An experimental investigation of rectangular exhaust-gas ejectors applicable for engine cooling
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COOLING TESTS↗
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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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Estimating Mass of Inflatable Aerodynamic Decelerators Using Dimensionless Parameters
This paper describes a technique for estimating mass for inflatable aerodynamic decelerators. The technique uses dimensional analysis to identify a set of dimensionless parameters for inflation pressure, mass of inflation gas, and mass of flexible material. The dimensionless parameters enable scaling of an inflatable concept with geometry parameters (e.g., diameter), environmental conditions (e.g., dynamic pressure), inflation gas properties (e.g., molecular mass), and mass growth allowance. This technique is applicable for attached (e.g., tension cone, hypercone, and stacked toroid) and trailing inflatable aerodynamic decelerators. The technique uses simple engineering approximations that were developed by NASA in the 1960s and 1970s, as well as some recent important developments. The NASA Mars Entry and Descent Landing System Analysis (EDL-SA) project used this technique to estimate the masses of the inflatable concepts that were used in the analysis. The EDL-SA results compared well with two independent sets of high-fidelity finite element analyses.
Samareh, Jamshid A.↗
Optimizing Consumable Gas Tank Usage while Maintaining Emergency Reserves Between Two Pressure Control Systems on Gateway
Two of NASA’s Lunar Space Station (Gateway) modules, the Habitation and Logistics Outpost (HALO) and International Habitat (IHAB) contain a pressure control system (PCS) that is used to supply Nitrogen (N2) and Oxygen (O2) to maintain a habitable environment within Gateway, with only one of the PCS active at any given time. To protect the crew during a contingency that is affecting pressure control and therefore gas consumables, Gateway is required to have sufficient amount of reserve consumable gas across the entire habitable Gateway stack of modules until the gas can be replenished by crew changing out a gas tank. This will occur in a non-contingency setting either on the current mission or on the next mission. To access the stack reserve Gateway features a Nitrogen Oxygen Transfer System (NOTS) between HALO and IHAB that allows each module’s PCS to access the gas tanks in the other module. The PCS designs are different between the two modules and lack interchangeable tanks so which module has active PCS must be accounted for in logistics planning. This paper describes the logistics resupply planning analysis used to determine the most efficient use of the tanks within each PCS, and a method for switching which module is active for PCS while maintaining the stack reserve that preserves enough gas to cover contingency cases.
Rachel Anne Sturtz↗
Thermal Management Challenges and Technology Options for Lunar Regenerative Fuel Cells
Regenerative Fuel Cells (RFCs) enable lunar surface hardware, from pressurized rovers to surface habitats, to survive the lunar night by providing the required energy storage with a lower mass than state of the art battery systems. RFCs consist of fuel cell and electrolyzer electrochemical stack(s), a fluidic balance of plant, and electrical balance of plant. Fuel cells operate by converting the stored chemical energy of reactants into DC electrical power, heat, and water. When supplied DC power from an available external source, electrolyzers regenerate the reactants through electrolysis. The balance of plant is a critical part of the integrated system consisting of many individual components and provides fluid pressure management and conditioning, fluid storage, and thermal management. Component technology development is required to create an RFC system that will be capable of surviving the harsh lunar environment and maximize specific energy (W-hr/kg). One critical component requiring development includes a kW-scale high flux thermal switch. The primary requirement for the thermal switch is the ability to maintain low thermal resistance with the RFC heat rejection interface during the lunar day to maximize heat rejection while switching to a high thermal resistance during the lunar night such that the RFC can conserve as much thermal energy as possible. Different technology including freeze tolerant pumped loop, passive louvers, and variable conductance heat pipes were assessed as potential solutions. NASA is exploring development options through internal and external partnerships to develop this technology critical for a spaceflight RFC system.
Energy Storage↗
Flexible plastic ring assembly makes durable shaft seal
Stacked flexible rings interleaved with solid metal rings of smaller width provide a durable seal ring for rotating shafts used in vacuum or pressure pumps.
Source record↗
Safe Replacement For Asbestos In Nickel/Hydrogen Cells
Polyethylene fibers and potassium titanate particles perform as well as asbestos. New material for separators of nickel-hydrogen electrochemical cells offers performance similar to that of asbestos separator material without adverse health effects. In one version, separator contains pure polyethylene fibers, and may or may not contain supplementary latices as bonding agents. In standard wet-laying papermaking process, fibers pressed into mat, then dried. Mat used as is or pressed further in hot calender stack to soften and fuse fibers at crossing points. Treatment reduces porosity and increases resistance of mat to passage of air bubbles under pressure. In alternative version, matrix of 20 to 40 percent polyethylene fibers and 60 to 80 percent potassium titanate particles formed on paper machine, then dried. It, too, can be treated by hot calendering.
