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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

Load balancing for multi-beam additive manufacturing systems

As powder bed fusion (PBF) additive manufacturing (AM) becomes a more mature field, system configurations are gradually moving away from the classic single heat source, layer-by-layer system configurations towards unconventional system configurations that offer higher throughput. Higher throughput systems allow PBF systems to be considered for a larger variety of industrial applications. However, the inclusion of multiple heat sources, or beams, also increases the complexity of the control schemes needed. For multi-beam systems with overlapping fields of view, the distribution of workload, or load balancing, across these beams directly affects the total print time for a build. Additionally, the probability of any beam failing in a multi-beam system increases with the number of beams. While manual methods of load balancing and dealing with beam failures are reasonable for current generation multi-beam systems, as system configurations become more complex, manual methods will become prohibitively inefficient. Here, this paper introduces two different ways to load balance multi-beam systems of various configuration types, regardless of their complexity, which are highly performant. A consequence of this performance is the enablement of on-the-fly load balancing in the event a beam fails, thus improving system robustness.

36 MATERIALS SCIENCE↗

Numerical and Experimental Study of a Novel Additively Manufactured Metal-Polymer Composite Heat-Exchanger for Liquid Cooling Electronics

In order to meet increasing power-dissipation requirements of the electronics industry, compact, low-cost, and lightweight heat exchangers (HXs) are desired. With proper design, materials, and manufacture, polymer composite heat exchangers could meet these requirements. This paper presents a novel crossflow air-to-water, low-cost, and lightweight metal-polymer composite HX. This HX, which is entirely additively manufactured, utilizes a novel cross-media approach that provides direct heat exchange between air and liquid sides by using connecting fins. A robust numerical model was developed, which includes the dimensional effects of additive manufacturing. The study consists of a simplified 3D CFD model based on ellipsoidal-shaped staggered tube banks for the laminar range. It then uses an analytical approach to compute entire HX performance. The model is validated experimentally within 8% for thermal performance, 12% for air-side impedance, and 18% for water-side impedance. Finally, HX is compared with a conventional CPU radiator and performs within 10% of the conventional unit for reasonable flow rates and pressure-drop ranges. Moreover, HX also provides added design and cost advantages over the conventional unit, which makes the HX a potential candidate for electronic cooling applications.

30 DIRECT ENERGY CONVERSION↗

Hydrothermal corrosion and steam oxidation behavior comparison of UAM and conventional Zry-4

Here, hydrothermal corrosion and steam exposures on ultrasonic additively manufactured (UAM) Zircaloy-4 (Zry-4) specimens were conducted to compare to wrought Zry-4 performance in both simulated pressurized water reactor (PWR) operation (330°C, 15 MPa, <50 ppb oxygen, 500h) and representative accident conditions (100% H 2 O(g) at 700, 900, and 1100°C for up to 1h). UAM Zry-4 specimens showed 50% higher mass gain in PWR conditions and 50-80% more mass gain in steam oxidation due to internal oxidation between build layers in both cases. UAM Zry-4 in 900°C steam showed breakaway oxidation leading to sample deformation. Titanium used as an interlayer in the UAM process was detected in the substrate after the 1100°C exposure. Additional experiments to better link as-built defects to oxidation behavior are needed.

36 MATERIALS SCIENCE↗

Production of microchannel plates using nano-scale additive manufacturing

Microchannel plate (MCP) detectors have been the workhorse detector for many applications, including space borne ultra-violet imaging and spectrographic instruments. Recent advances in additive manufacturing (AM) have enabled fabrication of complex structures with nano-scale resolution facilitating the production of highly customizable MCPs. Using AM to produce MCPs potentially has many advantages over traditional fused glass substrates, including better material control (e.g., more robust glasses or ceramics), better control of microscopic features (e.g., unique pore geometries to improve performance), and better control of macroscopic features (e.g., printing precision curved surfaces for focal plane matching). Through a collaboration with industry, national laboratory, and university partners, small format microcapillary array substrates were produced using a standard polymer photoresin. In conclusion, these substrates were functionalized using atomic layer deposition and their performance was compared to current state-of-the-art Pb-glass and borosilicate-glass MCPs.

