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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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Contents include the following: Introduction to space-flight high power applications. Problem description for current designs. Test plan for NiCd and NiMn. Results and analysis. Conclusion.
The Fission Surface Power (FSP) Technology Demonstration Unit (TDU) is a system-level demonstration of fission power technology intended for use on manned missions to Mars. The Baseline FSP systems consists of a 190 kWt UO2 fast-spectrum reactor cooled by a primary pumped liquid metal loop. This liquid metal loop transfers heat to two intermediate liquid metal loops designed to isolate fission products in the primary loop from the balance of plant. The intermediate liquid metal loops transfer heat to four Stirling Power Conversion Units (PCU), each of which produce 12 kWe (48 kW total) and reject waste heat to two pumped water loops, which transfer the waste heat to titanium-water heat pipe radiators. The FSP TDU simulates a single leg of the baseline FSP system using an electrically heater core simulator, a single liquid metal loop, a single PCU, and a pumped water loop which rejects the waste heat to a Facility Cooling System (FCS). When operated at the nominal operating conditions (modified for low liquid metal flow) during TDU testing the PCU produced 8.9 kW of power at an efficiency of 21.7% resulting in a net system power of 8.1 kW and a system level efficiency of 17.2%. The reduction in PCU power from levels seen during electrically heated testing is the result of insufficient heat transfer from the NaK heater head to the Stirling acceptor, which could not be tested at Sunpower prior to delivery to GRC. The maximum PCU power of 10.4 kW was achieved at the maximum liquid metal temperature of 875 K, minimum water temperature of 350 K, 1.1 kg/s liquid metal flow, 0.39 kg/s water flow, and 15.0 mm amplitude at an efficiency of 23.3%. This resulted in a system net power of 9.7 kW and a system efficiency of 18.7 %.
Nuclear electric propulsion has been identified as an enabling technology for future NASA space science missions, such as the Jupiter Icy Moons Orbiter (JIMO) now under study. An important element of the nuclear electric propulsion spacecraft is the power conversion system, which converts the reactor heat to electrical power for use by the ion propulsion system and other spacecraft loads. The electrical integration of the power converter and ion thruster represents a key technical challenge in making nuclear electric propulsion technology possible. This technical hurdle was addressed extensively on December 1, 2003, when a closed- Brayton-cycle power-conversion unit was tested with a gridded ion thruster at the NASA Glenn Research Center. The test demonstrated end-to-end power throughput and marked the first-ever coupling of a Brayton turbo alternator and a gridded ion thruster, both of which are candidates for use on JIMO-type missions. The testing was conducted at Glenn's Vacuum Facility 6, where the Brayton unit was installed in the 3-m-diameter vacuum test port and the ion thruster was installed in the 7.6-m-diameter main chamber.
The Fission Surface Power (FSP) Technology Demonstration Unit (TDU) is a system-level demonstration of fission power technology intended for use on manned missions to Mars. The Baseline FSP systems consists of a 190 kWt UO2 fast-spectrum reactor cooled by a primary pumped liquid metal loop. This liquid metal loop transfers heat to two intermediate liquid metal loops designed to isolate fission products in the primary loop from the balance of plant. The intermediate liquid metal loops transfer heat to four Stirling Power Conversion Units (PCU), each of which produce 12 kWe (48 kW total) and reject waste heat to two pumped water loops, which transfer the waste heat to titanium-water heat pipe radiators. The FSP TDU simulates a single leg of the baseline FSP system using an electrically heater core simulator, a single liquid metal loop, a single PCU, and a pumped water loop which rejects the waste heat to a Facility Cooling System (FCS). When operated at the nominal operating conditions (modified for low liquid metal flow) during TDU testing the PCU produced 8.9 kW of power at an efficiency of 21.7 percent resulting in a net system power of 8.1 kW and a system level efficiency of 17.2 percent. The reduction in PCU power from levels seen during electrically heated testing is the result of insufficient heat transfer from the NaK heater head to the Stirling acceptor, which could not be tested at Sunpower prior to delivery to the NASA Glenn Research Center (GRC). The maximum PCU power of 10.4 kW was achieved at the maximum liquid metal temperature of 875 K, minimum water temperature of 350 K, 1.1 kg/s liquid metal flow, 0.39 kg/s water flow, and 15.0 mm amplitude at an efficiency of 23.3 percent. This resulted in a system net power of 9.7 kW and a system efficiency of 18.7 percent.
