bodies must meet increasingly ambitious objectives requiring highly reliable "precision landing", and "hazard avoidance" capabilities. Robotic missions to the Moon and Mars demand landing at pre-designated sites of high scientific value near hazardous terrain features, such as escarpments, craters, slopes, and rocks. Missions aimed at paving the path for colonization of the Moon and human landing on Mars need to execute onboard hazard detection and precision maneuvering to ensure safe landing near previously deployed assets. Asteroid missions require precision rendezvous, identification of the landing or sampling site location, and navigation to the highly dynamic object that may be tumbling at a fast rate. To meet these needs, NASA Langley Research Center (LaRC) has developed a set of advanced lidar sensors under the Autonomous Landing and Hazard Avoidance Technology (ALHAT) project. These lidar sensors can provide precision measurement of vehicle relative proximity, velocity, and orientation, and high resolution elevation maps of the surface during the descent to the targeted body. Recent flights onboard Morpheus free-flyer vehicle have demonstrated the viability of ALHAT lidar sensors for future landing missions to solar system bodies.

Amzajerdian, Farzin↗

DOE OSTI2022

Plasma Ignition and Combustion Stabilization Technology to Improve Flexible Operation, Reliability and Economics of an Existing Coal-Fired Boiler

GE Steam Power, Inc. (GE) proposed to improve reliability, flexibility, and economics of an existing coal-fired power plant by applying a new advanced technology developed by GE, a plasma-assisted pulverized fuel firing system. The objective of this program is to demonstrate the achievement of lower load by improved flame stabilization and therefore lower operating costs in a full-scale field installation at coal-fired electric utility. GE’s Plasma Ignition and Combustion Stabilization System is designed to operate continuously to support low load operation. With the plasma on, the flame will be attached and stable, removing the firing system as a limitation to low load operation. In addition, GE’s exclusively from ABENZ company licensed AC based technology has a 90+% system efficiency compared to all other systems at which are DC and operate with ~75% efficiency. Plant operating costs are lowered by eliminating use of expensive support fuel as well as the ability to operate at lower loads. The utilities’ ability to better match the demand curve will result in significant savings. Maintenance is lower for an AC system than a DC system as it operates at lower current. This eliminates the need for a demineralized cooling water system and provides longer electrode life which translates into both material and labor savings. It is the objective of GE to not only demonstrate the additional low load achievable with a plasma system after best achievable tuning, sensor and software approach has been exhausted, but also the increased stability of the flame at all loads with plasma assistance as well as cost savings at all low loads using plasma instead of oil. Upon successful completion of this project, GE will have sufficient field experience to rapidly deploy the Plasma Technology. The project objectives were achieved through the implementation of plasma ignitor technology at PacifiCorp Hunter Station Unit 3. A plasma ignitor system was retrofitted on ten wall-fired burners, Mill 3-4 combustion system. The Plasma Ignitors installed at Hunter proved that this GE technology is a direct and complete replacement for the original oil ignitors. The Hunter Unit 3 burner management system allows the plasma system to be used in all applications that originally required oil to be burned. This includes any time the Mill 3-4 is started or stopped for any reason including boiler starts, load changes, and low load support.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2025

MOOSE-based Tritium Migration Analysis Program, Version 8 (TMAP8) for advanced open-source tritium transport and fuel cycle modeling

