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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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202 records · Page 12
All sourcesNASA NTRSDOE OSTI
NASA NTRS2015

Metallography of Battery Resistance Spot Welds

Li-ion cells provide an energy dense solution for systems that require rechargeable electrical power. However, these cells can undergo thermal runaway, the point at which the cell becomes thermally unstable and results in hot gas, flame, electrolyte leakage, and in some cases explosion. The heat and fire associated with this type of event is generally violent and can subsequently cause damage to the surrounding system or present a dangerous risk to the personnel nearby. The space flight environment is especially sensitive to risks particularly when it involves potential for fire within the habitable volume of the International Space Station (ISS). In larger battery packs such as Robonaut 2 (R2), numerous Li-ion cells are placed in parallel-series configurations to obtain the required stack voltage and desired run-time or to meet specific power requirements. This raises a second and less obvious concern for batteries that undergo certification for space flight use: the joining quality at the resistance spot weld of battery cells to component wires/leads and battery tabs, bus bars or other electronic components and assemblies. Resistance spot welds undergo materials evaluation, visual inspection, conductivity (resistivity) testing, destructive peel testing, and metallurgical examination in accordance with applicable NASA Process Specifications. Welded components are cross-sectioned to ensure they are free of cracks or voids open to any exterior surface. Pore and voids contained within the weld zone but not open to an exterior surface, and are not determined to have sharp notch like characteristics, shall be acceptable. Depending on requirements, some battery cells are constructed of aluminum canisters while others are constructed of steel. Process specific weld schedules must be developed and certified for each possible joining combination. The aluminum canisters' positive terminals were particularly difficult to weld due to a bi-metal strip that comes ultrasonically pre-welded by the manufacturer. This was further complicated as the maximum electrode force was limited to low-electrode force to prevent deflection of the aluminum can during welding. Other Li-ion cells are comprised of smaller diameter cylindrical steel canisters which are inherently capable of handling greater force from the electrodes. Allowing higher-electrode forces aids greatly in insuring a consistent resistance network for the weld. Overall lessons learned: developing good jigs is critical to insure the parts and electrodes are planer to one another and the location of the weld sites remains accurate and repeatable; maintaining strict control over materials is critical--materials must be of a specific hardness and chemical composition to insure that a weld schedule is repeatable; accuracy of the die used to stamp the projections is critical and worth the investment; and proper seasoning of the electrodes is critical to producing consistent welds--once the electrodes have been properly seasoned, cleaning/dressing should be avoided until it is absolutely necessary.

Martinez, J. E.↗
NASA NTRS1994

Effusive silicic volcanism in the Central Andes: The Chao dacite and other young lavas of the Altiplano-Puna Volcanic Complex

The largest known Quaternary silicic lava body in the world is Cerro Chao in north Chile, a 14-km-long coulee with a volume of at least 26 cu km. It is the largest of a group of several closely similar dacitic lavas erupted during a recent (less than 100,000 year old) magmatic episode in the Altiplano-Puna Volcanic Complex (APVC; 21-24 deg S) of the Centra; Andean Volcanic Zone. The eruption of Chao proceeded in three phases. Phase 1 was explosive and produced approximately 1 cu km of coarse, nonwelded dacitic pumice deposits and later block and ash flows that form an apron in front of the main lava body. Phase 2 was dominantly effusive and erupted approximately 22.5 cu km of magma in the form of a composite coulee covering approximately 53 sq km with a 400-m-high flow front and a small cone of poorly expanded pumice around the vent. The lava is homogeneous with rare flow banding and vesicular tops and selvages. Ogives (flow ridges) reaching heights of 30 m form prominent features on its surface. Phase 3 produced a 6-km-long, 3-km-wide flow that emanated from a collapsed dome. Ogives are subdued, and the lava is glassier than that produced in previous phases. All the Chao products are crystal-rich high-K dacites and rhyodacites with phenocrysts of plagioclase, quartz, hornblende, biotite, sphene, rare snidine, and oxides. Phenocryst contents reach 40-60 vol % (vesicle free) in the main phase 2 lavas but are lower in the phase 1 (20-25%) and phase 3 (approximately 40%) lavas. Ovoid andesitic inclusions with vesicular interiors and chilled margins up to 10 cm are found in the later stages of phase 2 and compose up to 5% of the phase 3 lava. There is little evidence for preeruptive zonation of the magma body in composition, temperature (approximately 840 C), fO2 (19(exp -11), or water content, so we propose that eruption of the Chao complex was driven by intrusion of fresh, hot andesitic magma into a crystallizing and largely homogeneous body of dacitic magma. Morphological measurements suggest that the Chao lavas had internal plastic viscosities of 10(exp 10) to 10(exp 12) Pa s, apparent viscosities of 10(exp 9) Pa s, surface viscosities of 10(exp 15) to 10(exp 24) Pa s, and a yield strength of 8 x 10(exp 5) Pa. These estimates indicate that Chao would have exhibited largely similar rheological properties to other silicic lava extrusions, notwithstanding its high phenocryst content. We suggest that Chao's anomalous size is a function of both the relatively steep local slope (20 deg to 3 deg) and the available volume of magma. The eruption duration for Chao's emplacement is thought to have been about 100 to 150 years, with maximum effusion rates of about 25 cu m/s for short periods. Four other lavas in the vicinity with volumes of approximately 5 cu km closely resemble Chao and are probably comagnetic. The suite as a whole shares a petrologic and chemical similarity with the voluminous regional Tertiary to Pleistocene ignimbrites of the APVC and may be derived from a zone of silicic magmatism that is thought to have been active since the late Tertiary. Chao and the other young lavas may represent either the waning of this system or a new episode fueled by intrusions of mafic magma.