Scott, William E.↗
Composite hot drape forming
This program was initiated to replace labor-intensive ply-by-ply layup of composite I-beam posts and angle stiffeners used in the Space Station Freedom (SSF) rack structure. Hot drape forming (HDF) has been successfully implemented by BCAG for 777 composite I-stringers and by Bell Helicopter/Textron for the V-22 I-stingers. The two companies utilize two vastly different approaches to the I-beam fabrication process. A drape down process is used by Bell Helicopter where the compacted ply charge is placed on top of a forming mandrel and heated. When the heated ply charge reached a set temperature, vacuum pressure is applied and the plies are formed over the mandrel. The BCAG 777 process utilizes an inverted forming process where the ply stack is placed on a forming table and the mandrel is inverted and placed upon the ply stack. A heating and vacuum bladder underneath the ply stack form the play stack up onto the mandrels after reaching the temperature setpoint. Both methods have their advantages, but the drape down process was selected for SSF because it was more versatile and could be fabricated from readily available components.
Ott, Thomas↗
Exhaust-stack nozzle area and shape for individual cylinder exhaust-gas jet-propulsion system
This report presents the results of an investigation conducted on the effect of exhaust-stack nozzle area, shape, and length on engine power, jet thrust, and gain in net thrust (engine propeller plus jet). Single-cylinder engine data were obtained using three straight stacks 25, 44, and 108 inches in length; an S-shaped stack, a 90 degree bend, a 180 degree bend, and a short straight stack having a closed branch faired into it. Each stack was fitted with nozzles varying in exit area from 0.91 square inch to the unrestricted area of the stack of 4.20 square inches. The engine was generally operated over a range of engine speeds from 1300 to 2100 r.p.m, inlet-manifold pressures from 22 to 30 inches of mercury absolute, and a fuel-air ratio of 0.08. The loss in engine power, the jet thrust, and the gain in net thrust are correlated in terms of several simple parameters. An example is given for determining the optimum nozzle area and the overall net thrust.
Pinkel, Benjamin↗
Determining the Source of Water Vapor in a Cerium Oxide Electrochemical Oxygen Separator to Achieve Aviator Grade Oxygen
More than a metric ton of water is transported to the International Space Station (ISS) each year to provide breathing oxygen for the astronauts. Water is a safe and compact form of stored oxygen. The water is electrolyzed on ISS and ambient pressure oxygen is delivered to the cabin. A much smaller amount of oxygen is used each year in spacesuits to conduct Extra Vehicular Activities (EVAs). Space suits need high pressure (>1000 psia) high purity oxygen (must meet Aviator Breathing Oxygen "ABO" specifications, >99.5% O2). The water / water electrolysis system cannot directly provide high pressure, high purity oxygen, so oxygen for EVAs is transported to ISS in high pressure gas tanks. The tanks are relatively large and heavy, and the majority of the system launch weight is for the tanks and not the oxygen. Extracting high purity oxygen from cabin air and mechanically compressing the oxygen might enable on-board production of EVA grade oxygen using the existing water / water electrolysis system. This capability might also benefit human spaceflight missions, where oxygen for EVAs could be stored in the form of water, and converted into high pressure oxygen on-demand. Cerium oxide solid electrolyte-based ion transport membranes have been shown to separate oxygen from air, and a supported monolithic wafer form of the CeO2 electrolyte membrane has been shown to deliver oxygen at pressures greater than 300 psia. These supported monolithic wafers can withstand high pressure differentials even though the membrane is very thin, because the ion transport membrane is supported on both sides (Fig 1). The monolithic supported wafers have six distinct layers, each with matched coefficients of thermal expansion. The wafers are assembled into a cell stack which allows easy air flow across the wafers, uniform current distribution, and uniform current density (Fig 2). The oxygen separation is reported to be "infinitely selective" to oxygen [1] with reported purity of 99.99% [2]. Combined with a mechanical compressor, a Solid Electrolyte Oxygen Separator (SEOS) should be capable of producing ABO grade oxygen at pressures >2400 psia, on the space station. Feasibility tests using a SEOS integrated with a mechanical compressor identified an unexpected contaminant in the oxygen: water vapour was found in the oxygen product, sometimes at concentrations higher than 40 ppm (the ABO limit for water vapour is 7 ppm). If solid electrolyte membranes are really "infinitely selective" to oxygen as they are reported to be, where did the water come from? If water is getting into the oxygen, what other contaminants might get into the oxygen? Microscopic analyses of wafers, welds, and oxygen delivery tubes were performed in an attempt to find the source of the water vapour contamination. Hot and cold pressure decay tests were performed. Measurements of water vapour as a function of O2 delivery rate, O2 delivery pressure, and process air humidity levels were the most instructive in finding the source of water contamination (Fig 3). Water contamination was directly affected by oxygen delivery rate (doubling the oxygen production rate cut the water level in half). Water was affected by process air humidity levels and delivery pressure in a way that indicates the water was diffusing into the oxygen delivery system.