Tritium management is critical for the safety, sustainability, and economics of fusion energy systems, and advanced and reliable modeling tools help accelerate the development of tritium technologies. This paper presents the Tritium Migration Analysis Program, Version 8 (TMAP8), an open-source, MOOSE-based application developed to provide state-of-the-art tritium transport and fuel cycle modeling capabilities. TMAP8 aims to expand the capabilities of previous versions (i.e., TMAP4 and TMAP7) by leveraging modern computational techniques, ensuring high software quality assurance standards (key to building trust), and enabling multispecies, multiscale, and multiphysics simulations for integrated tritium transport modeling in complex geometries. This paper outlines TMAP8’s scope and rigorous development practices, emphasizing its transparency, accessibility, modularity, and reliability. We present the current suite of verification and validation cases based on those from TMAP4, demonstrating TMAP8’s accuracy and reliability against analytical solutions and experimental data. Additionally, the paper showcases TMAP8’s integrated fuel cycle modeling capabilities, highlighting its applicability at various scales and levels. The TMAP8 code and documentation are openly available, promoting collaborative development and widespread adoption within the fusion community. Future work will soon expand TMAP8’s verification and validation suite to include those from TMAP7 and other recent experimental studies for validation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Water Power Technologies Office: Multi-Year Program Plan

The U.S. Department of Energy’s Water Power Technologies Office (WPTO) has released its first Multi-Year Program Plan (MYPP), which outlines the Office’s research priorities and plans through 2025. Cover of the WPTO MYPP 2022. The MYPP serves as both a strategic vision and an operational guide to help WPTO manage and coordinate its activities, as well as a vehicle to communicate WPTO’s mission, goals, and plans to water power stakeholders and the public. It details WPTO’s research, development, demonstration, and commercial activities across both hydropower and marine energy for the coming years and outlines how these efforts can help meet the nation’s energy and sustainability goals. The MYPP features key performance goals for 2025, as well as additional objectives running through 2030. All outlined goals contribute to the overarching mission of WPTO to enable research, development, and testing of new technologies to advance marine energy and hydropower systems for a flexible, reliable grid.

13 HYDRO ENERGY↗

NASA NTRS1979

Synchronous orbit power technology needs

The needs are defined for future geosynchronous orbit spacecraft power subsystem components, including power generation, energy storage, and power processing. A review of the rapid expansion of the satellite communications field provides a basis for projection into the future. Three projected models, a mission model, an orbit transfer vehicle model, and a mass model for power subsystem components are used to define power requirements and mass limitations for future spacecraft. Based upon these three models, the power subsystems for a 10 kw, 10 year life, dedicated spacecraft and for a 20 kw, 20 year life, multi-mission platform are analyzed in further detail to establish power density requirements for the generation, storage and processing components of power subsystems as related to orbit transfer vehicle capabilities. Comparison of these requirements to state of the art design values shows that major improvements, by a factor of 2 or more, are needed to accomplish the near term missions. However, with the advent of large transfer vehicles, these requirements are significantly reduced, leaving the long lifetime requirement, associated with reliability and/or refurbishment, as the primary development need. A few technology advances, currently under development, are noted with regard to their impacts on future capability.

Slifer, L. W., Jr.↗

NASA NTRS1993

The Iridium (tm) system: Personal communications anytime, anyplace

The Iridium system is designed to provide handheld personal communications between diverse locations around the world at any time and without prior knowledge of the location of the personal units. This paper provides an overview of the system, the services it provides, its operation, and an overview of the commercial practices and relatively high volume satellite production techniques which will make the system cost effective. A constellation of 66 satellites will provide an orbiting, spherical-shell, infrastructure for this global calling capability. The satellites act as tall cellular towers and allow convenient operation for portable handheld telephones. The system will provide a full range of services including voice, paging, data, geolocation, and fax capabilities. Motorola is a world leader in the production of high volume, high quality, reliable telecommunications hardware. One of Iridium's goals is to apply these production techniques to high reliability space hardware. Concurrent engineering, high performance work teams, advanced manufacturing technologies, and improved assembly and test methods are some of the techniques that will keep the Iridium system cost effective. Mobile, global, flexible personal communications are coming that will allow anyone to call or receive a call from/to anyplace at anytime. The Iridium system will provide communications where none exist today. This connectivity will allow increased information transfer, open new markets for various business endeavors, and in general increase productivity and development.

