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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 235 records · Page 13

Characterizing The Internal Morphology of Transition Regions in Large-Scale Extrusion Deposition Additive Manufacturing

A dual-hopper feed system that was developed for the Big Area Additive Manufacturing (BAAM) system allows for transitioning between different materials while maintaining continuous deposition. This technique creates a step-change in material feedstock by switching the pellet feeding system to alternate which hopper is currently supplying material, allowing for multi-material construction. The step-change in feedstock material produces a transition region that is characterized by a compositional gradient and blended internal morphology. Initial cross-sectional imaging of the transition region revealed a non-homogenous blend of materials with distinct domains of each material, likely due to incomplete mixing within the screw. This study used a carbon fiber reinforced acrylonitrile butadiene styrene (CF-ABS) and an unfilled ABS to characterize the internal structure and to correlate it to mechanical performance by tracking microhardness across cross-sections of the transition region.

Brackett, James↗

NH 4 OH Looping with Membrane CO 2 Absorber and Distributed Stripper for Enhanced Algae Growth

The University of Kentucky Center for Applied Energy (UK CAER) has devised a unique, integrated CO2 capture and utilization technology. CO2 from coal-fired power generation flue gas is first captured at half the operating cost of a typical aqueous CO2 capture system (CCS), distributed in an aqueous stream and then fixed by algae in bioreactors where the algae production is increased by 50% over that with a typical intermittent nutrient feeding system. Lower CCS operating cost is achieved by eliminating the flue gas pretreatment step for cooling and SO2 removal, eliminating steam extraction from the power generation steam cycle for solvent regeneration, and eliminating CO2 compression. Higher algae production is achieved by continuous, just-in-time nutrient feed to the bioreactors directly from a distributed solvent regenerator, which maintains the bioreactor pH for optimum growth. The process starts with a uniquely configured membrane absorber, where the flue gas is indirectly contacted with an ammonium hydroxide (NH4OH) solvent. Dissolved NH3 is attractive for both CO2 capture and as an algae nutrient. For CO2 capture it is inexpensive, has a low regeneration energy, is thermally- and oxidatively-stable and has a viscosity near that of water, which makes is easy to transport. Numerous studies have shown that the scrubbing capacity of NH3 is approximately 0.9-1.2 kg of CO2/kg of NH3, with a CO2 removal efficiency of ~99% and half the solvent regeneration energy than that of 30 wt% MEA[1, 2, 3]. NH3 is attractive as an algae nutrient due to its low cost. The rich NH4OH solvent is pumped to a set of distributed regenerators which are co-located with the algae bioreactors. Solvent pumping, transport and distribution reduces the balance of plant (BOP) cost compared to a typical aqueous CCS related to the flue gas duct and boost fan required to transport the flue gas. The energy required for the distributed solvent regeneration is supplied by solar-thermal panels eliminating the need for steam extraction from the power generation steam cycle. After solvent regeneration, the product stream contains both the CO2 captured from the flue gas and volatized NH3 from the solvent. This product stream is fed directly to the bioreactors, eliminating the need for compression of the CO2 stream. The relative amounts of CO2 and NH3 in the product stream are adjusted and controlled by a controlling the regeneration conditions (pressure and temperature). The continuous feed of the right ratio of nutrients overcomes the typical inhibition of algae growth resulting from frequent pH swings in the bioreactor due to unbalanced (intermittent) feeding systems for CO2 and N. Also, because the regenerators will operate at pressure and be located in close proximity to the bioreactors, there is no worry about pressure drop when sparging the gas into the algae. Sparging produces small bubbles which is beneficial for mass transfer efficiency. One known challenge when using an NH4OH solvent is high NH3 emission. Hydrophobic membranes are used for CO2 capture using an aqueous NH3 solution[4, 5] without the direct contact between flue gas and aqueous solution. Additionally, UK CAER CO2 capture and utilization process manages NH3 slip in three extra measures. First, NH3 slip is minimized by working with minimal species partial pressure, which is proportional to the concentration in the liquid. Hence, lowering the capture solvent concentration will lower the NH3 partial pressure. Second, UK CAER’s previous work has demonstrated that the addition of Zn2+ into NH3 solutions to chelate the NH3 can reduce NH3 volatility. Third, the configuration of the membrane CO2 absorber utilizes condensed water from the flue gas to continually wash the gas-side of the membrane to reduce fouling and recapture NH3 slip. Additional details about the UK CAER unique, integrated CO2 capture and utilization technology will be presented along with technology development plans. Diao, N., Q. Li, and Z. Fang. 2004. Heat transfer in ground heat exchangers with groundwater advection. International Journal of Thermal Sciences. 43: 1203-1211, He, Q., M. Chen, L. Meng, K. Liu, and W. Pan. 2004. Study on Carbon Dioxide Removal from Flue Gas by Absorption of Aqueous Ammonia. Western Kentucky University. Yeh, A.C., and H. Bai. 1999. Comparison of ammonia and monoethanolamine solvents to reduce CO2 greenhouse gas emissions. The Science of the Total Environment. 228: 121-133, Villeneuve, K., D. Roizard, J.C. Remigy, M. Iacono, and S. Rode. 2018. CO2 capture by aqueous ammonia with hollow fiber membrane contactors: Gas phase reactions and performance stability. Separation and Purification Technology, 199: 189-197, Toro Molina, C., and C. Bouallou. 2016. Carbon dioxide absorption by ammonia intensified with membrane contactors. Clean Techn Environ Policy 18, 2133–2146 (2016)