Graf, John↗
Improved Thermal-Insulation Systems for Low Temperatures
Improved thermal-insulation materials and structures and the techniques for manufacturing them are undergoing development for use in low-temperature applications. Examples of low-temperature equipment for which these thermal insulation systems could provide improved energy efficiency include storage tanks for cryogens, superconducting electric-power-transmission equipment, containers for transport of food and other perishable commodities, and cold boxes for low-temperature industrial processes. These systems could also be used to insulate piping used to transfer cryogens and other fluids, such as liquefied natural gas, refrigerants, chilled water, crude oil, or low-pressure steam. The present thermal-insulation systems are layer composites based partly on the older class of thermal-insulation systems denoted generally as multilayer insulation (MLI). A typical MLI structure includes an evacuated jacket, within which many layers of radiation shields are stacked or wrapped close together. Low-thermal-conductivity spacers are typically placed between the reflection layers to keep them from touching. MLI can work very well when a high vacuum level (less than 10(exp-4) torr) is maintained and utmost care is taken during installation, but its thermal performance deteriorates sharply as the pressure in the evacuated space rises into the soft vacuum range [pressures greater than 0.1 torr (greater than 13 Pa)]. In addition, the thermal performance of MLI is extremely sensitive to mechanical compression and edge effects and can easily decrease from one to two orders of magnitude from its ideal value even when the MLI is kept under high vacuum condition. The present thermal-insulation systems are designed to perform well under soft vacuum level, in particular the range of 1 to 10 torr. They are also designed with larger interlayer spacings to reduce vulnerability to compression (and consequent heat leak) caused by installation and use. The superiority of these systems is the synergistic effect of improvements in materials, design, and manufacture.
Fesmire, James E.↗
Multiport high-pressure synchrotron x-ray microscopy cell (CRADA Final Report)
The LBNL team developed a multiport cell allowing for fluid flow, with electrical contacts for sample bias, and with reference electrodes. The cell is currently installed and operating in beam-line 11.0.2 of the ALS, the Berkeley Synchrotron. The cell is closed by a membrane consisting of several stacked layers of graphene (1 to 3). The graphene membrane is supported on a 100 nm thick Si3N4 membrane covered with a 20 nm thin gold film for improved adhesion of the graphene and to ensure electrical conductivity. The Si3N4 film is perforated with a periodic array of holes 1 to 2 micrometers diameter. The cell can withhold an internal pressure (gas or liquid) of up to 10 atmospheres for in situ/operando studies using X-ray Photoelectron emission (XPS), and X-ray Absorption Spectroscopy (XAS). It is also ideal for tip-enhanced nano-Infrared Spectroscopy studies of molecules at the interface between the graphene and the liquid or gas filling the cell. Materials studied in the LBNL laboratory are in the form of nanoparticles, or thin films (few nm) deposited on the side of the graphene membrane facing the solution or gas inside the cell.
36 MATERIALS SCIENCE↗
Structural tailoring using the SSME/STAEBL code
Space Shuttle Main Engine/Structural Tailoring of Engine Blades (SSME/STAEBL) was developed by systematically modifying and enhancing the STAEBL code developed by Pratt and Whitney under contract to NASA Lewis Research Center. STAEBL was designed for application to gas turbine blade design. Typical design variables include blade thickness distribution and root chord. Typical constraints include resonance margins, root stress, and root to chord ratios. In this program, the blade is loaded by centrifugal forces only. Additions and modifications of STAEBL included in SSME/STAEBL include (1) thermal stress analysis; (2) gas dynamic (pressure) loads; (3) temperature dependent material and thermal properties; (4) forced vibrations; (5) tip displacement constraints; (6) single crystal material analysis; (7) blade cross section stacking offsets; and (8) direct time integration algorithm for transient dynamic response. Capabilities are also included which permit data transfer from finite element models and stand-alone analysis.