36 MATERIALS SCIENCE↗

Additive Manufacturing of Frequency-Agile W-Band Packaging

Abstract —In this paper we demonstrate a fully additively manufactured packaged W-band amplifier with integrated bypass capacitors. This package was fabricated using a chip-first approach and aerosol jet printing. Package substrates (dielectrics), conductors and interconnects are printed around a bare die attached to a carrier. This package uses shaped ramp interconnects, allowing for frequency agnostic package performance of the interconnect with no impedance discontinuity, within the physical limits of the printer. High dielectric constant thin films of a polymer-matrix nanocomposite for bypass capacitors were printed using multi-material aerosol jet printing. The maximum measured packaged gain is 14.9 dB in the W-band, compared to the maximum bare die gain of 15.5 dB in the same frequency range. From 75 - 92 GHz, the average package loss is 1.1 dB including 3 mm transmission line, interconnects, and a GSG launch structure correlating to an average loss of 0.37 dB/mm.

Additive manufacturing, aerosol jet printing, hete↗

A Market Feedback Framework for Improved Estimates of the Arbitrage Value of Energy Storage Using Price-Taker Models

Price-taker (PT) models are often used to assess the potential value or revenue of energy arbitrage opportunities for energy storage in wholesale markets. But as greater amounts of energy storage are deployed on the grid, current PT models fail to predict the effects that energy storage itself can have on market prices. This can lead to an overestimation of the economic value of storage and an inability to capture price suppression. In this paper, we propose the use of a modified PT model to simulate the impact of increased storage deployment on energy prices and the resulting impact on revenue. Our method uses a gradient-boosting regressor to estimate the impact on prices, and we apply our method on historical price data from the PJM and California Independent System Operator wholesale markets. We use this approach to explore possible causes of electricity price suppression that occur from storage capacity additions, which is generally not possible with PT models.

arbitrage↗

Effects of Pectinase on Bacterial Succession during Hemp Retting

Pectinase accelerates hemp retting. An elevated temperature during the enzymatic action is favorable for bacterial colonization. Industrial hemp (Cannabis sativa L.) bast fiber was retted in a 40 °C water bath under four different conditions: water retting, pectinase retting, bacterial retting, and bacterial retting with the presence of pectinase. Bacterial communities were sampled from the retting liquid of each condition at the beginning of retting and on days 1, 3, and 5. The bacterial successions were identified by 16S rRNA gene metagenomic sequencing. The results showed that Bacillaceae dominated the hemp retting conditions containing 1% (m/v) pectinase, suggesting that pectinase can manipulate the bacterial community succession by changing the nutrients available to bacteria through the breakdown of pectin. Micromorphological analysis also observed the degradation of a gum-like substance and the aggregation of bacteria with the addition of pectinase.

Engineering↗

Parametric flutter studies of an arrow-wing configuration: Some early results

Some early experimental results from a combined experimental and analytical study being conducted at NASA-Langley of the transonic flutter characterisitics of a generic arrow wing configuration are presented. The planned study includes the parametric variation of a variety of structural and geometric characteristics. Presented here are flutter results of the basic arrow wing, for the basic wing with the addition of two simulated lower-surface-mounted engine nacelles, and for the basic wing with the addition of both the fin and the engine nacelles.

Durham, Michael H.↗

Absolute magnitude estimation and relative judgement approaches to subjective workload assessment

Two rating scale techniques employing an absolute magnitude estimation method, were compared to a relative judgment method for assessing subjective workload. One of the absolute estimation techniques used was an unidimensional overall workload scale and the other was the multidimensional NASA-Task Load Index technique. Thomas Saaty's Analytic Hierarchy Process was the unidimensional relative judgment method used. These techniques were used to assess the subjective workload of various single- and dual-tracking conditions. The validity of the techniques was defined as their ability to detect the same phenomena observed in the tracking performance. Reliability was assessed by calculating test-retest correlations. Within the context of the experiment, the Saaty Analytic Hierarchy Process was found to be superior in validity and reliability. These findings suggest that the relative judgment method would be an effective addition to the currently available subjective workload assessment techniques.