20 FOSSIL-FUELED POWER PLANTS↗

Direct Air Capture and Utilization System (DACUS): FEED Study of CarbonCapture Inc. DAC and CarbonCure Utilization Technologies Using United States Steel’s Gary Works Plant Waste Heat

The effects of climate change are drastically perceived through the alarming rates of severe events such as flooding, hurricanes, wildfires, global temperature rise, sea-level rise, and ocean acidification etc., which has prompted the nations across the globe to control & reduce greenhouse gas (GHG) emissions, by massive adoption of electric vehicles, switching to renewal energy sources and promoting sustainable green products. However, recent climate studies have shown that such efforts will not be enough to keep the global temperature rising under 1.5° Celsius by the year 2050, which lead to the development of multiple Direct Air Capture (DAC) technologies. A DAC system extracts CO2 directly from the atmosphere, which is either stored underground for long term or utilized in other processes. The DACUS proposed at U.S. Steel Corporation’s Gary Works Plant in Gary, Indiana, will include an innovative DAC technology from CarbonCapture Inc. (CCI), which will be collocated and powered by waste heat from the steel plant to capture CO2 from ambient air, and CarbonCure CO2 utilization technology- which is a commercial technology that is already installed and in use by early adopters in more than 150 concrete mixing plants across North America and Asia. The University of Illinois at Urbana Champaign spearheaded this Front-End Engineering Design (FEED) study project, which was funded by US Department of Energy (DOE), aimed at designing a state-of-the art DACU system that can remove minimum of 5,000 tonne/year net CO2 from air (based on cradle-to-gate LCA) and converting the captured CO2 into low carbon intensity products. The off takers of the low Carbon product produced by the DACUS have also been identified near the steel plant in the Indiana, Illinois & Wisconsin Region. This creates a full CO2 value chain and provides a means to assess the impact of this holistic approach on job creation, regional economic impact, and environmental justice. DACUS is a promising new technology for reducing greenhouse gas in the atmosphere. Operation costs are minimized by locating CCI’s innovative DAC collector at United States Steel's Gary Works site where waste heat is utilized. Carbon emissions are minimized in CO2 transportation. The captured CO2 will be permanently sequestered in concrete used as construction material. This DOE funded FEED study demonstrates a full CO2 value chain for a DACU system, supported by an industrial facility. If this project were constructed, it would have a very positive and lasting impact on both the environment and the community.

42 ENGINEERING↗

Passive propellant system

A passive propellant acquisition and feed system is disclosed which acquires and feeds gas-free propellant in low or zero-g environments during orbital maneuvers and retains this propellant under high axially directed acceleration such as may be experienced during launch of a space vehicle and orbit-to-orbit transfer is described. The propellant system includes a dual compartment propellant tank with independent surface tension acquisition channels in each compartment to provide gas-free flow of pressurized liquid propellant from one compartment to the other in one direction only.