Rubinstein, Robert↗
Technology development for phosphoric acid fuel cell powerplant, phase 2
The development of materials, cell components, and reformers for on site integrated energy systems is described. Progress includes: (1) heat-treatment of 25 sq cm, 350 sq cm and 1200 sq cm cell test hardware was accomplished. Performance of fuel cells is improved by using this material; (2) electrochemical and chemical corrosion rates of heat-treated and as-molded graphite/phenolic resin composites in phosphoric acid were determined; (3) three cell, 5 in. x 15 in. stacks operated for up to 10,000 hours and 12 in. x 17 in. five cell stacks were tested for 5,000 hours; (4) a three cell 5 in. x 15 in. stack with 0.12 mg Pt/sq cm anodes and 0.25 mg Pt/sq cm cathodes was operated for 4,500 hours; and (5) an ERC proprietary high bubble pressure matrix, MAT-1, was tested for up to 10,000 hours.
Christner, L.↗
A Preliminary Investigation of Exhaust-gas Ejectors for Ground Cooling
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BAFFLES - ENGINE CYLINDERS - PRESSURE DROP↗
Predicting Ares I Reaction Control System Performance by Utilizing Analysis Anchored with Development Test Data
The Ares I launch vehicle is an integral part of NASA s Constellation Program, providing a foundation for a new era of space access. The Ares I is designed to lift the Orion Crew Module and will enable humans to return to the Moon as well as explore Mars.1 The Ares I is comprised of two inline stages: a Space Shuttle-derived five-segment Solid Rocket Booster (SRB) First Stage (FS) and an Upper Stage (US) powered by a Saturn V-derived J-2X engine. A dedicated Roll Control System (RoCS) located on the connecting interstage provides roll control prior to FS separation. Induced yaw and pitch moments are handled by the SRB nozzle vectoring. The FS SRB operates for approximately two minutes after which the US separates from the vehicle and the US Reaction Control System (ReCS) continues to provide reaction control for the remainder of the mission. A representation of the Ares I launch vehicle in the stacked configuration and including the Orion Crew Exploration Vehicle (CEV) is shown in Figure 1. Each Reaction Control System (RCS) design incorporates a Gaseous Helium (GHe) pressurization system combined with a monopropellant Hydrazine (N2H4) propulsion system. Both systems have two diametrically opposed thruster modules. This architecture provides one failure tolerance for function and prevention of catastrophic hazards such as inadvertent thruster firing, bulk propellant leakage, and over-pressurization. The pressurization system on the RoCS includes two ambient pressure-referenced regulators on parallel strings in order to attain the required system level single Fault Tolerant (FT) design for function while the ReCS utilizes a blow-down approach. A single burst disk and relief valve assembly is also included on the RoCS to ensure single failure tolerance for must-not-occur catastrophic hazards. The Reaction Control Systems are designed to support simultaneously firing multiple thrusters as required
Stein, William B.↗
Aerodynamic Design and Optimization of Fan Stage for Boundary Layer Ingestion Propulsion System
The present paper addresses the process of preliminary design of a low-pressure fan and outlet guide vane (OGV) of a boundary layer ingestion (BLI) propulsion system. The tail-cone thruster systems of NASA's STARC_ABL (Single-aisle Turboelectric Aircraft with an Aft Boundary-Layer propulsor) adopts an axi-symmetric BLI type inlet as opposed to other embedded engine systems. Thus, the focus of the present work is placed on maximizing the efficiency of the fan and OGV stages under a significant radial distortion. A parameterization with B-spline function for camber line angles, metal chord, thickness distribution and stacking axis of blades is presented. The flowpath lines are also parameterized by B-spline function and aggregated in the design system of blades. The design optimization with evolutionary algorithm is performed with constraints of fan pressure ratio, OGV exit swirl angle and nozzle exit properties. The inlet conditions for the turbo-machinery CFD (Computational Fluid Dynamics) domain and the design goal of the fan stage are driven by a propulsion airframe integration (PAI) model that uses a 3-D unstructured RANS (Reynolds Average Navier Stokes) solver and actuator disk model. The expected power saving of the BLI propulsor is quantified via PAI analysis and the resulting preliminary design of the fan stages is compared with a clean-inlet flow propulsor.
Turbo-machinery↗
Metallic Thin-Film Bonding and Alloy Generation
Diffusion bonding a stack of aluminum thin films is particularly challenging due to a stable aluminum oxide coating that rapidly forms on the aluminum thin films when they are exposed to atmosphere and the relatively low meting temperature of aluminum. By plating the individual aluminum thin films with a metal that does not rapidly form a stable oxide coating, the individual aluminum thin films may be readily diffusion bonded together using heat and pressure. The resulting diffusion bonded structure can be an alloy of choice through the use of a carefully selected base and plating metals. The aluminum thin films may also be etched with distinct patterns that form a microfluidic fluid flow path through the stack of aluminum thin films when diffusion bonded together.
Fryer, Jack Merrill↗