On-going testing of an 11 cell, 10.7 in. x 14 in. stack (about 1 kW) reached 2600 hours on steady load. Nonmetallic cooling plates and an automated electrolyte replenishment system continued to perform well. A 10 cell, 10.7 in. x 14 in. stack was constructed with a modified electrolyte matrix configuration for the purpose of reducing cell IR loss. The desired effect was achieved, but the general cell performance level was irregular. Evaluation is continuing. Preparations for a long term 25 cell, 13 in. x 23 in. test stack (about 4 kW) approached completion. Start up in early May 1984 is expected.
A national photovoltaic power systems test facility (of initial 10-kW peak power rating) is described. It consists of a solar array to generate electrical power, test-hardware for several alternate methods of power conversion, electrical energy storage systems, and an instrumentation and data acquisition system.
A series of tests were conducted in the space power facility to investigate the failure of the Centaur oxidizer boost pump during the Titan/Centaur proof flight February 11, 1974. The three basic objectives of the tests were: (1) demonstrate if an evaporative freezing type failure mechanism could have prevented the pump from operating, (2) determine if steam from the exhaust of one of the attitude control engine could have entered a pump seal cavity and caused the failure, and (3) obtain data on the heating effects of the exhaust plume from a hydrogen peroxide attitude control engine.
The NASA John H. Glenn Research Center (GRC) and the U.S. Department of Energy (DOE) are currently developing a high efficient, long life, free piston Stirling convertor for use as an advanced spacecraft power system for future NASA missions. As part of this development, a Stirling Technology Demonstrator Convertor (TDC), developed by Stirling Technology Company (STC) for DOE, was vibration tested at GRC s Structural Dynamics Laboratory (SDU7735) in November- December 1999. This testing demonstrated that the Stirling TDC is able to withstand the harsh random vibration (20 to 2000 Hertz) seen during a typical spacecraft launch and survive with no structural damage or functional power performance degradation, thereby enabling its usage in future spacecraft power systems. The Stirling Vibration Test Team at NASA GRC and STC personnel conducted tests on a single 55 electric watt TDC. The purpose was to characterize the TDC s structural response to vibration and determine if the TDC could survive the vibration criteria established by the Jet Propulsion Laboratory (JPL) for launch environments. The TDC was operated at full-stroke and full power conditions during the vibration testing. The TDC was tested in two orientations, with the direction of vibration parallel and perpendicular to the TDC s moving components (displacer and piston). The TDC successfully passed a series of sine and random vibration tests. The most severe test was a 12.3 Grms random vibration test (peak vibration level of 0.2 g2/Hz from 50 to 250 Hertz) with test durations of 3 minutes per axis. The random vibration test levels were chosen to simulate, with margin, the maximum anticipated launch vibration conditions. As a result of this very successful vibration testing and successful evaluations in other key technical readiness areas, the Stirling power system is now considered a viable technology for future application for NASA spacecraft missions. Possible usage of the Stirling power system would be to supply on- board electric spacecraft power for future NASA Deep-Space Missions, performing as an attractive alternative to Radioisotope Thermoelectric Generators (RTG). Usage of the Stirling technology is also being considered as the electric power source for future Mars rovers, whose mission profiles may exclude the use of photovoltaic power systems (such as exploring at high Martian latitudes or for missions of lengthy durations). GRC s Thermo-Mechanical Systems Branch (5490) provides Stirling technology expertise under a Space Act Agreement with the DOE. Additional vibration testing, by GRC s Structural Systems Dynamics Branch (7733, is planned to continue to demonstrate the Stirling power system s vibration capability as its technology and flight system designs progress.
Space power system material compatibility tests of selected refractory metal alloys with boiling potassium
Explorer XIII power-supply systems and test solar cells
Automated endurance testing of 2-15 kWe Brayton power conversion system, using rotating unit, heat exchanger, electronic voltage regulator, parasitic speed control
A base pressure data correlation study was conducted to define exhaust plume similarity parameters for use in Space Shuttle power-on launch vehicle aerodynamic test programs. Data correlations were performed for single bodies having, respectively, single and triple nozzle configurations and for a triple body configuration with single nozzles on each of the outside bodies. Base pressure similarity parameters were found to differ for the single nozzle and triple nozzle configurations. However, the correlation parameter for each was found to be a strong function of the nozzle exit momentum. Results of the data base evaluation are presented indicating an assessment of all data points. Analytical/experimental data comparisons were made for nozzle calibrations and correction factors derived, where indicated for use in nozzle exit plane data calculations.