Hess, D. A.↗

Evaluation of externally heated pulsed MPD thruster cathodes

Recent interest in solar electric orbit transfer vehicles (SEOTV's) has prompted a reevaluation of pulsed magnetoplasmadynamic (MPD) thruster systems due to their ease of power scaling and reduced test facility requirements. In this work the use of externally heated cathodes was examined in order to extend the lifetime of these thrusters to the 1000 to 3000 hours required for SEOTV missions. A pulsed MPD thruster test facility was assembled, including a pulse-forming network (PFN), ignitor supply and propellant feed system. Results of cold cathode tests used to validate the facility, PFN, and propellant feed system design are presented, as well as a preliminary evaluation of externally heated impregnated tungsten cathodes. The cold cathode thruster was operated on both argon and nitrogen propellants at peak discharge power levels up to 300 kW. The results confirmed proper operation of the pulsed thruster test facility, and indicated that large amounts of gas were evolved from the BaO-CaO-Al2O3 cathodes during activation. Comparison of the expected space charge limited current with the measured vacuum current when using the heated cathode indicate that either that a large temperature difference existed between the heater and the cathode or that the surface work function was higher than expected.

Myers, Roger M.↗

Capillary Liquid Acquisition Device Heat Entrapment

Cryogenic liquid acquisition devices (LADs) for space-based propulsion interface directly with the feed system, which can be a significant heat leak source. Further, the accumulation of thermal energy within LAD channels can lead to the loss of subcooled propellant conditions and result in feed system cavitation during propellant outflow. Therefore, the fundamental question addressed by this program was: To what degree is natural convection in a cryogenic liquid constrained by the capillary screen meshes envisioned for LADs? Testing was first conducted with water as the test fluid, followed by LN2 tests. In either case, the basic experimental approach was to heat the bottom of a cylindrical column of test fluid to establish stratification patterns measured by temperature sensors located above and below a horizontal screen barrier position. Experimentation was performed without barriers, with screens, and with a solid barrier. The two screen meshes tested were those typically used by LAD designers, 200x1400 and 325x2300, both with Twill Dutch Weave. Upon consideration of both the water and LN2 data, it was concluded that heat transfer across the screen meshes was dependent upon barrier thermal conductivity and that the capillary screen meshes were impervious to natural convection currents.

Bolshinskiy, L. G.↗

Cryogenic Capillary Screen Heat Entrapment

Cryogenic liquid acquisition devices (LADs) for space-based propulsion interface directly with the feed system, which can be a significant heat leak source. Further, the accumulation of thermal energy within LAD channels can lead to the loss of sub-cooled propellant conditions and result in feed system cavitation during propellant outflow. Therefore, the fundamental question addressed by this program was: "To what degree is natural convection in a cryogenic liquid constrained by the capillary screen meshes envisioned for LADs.?"Testing was first conducted with water as the test fluid, followed by LN2 tests. In either case, the basic experimental approach was to heat the bottom of a cylindrical column of test fluid to establish stratification patterns measured by temperature sensors located above and below a horizontal screen barrier position. Experimentation was performed without barriers, with screens, and with a solid barrier. The two screen meshes tested were those typically used by LAD designers, "200x1400" and "325x2300", both with Twill Dutch Weave. Upon consideration of both the water and LN2 data it was concluded that heat transfer across the screen meshes was dependent upon barrier thermal conductivity and that the capillary screen meshes were impervious to natural convection currents.

Bolshinskiy, L.G.↗

Multibeam Antenna Design and Development for NASA Advanced Communications Technology Satellite (ACTS)

The design of the ACTS multibeam antenna is described, and its performance is evaluated. The multibeam antenna is designed to cover the continential U.S. and provides three fixed spot beams for high burst rate operations and two scanning beams for low burst rate operations. The antenna has one main reflector, a dual polarized subreflector, and two orthogonal feed assemblies. The feed system is to receive a linearly polarized communication signal from 28.9-30.0 GHz and to provide the elevation and azimuth error tracking signals at 29.975 GHz with a 0.01 deg tracking accuracy. The feed system uses a single multiflare conical horn and a multimode coupler to provide a symmetric primary pattern for the communication signal. The sidelobe characteristics of the reflector, and the relation between the sidelobe level and surface distortion are studied. It is noted that the performance measurements for the multibeam antenna correlate well with predictions for secondary patterns and scan characteristics.