Vidulich, Michael A.↗

Helium 3/Helium 4 dilution cryocooler for space

Prototype dilution cryocoolers based on dilution refrigeration and adiabatic demagnetization refrigeration (ADR) cycles were designed, constructed, and tested. Although devices the devices did not operate as fully functional dilution cryocoolers, important information was gathered. The porous metal phase separator was demonstrated to operate in the -1-g configuration; this phase separation is the critical element in the He-3 circulation dilution cryocooler. Improvements in instrumentation needed for additional tests and development were identified.

Hendricks, John B.↗

Evolutionary Cell Computing: From Protocells to Self-Organized Computing

On the path from inanimate to animate matter, a key step was the self-organization of molecules into protocells - the earliest ancestors of contemporary cells. Studies of the properties of protocells and the mechanisms by which they maintained themselves and reproduced are an important part of astrobiology. These studies also have the potential to greatly impact research in nanotechnology and computer science. Previous studies of protocells have focussed on self-replication. In these systems, Darwinian evolution occurs through a series of small alterations to functional molecules whose identities are stored. Protocells, however, may have been incapable of such storage. We hypothesize that under such conditions, the replication of functions and their interrelationships, rather than the precise identities of the functional molecules, is sufficient for survival and evolution. This process is called non-genomic evolution. Recent breakthroughs in experimental protein chemistry have opened the gates for experimental tests of non-genomic evolution. On the basis of these achievements, we have developed a stochastic model for examining the evolutionary potential of non-genomic systems. In this model, the formation and destruction (hydrolysis) of bonds joining amino acids in proteins occur through catalyzed, albeit possibly inefficient, pathways. Each protein can act as a substrate for polymerization or hydrolysis, or as a catalyst of these chemical reactions. When a protein is hydrolyzed to form two new proteins, or two proteins are joined into a single protein, the catalytic abilities of the product proteins are related to the catalytic abilities of the reactants. We will demonstrate that the catalytic capabilities of such a system can increase. Its evolutionary potential is dependent upon the competition between the formation of bond-forming and bond-cutting catalysts. The degree to which hydrolysis preferentially affects bonds in less efficient, and therefore less well-ordered, peptides is also critical to evolution of a non-genomic system. Based on these results, a new computational object called a "molnet" is defined. Like a neural network, it is formed of interconnected units that send "signals" to each other. Like molecules, neural networks have a specific function once their structure is defined. The difference between a molnet and traditional neural networks, is that input to molnets is not simply passed along and processed from input to output units, but rather it is utilized to form and break connections(bonds), and thus to form new structures. Molnets represent a powerful tool that can be used to understand the conditions under which chemical systems can form large molecules, such as proteins, and display ever more complex functions. This has direct applications, for example to the design of smart,synthetic fabrics. Additional information is contained in the original.