The NASA Lewis Research Center (LeRC) has been testing free-piston Stirling engine/linear alternators (FPSE/LA) to develop advanced power convertors for space-based electrical power generation. Tests reported herein were performed to evaluate the interaction and transient behavior of FPSE/LA-based power systems with typical user loads. Both resistive and small induction motor loads were tested with the space power research engine (SPRE) power system. Tests showed that the control system could maintain constant long term voltage and stable periodic operation over a large range of engine operating parameters and loads. Modest resistive load changes were shown to cause relatively large voltage and, therefore, piston and displacer amplitude excursions. Starting a typical small induction motor was shown to cause large and, in some cases, deleterious voltage transients. The tests identified the need for more effective controls, if FPSE/LAs are to be used for stand-alone power systems. The tests also generated a large body of transient dynamic data useful for analysis code validation.
The application of statistical Design of Experiments (DOE) to helicopter wind tunnel testing was explored during two powered rotor wind tunnel entries during the summers of 2012 and 2013. These tests were performed jointly by the U.S. Army Aviation Development Directorate Joint Research Program Office and NASA Rotary Wing Project Office, currently the Revolutionary Vertical Lift Project, at NASA Langley Research Center located in Hampton, Virginia. Both entries were conducted in the 14- by 22-Foot Subsonic Tunnel with a small portion of the overall tests devoted to developing case studies of the DOE approach as it applies to powered rotor testing. A 16-47 times reduction in the number of data points required was estimated by comparing the DOE approach to conventional testing methods. The average error for the DOE surface response model for the OH-58F test was 0.95 percent and 4.06 percent for drag and download, respectively. The DOE surface response model of the Active Flow Control test captured the drag within 4.1 percent of measured data. The operational differences between the two testing approaches are identified, but did not prevent the safe operation of the powered rotor model throughout the DOE test matrices.
Wind-tunnel tests were made of a 1/25 scale model of the Martin JRM-1 airplane to determine: (1) The longitudinal stability and control characteristics of the JRM-1 model near the water and lateral and directional stability characteristics with power while moving on the surface of the water, the latter being useful for the design of tip floats; (2) The stability and stalling characteristics of the wing with a modified airfoil contour; (3) Stability characteristics of a hull of larger design gross weight; The test results indicated that the elevator was powerful enough to trim the original model in a landing configuration at any lift coefficient within the specified range of centers of gravity. The ground-board tests for evaluating the aerodynamic forces and moments on an airplane in a simulated cross wind indicate a high dihedral effect in the presence of the ground board and, consequently, during low-speed taxying and take-off, large overturning moments would result which would have to be overcome by the tip floats.
Impact tests on thermoelectric hardware for space power applications
Tests of a 250 horsepower proof-of-concept (POC) split torque face gear transmission were completed by The Boeing Company in Mesa, Arizona, while working under a Defense Advanced Research Projects Agency (DARPA) Technology Reinvestment Program (TRP) This report provides a summary of these cooperative tests, which were jointly funded by Boeing and DARPA Design, manufacture and testing of the scaled-power TRP split torque gearbox followed preliminary evaluations of the concept performed early in the program The testing demonstrated the theory of operation for the concentric, tapered face gear assembly The results showed that the use of floating pinions in a concentric face gear arrangement produces a nearly even torque split The POC split torque tests determined that, with some improvements, face gears can be applied effectively in a split torque configuration which yields significant weight, cost and reliability improvements over conventional designs.
A three-phase helical induction electromagnetic pump designed for the boiler feed pump of a potassium Rankine cycle space power system was developed and built. It was mounted in a liquid metal test loop and successfully tested over a range of potassium temperatures from 900 to 1400 F, flow rates from 0.75 to 4.85 lb/sec, developed pressures up to 340 psi, net positive suction head from 1 to 22 psi, and NaK coolant temperatures from 800 to 950 F. Maximum efficiency at design point conditions of 3.25 lb/sec flow rate, 240 psi developed head, 1000 F potassium inlet temperature, and 800 F NaK coolant inlet temperature was 16.3 percent. After the performance tests the pump was operated without any difficulty at design point for 10,000 hours, and then a limited number of repeat performance tests were made. There was no appreciable change in pump performance after 10,000 hours of operation. A supplementary series of tests using the quasi-square wave power output of a dc to three-phase ac inverter showed that the pump would operate without difficulty at a frequency as low as 25 Hz, with little loss in efficiency.