Choung, Youn H.↗

Propulsion System Development for the Iodine Satellite (iSAT) Demonstration Mission

The development and testing of a 200-W iodine-fed Hall thruster propulsion system that will be flown on a 12-U CubeSat is described. The switch in propellant from more traditional xenon gas to solid iodine yields the advantage of high density, low pressure propellant storage but introduces new requirements that must be addressed in the design and operation of the propulsion system. The thruster materials have been modified from a previously-flown xenon Hall thruster to make it compatible with iodine vapor. The cathode incorporated into this design additionally requires little or no heating to initiate the discharge, reducing the power needed to start the thruster. The feed system produces iodine vapor in the propellant reservoir through sublimation and then controls the flow to the anode and cathode of the thruster using a pair of proportional flow control valves. The propellant feeding process is controlled by the power processing unit, with feedback control on the anode flow rate provided through a measure of the thruster discharge current. Thermal modeling indicates that it may be difficult to sufficiently heat the iodine if it loses contact with the propellant reservoir walls, serving to motivate future testing of that scenario to verify the modeling result and develop potential mitigation strategies. Preliminary, short-duration materials testing has thus-far indicated that several materials may be acceptable for prolonged contact with iodine vapor, motivating longer-duration testing. A propellant loading procedure is presented that aims to minimize the contaminants in the feed system and propellant reservoir. Finally, an 80-hour duration test being performed to gain experience operating the thruster over long durations and multiple restarts is discussed.

Polzin, Kurt A.↗

Double time lag combustion instability model for bipropellant rocket engines

A bipropellant stability model is presented in which feed system inertance and capacitance are treated along with injection pressure drop and distinctly different propellant time lags. The model is essentially an extension of Crocco's and Cheng's monopropellant model to the bipropellant case assuming that the feed system inertance and capacitance along with the resistance are located at the injector. The neutral stability boundaries are computed in terms of these parameters to demonstrate the interaction among them.

Liu, C. K.↗

Characterization of Low-Frequency Combustion Stability of the Fastrac Engine

A series of tests were conducted to measure the combustion performance of the Fastrac engine thrust chamber. During mainstage, the thrust chamber exhibited no large-amplitude chamber pressure oscillations that could be identified as low-frequency combustion instability or 'chug'. However, during start-up and shutdown, the thrust chamber very briefly exhibited large-amplitude chamber pressure oscillations that were identified as chug. These instabilities during start-up and shutdown were regarded as benign due to their brevity. Linear models of the thrust chamber and the propellant feed systems were formulated for both the thrust chamber component tests and the flight engine tests. These linear models determined the frequency and decay rate of chamber pressure oscillations given the design and operating conditions of the thrust chamber and feed system. The frequency of chamber pressure oscillations determined from the model closely matched the frequency of low-amplitude, low-frequency chamber pressure oscillations exhibited in some of the later thrust chamber mainstage tests. The decay rate of the chamber pressure oscillations determined from the models indicated that these low-frequency oscillations were stable. Likewise, the decay rate, determined from the model of the flight engine tests indicated that the low-frequency chamber pressure oscillations would be stable.

Rocker, Marvin↗

Mass Flow Rate and Isolation Characteristics of Injectors for Use with Self-Pressurizing Oxidizers in Hybrid Rockets

Self-pressurizing rocket propellants are currently gaining popularity in the propulsion community, particularly in hybrid rocket applications. Due to their high vapor pressure, these propellants can be driven out of a storage tank without the need for complicated pressurization systems or turbopumps, greatly minimizing the overall system complexity and mass. Nitrous oxide (N2O) is the most commonly used self pressurizing oxidizer in hybrid rockets because it has a vapor pressure of approximately 730 pounds per square inch (5.03 megapascals) at room temperature and is highly storable. However, it can be difficult to model the feed system with these propellants due to the presence of two-phase flow, especially in the injector. An experimental test apparatus was developed in order to study the performance of nitrous oxide injectors over a wide range of operating conditions. Mass flow rate characterization has been performed to determine the effects of injector geometry and propellant sub-cooling (pressurization). It has been shown that rounded and chamfered inlets provide nearly identical mass flow rate improvement in comparison to square edged orifices. A particular emphasis has been placed on identifying the critical flow regime, where the flow rate is independent of backpressure (similar to choking). For a simple orifice style injector, it has been demonstrated that critical flow occurs when the downstream pressure falls sufficiently below the vapor pressure, ensuring bulk vapor formation within the injector element. It has been proposed to leverage the insensitivity of critical mass flow rate to downstream pressure as a means of preventing the occurrence of feed system coupled combustion instabilities in hybrid rockets utilizing nitrous oxide. Additionally, observations indicate that the existence of two-phase flow can attenuate pressure fluctuations traveling upstream through the injector, providing a degree of isolation between the feed line and downstream pressure disturbances. In consideration of safety, carbon dioxide (CO2) has been used as an analog to nitrous oxide in many of these studies. It has been observed experimentally that carbon dioxide serves as a good analog to nitrous oxide in both the single-phase and two-phase flow regimes.