Hatlelid, John E.↗

NASA NTRS1994

Hidden Markov Models for Fault Detection in Dynamic Systems

Continuous monitoring of complex dynamic systems is an increasingly important issue in diverse areas such as nuclear plant safety, production line reliability, and medical health monitoring systems. Recent advances in both sensor technology and computational capabilities have made on-line permanent monitoring much more feasible than it was in the past. In this paper it is shown that a pattern recognition system combined with a finite-state hidden Markov model provides a particularly useful method for modelling temporal context in continuous monitoring. The parameters of the Markov model are derived from gross failure statistics such as the mean time between failures. The model is validated on a real-world fault diagnosis problem and it is shown that Markov modelling in this context offers significant practical benefits.

Smyth, Padhraic↗

NASA NTRS2001

Using Neural Networks in Decision Making for a Reconfigurable Electro Mechanical Actuator (EMA)

The objectives of this project were to demonstrate applicability and advantages of a neural network approach for evaluating the performance of an electro-mechanical actuator (EMA). The EMA in question was intended for the X-37 Advanced Technology Vehicle. It will have redundant components for safety and reliability. The neural networks for this application are to monitor the operation of the redundant electronics that control the actuator in real time and decide on the operating configuration. The system we proposed consists of the actuator, sensors, control circuitry and dedicated (embedded) processors. The main purpose of the study was to develop suitable hardware and neural network capable of allowing real time reconfiguration decisions to be made. This approach was to be compared to other methods such as fuzzy logic and knowledge based systems considered for the same application. Over the course of the project a more general objective was the identification of the other neural network applications and the education of interested NASA personnel on the topic of Neural Networks.

Latino, Carl D.↗

NASA NTRS1996

High-Temperature Extensometry and PdCr Temperature-Compensated Wire Resistance Strain Gages Compared

Source record↗

NASA NTRS1997

High-Temperature Extensometry and PdCr Temperature-Compensated Wire Resistance Strain Gages Compared

A detailed experimental evaluation is underway at the NASA Lewis Research Center to compare and contrast the performance of the PdCr/Pt dual-element temperature-compensated wire resistance strain gage with that of conventional high-temperature extensometry. The advanced PdCr gage, developed by researchers at Lewis, exhibits desirable properties and a relatively small and repeatable apparent strain to 800 C. This gage represents a significant advance in technology because existing commercial resistance strain gages are not reliable for quasi-static strain measurements above approx. 400 C. Various thermal and mechanical loading spectra are being applied by a high-temperature thermomechanical uniaxial testing system to evaluate the two strain-measurement systems. This is being done not only to compare and contrast the two strain sensors, but also to investigate the applicability of the PdCr strain gage to the coupon-level specimen testing environment typically employed when the high-temperature mechanical behavior of structural materials is characterized. Strain measurement capabilities to 800 C are being investigated with a nickel-base superalloy, Inconel 100 (IN 100), substrate material and application to TMC's is being examined with the model system, SCS-6/Ti-15-3. Furthermore, two gage application techniques are being investigated in the comparison study: namely, flame-sprayed and spot welding. The apparent strain responses of both the weldable and flame-sprayed PdCr wire strain gages were found to be cyclically repeatable on both IN 100 and SCS-6/Ti-15-3 [0]_8. In general, each gage exhibited some uniqueness with respect to apparent strain behavior. Gages mounted on the IN 100 specimens tended to show a repeatable apparent strain within the first few cycles, because the thermal response of IN 100 was stable. This was not the case, however, for the TMC specimens, which typically required several thermal cycles to stabilize the thermal strain response. Thus, progressive changes in the apparent strain behavior were corroborated by the extensometer, which unlike the mounted gage can distinguish quantitative changes in the material's thermal strain response. One specimen was instrumented with both a fixed and floating gage. From the difference in output of these two gages, the thermal expansion strains were calculated. These data, which are given in the figure, show excellent agreement with the values measured by the high-temperature extensometry.

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