De Silva, S. L.↗
NASA NTRS2012

Remediation Technologies Eliminate Contaminants

All research and development has a story behind it, says Jacqueline Quinn, environmental engineer at Kennedy Space Center. For Quinn, one such story begins with the Saturn 1B launch stand at Kennedy and ends with a unique solution to a challenging environmental problem. Used in a number of Apollo missions and during the Skylab program, the Saturn 1B launch stand was dismantled following the transition to the Space Shuttle Program and stored in an open field at Kennedy. Decades later, the Center s Environmental Program Office discovered evidence of chemicals called polychlorinated biphenyls (PCBs) in the field s soil. The findings were puzzling since PCBs a toxin classified as a probable carcinogen by the Environmental Protection Agency (EPA) have been banned in the United States since 1979. Before the ban, PCBs were commonly used in transformer oils that leached into the ground when the oils were changed out and dumped near transformer sites, but there were no electrical transformers near the dismantled stand. It soon became apparent that the source of the PCBs was the launch stand itself. Prior to the ban, PCBs were used extensively in paints to add elasticity and other desirable characteristics. The PCB-laden paint on the Saturn 1B launch stand was flaking off into the field s soil. Nobody knew there were PCBs in the paint, says Quinn, noting that the ingredient was not monitored carefully when it was in use in 1960s. In fact, she says, the U.S. EPA was not even established until 1970, a year after Neil Armstrong first set foot on the Moon. Nobody knew any better at the time, Quinn says, but today, we have the responsibility to return any natural environmental media to as close to pristine a condition as possible. Quinn, fellow engineer Kathleen Loftin, and other Kennedy colleagues already had experience developing unprecedented solutions for environmental contamination; the team invented the emulsified zero-valent iron (EZVI) technology to safely treat groundwater tainted by chlorinated solvents once used to clean rocket engine components. The award-winning innovation (Spinoff 2010) is now NASA s most licensed technology to date. PCBs in paint presented a new challenge. Removing the launch stand for recycling proved a difficult operation; the toxic paint had to be fully stripped from the steel structure, a lengthy and costly process that required the stripped paint to be treated before disposal. Noting the lack of efficient, environmentally friendly options for dealing with PCBs, Quinn and her colleagues developed the Activated Metal Treatment System (AMTS). AMTS is a paste consisting of a solvent solution containing microscale particles of activated zero-valent metal. When applied to a painted surface, the paste extracts and degrades the PCBs into benign byproducts while leaving the paint on the structure. This provides a superior alternative to other methods for PCB remediation, such as stripping the paint or incinerating the structure, which prevents reuse and can release volatized PCBs into the air. Since its development, AMTS has proven to be a valuable solution for removing PCBs from paint, caulking, and various insulation and filler materials in older buildings, naval ships, and former munitions facilities where the presence of PCBs interferes with methods for removing trace explosive materials. Miles of potentially toxic caulking join sections of runways at airports. Any of these materials installed before 1979 potentially contain PCBs, Quinn says. "This is not just a NASA problem," she says. "It s a global problem."

Source record↗
NASA NTRS2008

Active Co-Storage of Cryogenic Propellants for Lunar Explortation

Long-term storage of cryogenic propellants is a critical requirement for NASA's effort to return to the moon. Liquid hydrogen and liquid oxygen provide the highest specific impulse of any practical chemical propulsion system, and thus provides the greatest payload mass per unit of launch mass. Future manned missions will require vehicles with the flexibility to remain in orbit for months, necessitating long-term storage of these cryogenic liquids. For decades cryogenic scientific satellites have used dual cryogens with different temperatures to cool instruments. This technology utilizes a higher temperature cryogen to provide a stage that efficiently intercepts a large fraction of the heat that would otherwise be incident on the lower temperature cryogen. This interception reduces the boil-off of the lower temperature cryogen and increasing the overall life-time of the mission. The Active Co-Storage concept is implemented similarly; the 101 K liquid oxygen thermally shields the 24 K liquid hydrogen. A thermal radiation shield that is linked to the liquid oxygen tank shrouds the liquid hydrogen tank, thereby preventing the liquid hydrogen tank from being directly exposed to the 300 K external environment. Modern cryocooler technology can eliminate the liquid oxygen boil-off and also cool the thermal radiation shield thereby reducing the liquid hydrogen boil-off to a small fraction of the unshielded rate. The thermal radiation shield can be a simple conductive shroud or a more sophisticated but lighter Broad Area Cooling (BAC) shroud. The paper describes the design impact of an active co-storage system for the Altair Descent Vehicle. This paper also compares the spacecraft-level impacts of the conductive shroud and the BAC shroud active co-storage concepts with a passive storage option in the context of the different scales of spacecraft that will be used for the lunar exploration effort - the Altair Ascent and Descent Vehicles, the Orion, and the Ares V Earth Departure Stage. The paper also reports on a subscale test of this active co-storage configuration. The test tank is 0.7 m in diameter, approximately one-third the dimension of tanks that would be needed in a lunar ascent module. A thin-walled fiberglass skirt supports and isolates the tank from a 100 K stage. A similar thin-walled skirt supports the lOOK stage from the ambient temperature structure. An aluminum shield with a heavy MLI blanket surrounds the tank and is attached at the 100 K stage. In this initial phase of the project, there is no tank on the 100 K stage, but it is actively cooled by a single-stage cryocooler similar in design to the one used on the RHESSI mission. The test configuration includes a number of innovative elements, including a helical support heat exchanger and an external thermodynamic vent/heat interception system. To avoid the complexity of an explosive gas handling system, testing will be done with liquid helium and liquid neon as simulant fluids. The properties of these fluids bracket the properties of liquid hydrogen. Instrumentation allows tank temperature and shield temperature profiles, tank liquid levels, and pressure drops through the flow lines, to be measured.

Mustafi, S.↗