Colombano, Silvano↗

Adaptive Error Estimation in Linearized Ocean General Circulation Models

Data assimilation methods are routinely used in oceanography. The statistics of the model and measurement errors need to be specified a priori. This study addresses the problem of estimating model and measurement error statistics from observations. We start by testing innovation based methods of adaptive error estimation with low-dimensional models in the North Pacific (5-60 deg N, 132-252 deg E) to TOPEX/POSEIDON (TIP) sea level anomaly data, acoustic tomography data from the ATOC project, and the MIT General Circulation Model (GCM). A reduced state linear model that describes large scale internal (baroclinic) error dynamics is used. The methods are shown to be sensitive to the initial guess for the error statistics and the type of observations. A new off-line approach is developed, the covariance matching approach (CMA), where covariance matrices of model-data residuals are "matched" to their theoretical expectations using familiar least squares methods. This method uses observations directly instead of the innovations sequence and is shown to be related to the MT method and the method of Fu et al. (1993). Twin experiments using the same linearized MIT GCM suggest that altimetric data are ill-suited to the estimation of internal GCM errors, but that such estimates can in theory be obtained using acoustic data. The CMA is then applied to T/P sea level anomaly data and a linearization of a global GFDL GCM which uses two vertical modes. We show that the CMA method can be used with a global model and a global data set, and that the estimates of the error statistics are robust. We show that the fraction of the GCM-T/P residual variance explained by the model error is larger than that derived in Fukumori et al.(1999) with the method of Fu et al.(1993). Most of the model error is explained by the barotropic mode. However, we find that impact of the change in the error statistics on the data assimilation estimates is very small. This is explained by the large representation error, i.e. the dominance of the mesoscale eddies in the T/P signal, which are not part of the 21 by 1" GCM. Therefore, the impact of the observations on the assimilation is very small even after the adjustment of the error statistics. This work demonstrates that simult&neous estimation of the model and measurement error statistics for data assimilation with global ocean data sets and linearized GCMs is possible. However, the error covariance estimation problem is in general highly underdetermined, much more so than the state estimation problem. In other words there exist a very large number of statistical models that can be made consistent with the available data. Therefore, methods for obtaining quantitative error estimates, powerful though they may be, cannot replace physical insight. Used in the right context, as a tool for guiding the choice of a small number of model error parameters, covariance matching can be a useful addition to the repertory of tools available to oceanographers.

Chechelnitsky, Michael Y.↗

Asteroids: Does Space Weathering Matter?

The interpretive calibrations and methodologies used to extract mineralogy from asteroidal spectra appear to remain valid until the space weathering process is advanced to a degree which appears to be rare or absent on asteroid surfaces. Additional information is contained in the original extended abstract.

Gaffey, Michael J.↗

Models of Protocellular Structure, Function and Evolution

In the absence of any record of protocells, the most direct way to test our understanding of the origin of cellular life is to construct laboratory models that capture important features of protocellular systems. Such efforts are currently underway in a collaborative project between NASA-Ames, Harvard Medical School and University of California. They are accompanied by computational studies aimed at explaining self-organization of simple molecules into ordered structures. The centerpiece of this project is a method for the in vitro evolution of protein enzymes toward arbitrary catalytic targets. A similar approach has already been developed for nucleic acids in which a small number of functional molecules are selected from a large, random population of candidates. The selected molecules are next vastly multiplied using the polymerase chain reaction. A mutagenic approach, in which the sequences of selected molecules are randomly altered, can yield further improvements in performance or alterations of specificities. Unfortunately, the catalytic potential of nucleic acids is rather limited. Proteins are more catalytically capable but cannot be directly amplified. In the new technique, this problem is circumvented by covalently linking each protein of the initial, diverse, pool to the RNA sequence that codes for it. Then, selection is performed on the proteins, but the nucleic acids are replicated. Additional information is contained in the original extended abstract.

New, Michael H.↗

Risk-Based Probabilistic Approach to Aeropropulsion System Assessment

In an era of shrinking development budgets and resources, where there is also an emphasis on reducing the product development cycle, the role of system assessment, performed in the early stages of an engine development program, becomes very critical to the successful development of new aeropropulsion systems. A reliable system assessment not only helps to identify the best propulsion system concept among several candidates, it can also identify which technologies are worth pursuing. This is particularly important for advanced aeropropulsion technology development programs, which require an enormous amount of resources. In the current practice of deterministic, or point-design, approaches, the uncertainties of design variables are either unaccounted for or accounted for by safety factors. This could often result in an assessment with unknown and unquantifiable reliability. Consequently, it would fail to provide additional insight into the risks associated with the new technologies, which are often needed by decision makers to determine the feasibility and return-on-investment of a new aircraft engine. In this work, an alternative approach based on the probabilistic method was described for a comprehensive assessment of an aeropropulsion system. The statistical approach quantifies the design uncertainties inherent in a new aeropropulsion system and their influences on engine performance. Because of this, it enhances the reliability of a system assessment. A technical assessment of a wave-rotor-enhanced gas turbine engine was performed to demonstrate the methodology. The assessment used probability distributions to account for the uncertainties that occur in component efficiencies and flows and in mechanical design variables. The approach taken in this effort was to integrate the thermodynamic cycle analysis embedded in the computer code NEPP (NASA Engine Performance Program) and the engine weight analysis embedded in the computer code WATE (Weight Analysis of Turbine Engines) with the fast probability integration technique (FPI). FPI was developed by Southwest Research Institute under contract with the NASA Glenn Research Center. The results were plotted in the form of cumulative distribution functions and sensitivity analyses and were compared with results from the traditional deterministic approach. The comparison showed that the probabilistic approach provides a more realistic and systematic way to assess an aeropropulsion system. The current work addressed the application of the probabilistic approach to assess specific fuel consumption, engine thrust, and weight. Similarly, the approach can be used to assess other aspects of aeropropulsion system performance, such as cost, acoustic noise, and emissions. Additional information is included in the original extended abstract.