Oxidizer↗

Testing Fundamental Properties of Ionic Liquids for Colloid Microthruster Applications

NASA's New Millennium Program is scheduled to test a Disturbance Reduction System (DRS) on Space Technology 7 (ST7) as part of the European Space Agency's (ESA's) LISA Pathfinder Mission in late 2009. Colloid Micronewton Thrusters (CMNTs) will be used to counteract forces, mainly solar photon pressure, that could disturb gravitational reference sensors as part of the DRS. The micronewton thrusters use an ionic liquid, a room temperature molten salt, as propellant. The ionic liquid has a number of unusual properties that have a direct impact on thruster design. One of the most important issues is bubble formation before and during operation, especially during rapid pressure transitions from atmospheric to vacuum conditions. Bubbles have been observed in the feed system causing variations in propellant flow rate that can adversely affect thruster control. Bubbles in the feed system can also increase the likelihood that propellant will spray onto surfaces that can eventually lead to shorting high voltage electrodes. Two approaches, reducing the probability of bubble formation and removing bubbles with a new bubble eliminator device in the flow system, were investigated at Busek Co., Inc. and the Jet Propulsion Laboratory (JPL) to determine the effectiveness of both approaches. Results show that bubble formation is mainly caused by operation at low pressure and volatile contaminants in the propellant coming out of solution. A specification for the maximum tolerable level of contamination has been developed, and procedures for providing system cleanliness have been tested and implemented. The bubble eliminator device has also been tested successfully and has been implemented in recent thruster designs at Busek. This paper focuses on the propellant testing work at JPL, including testing of a breadboard level bubble eliminator device.

bubble formation↗

Robotically Assembled Aerospace Structures: Digital Material Assembly using a Gantry-Type Assembler

This paper evaluates the development of automated assembly techniques for discrete lattice structures using a multi-axis gantry type CNC machine. These lattices are made of discrete components called digital materials. We present the development of a specialized end effector that works in conjunction with the CNC machine to assemble these lattices. With this configuration we are able to place voxels at a rate of 1.5 per minute. The scalability of digital material structures due to the incremental modular assembly is one of its key traits and an important metric of interest. We investigate the build times of a 5x5 beam structure on the scale of 1 meter (325 parts), 10 meters (3,250 parts), and 30 meters (9,750 parts). Utilizing the current configuration with a single end effector, performing serial assembly with a globally fixed feed station at the edge of the build volume, the build time increases according to a scaling law of n4, where n is the build scale. Build times can be reduced significantly by integrating feed systems into the gantry itself, resulting in a scaling law of n3. A completely serial assembly process will encounter time limitations as build scale increases. Automated assembly for digital materials can assemble high performance structures from discrete parts, and techniques such as built in feed systems, parallelization, and optimization of the fastening process will yield much higher throughput.

Mechanical Structure↗

Robotically Assembled Aerospace Structures: Digital Material Assembly using a Gantry-Type Assembler

This paper evaluates the development of automated assembly techniques for discrete lattice structures using a multi-axis gantry type CNC machine. These lattices are made of discrete components called "digital materials." We present the development of a specialized end effector that works in conjunction with the CNC machine to assemble these lattices. With this configuration we are able to place voxels at a rate of 1.5 per minute. The scalability of digital material structures due to the incremental modular assembly is one of its key traits and an important metric of interest. We investigate the build times of a 5x5 beam structure on the scale of 1 meter (325 parts), 10 meters (3,250 parts), and 30 meters (9,750 parts). Utilizing the current configuration with a single end effector, performing serial assembly with a globally fixed feed station at the edge of the build volume, the build time increases according to a scaling law of n4, where n is the build scale. Build times can be reduced significantly by integrating feed systems into the gantry itself, resulting in a scaling law of n3. A completely serial assembly process will encounter time limitations as build scale increases. Automated assembly for digital materials can assemble high performance structures from discrete parts, and techniques such as built in feed systems, parallelization, and optimization of the fastening process will yield much higher throughput.

Manufacturing↗

Antenna feeds and receivers

The results of 7 months of study, tradeoffs, test design, and fabrication are presented for an effort to modify three ground stations in support of the ATS-F program. As a result of tests on the existing feed system of the Rosman No. 2 85-foot antenna and on the transportable ground station (TGS) 40-foot antenna, it was determined that modifications of the existing phase-compensating rotary joints at Rosman are feasible. Other components must be completely replaced. In the TGS antenna feed system, it was found to be feasible to broadband the existing monopulse comparator by adding simple irises and posts; both spare and active comparators were modified. The TGS polarizers can be broadbanded by adjusting existing pins and adding two new pins. These modifications are also directly applicable to the Mojave 40-foot antenna. Detailed electrical and mechanical characteristics are presented for the new equipment, as well as installation plans to enable NASA and its contractors to determine the adequacy of the designs and to confirm that planned locations are both available and compatible with planned operational concepts.

Mccall, B.↗

Analyses of Longitudinal Mode Combustion Instability in J-2X Gas Generator Development

The National Aeronautics and Space Administration (NASA) and Pratt & Whitney Rocketdyne are developing a liquid oxygen/liquid hydrogen rocket engine for future upper stage and trans-lunar applications. This engine, designated the J-2X, is a higher pressure, higher thrust variant of the Apollo-era J-2 engine. The contract for development was let to Pratt & Whitney Rocketdyne in 2006. Over the past several years, development of the gas generator for the J-2X engine has progressed through a variety of workhorse injector, chamber, and feed system configurations on the component test stand at the NASA Marshall Space Flight Center (MSFC). Several of the initial configurations resulted in combustion instability of the workhorse gas generator assembly at a frequency near the first longitudinal mode of the combustion chamber. In this paper, several aspects of these combustion instabilities are discussed, including injector, combustion chamber, feed system, and nozzle influences. To ensure elimination of the instabilities at the engine level, and to understand the stability margin, the gas generator system has been modeled at the NASA MSFC with two techniques, the Rocket Combustor Interaction Design and Analysis (ROCCID) code and a lumped-parameter MATLAB(TradeMark) model created as an alternative calculation to the ROCCID methodology. To correctly predict the instability characteristics of all the chamber and injector geometries and test conditions as a whole, several inputs to the submodels in ROCCID and the MATLAB(TradeMark) model were modified. Extensive sensitivity calculations were conducted to determine how to model and anchor a lumped-parameter injector response, and finite-element and acoustic analyses were conducted on several complicated combustion chamber geometries to determine how to model and anchor the chamber response. These modifications and their ramification for future stability analyses of this type are discussed.

Hulka, J. R.↗

Use of Atomic Fuels for Rocket-Powered Launch Vehicles Analyzed

At the NASA Lewis Research Center, the launch vehicle gross lift-off weight (GLOW) was analyzed for solid particle feed systems that use high-energy density atomic propellants (ref. 1). The analyses covered several propellant combinations, including atoms of aluminum, boron, carbon, and hydrogen stored in a solid cryogenic particle, with a cryogenic liquid as the carrier fluid. Several different weight percents for the liquid carrier were investigated, and the GLOW values of vehicles using the solid particle feed systems were compared with that of a conventional oxygen/hydrogen (O2/H2) propellant vehicle. Atomic propellants, such as boron, carbon, and hydrogen, have an enormous potential for high specific impulse Isp operation, and their pursuit has been a topic of great interest for decades. Recent and continuing advances in the understanding of matter, the development of new technologies for simulating matter at its most basic level, and manipulations of matter through microtechnology and nanotechnology will no doubt create a bright future for atomic propellants and an exciting one for the researchers exploring this technology.

Palaszewski, Bryan A.↗