Tong, Michael T.↗

Metamorphosed CM and CI Carbonaceous Chondrites Could Be from the Breakup of the Same Earth-crossing Asteroid

Far from being the relatively unprocessed materials they were once believed to be, we now know that a significant number of carbonaceous chondrites were thermally metamorphosed on their parent asteroid(s). Numerous studies indicate that 7 "CM" and 2 "CI" chondrites have been naturally heated, variously, at from 400 to over 700 C on their parent asteroid(s). Petrographic textures reveal that this thermal metamorphism occurred after the dominant aqueous alteration phase, although some meteorites show evidence of a heating event between two aqueous alteration episodes, i.e. pro- and retrograde aqueous alteration. Aside from the issues of the identification of the transient heat source, timing of metamorphism, and the relation of these materials (if any) to conventional CM and CI chondrites, there is also a mystery related to their recovery. All of these meteorites have been recovered from the Antarctic; none are falls or finds from anyplace else. Indeed, the majority have been collected by the Japanese NIPR field parties in the Yamato Mountains. In fact, one estimate is that these meteorites account for approx. 64 wt% of the CM carbonaceous chondrites at the NIPR. The reasons for this are unclear and might be due in part to simple sampling bias. However we suggest that this recovery difference is related to the particular age of the Yamato Mountains meteorite recovery surfaces, and differences in meteoroid fluxes between the Yamato meteorites and recent falls and substantially older Antarctic meteorites. Additional information is included in the original extended abstract.

Zolensky, Michael↗

Disinfection of Spacecraft Potable Water Systems by Passivation with Ionic Silver

Microbial growth is common on wetted surfaces in spacecraft environmental control and life support systems despite the use of chemical and physical disinfection methods. Advanced control technologies are needed to limit microorganisms and increase the reliability of life support systems required for long-duration human missions. Silver ions and compounds are widely used as antimicrobial agents for medical applications and continue to be used as a residual biocide in some spacecraft water systems. The National Aeronautics and Space Administration (NASA) has identified silver fluoride for use in the potable water system on the next generation spacecraft. Due to ionic interactions between silver fluoride in solution and wetted metallic surfaces, ionic silver is rapidly depleted from solution and loses its antimicrobial efficacy over time. This report describes research to prolong the antimicrobial efficacy of ionic silver by maintaining its solubility. Three types of metal coupons (lnconel 718, Stainless Steel 316, and Titanium 6AI-4V) used in spacecraft potable water systems were exposed to either a continuous flow of water amended with 0.4 mg/L ionic silver fluoride or to a static, pre-treatment passivation in 50 mg/L ionic silver fluoride with or without a surface oxidation pre-treatment. Coupons were then challenged in a high-shear, CDC bioreactor (BioSurface Technologies) by exposure to six bacteria previously isolated from spacecraft potable water systems. Continuous exposure to 0.4 mg/L ionic silver over the course of 24 hours during the flow phase resulted in a >7-log reduction. The residual effect of a 24-hour passivation treatment in 50 mg/L of ionic silver resulted in a >3-log reduction, whereas a two-week treatment resulted in a >4-log reduction. Results indicate that 0.4 mg/L ionic silver is an effective biocide against many bacteria and that a prepassivation of metal surfaces with silver can provide additional microbial control.

Birmele, Michele N.↗