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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 253 records · Page 14
All sourcesNASA NTRSDOE OSTI
NASA NTRS2015

Elastomeric Seal Performance after Terrestrial Ultraviolet Radiation Exposure

Ultraviolet radiation was evaluated to determine its negative effects on the performance of elastomeric gas pressure seals. The leak rates of the silicone elastomer S0383-70 O-ring test articles were used to quantify the degradation of the seals after exposure to vacuum-ultraviolet and/or middle-to-near-ultraviolet wavelength radiation. Three groups of seals were exposed in terrestrial facilities to 115-165 nm wavelength radiation, 230-500 nm wavelength radiation, or both spectrums, for an orbital spaceflight equivalent of 125 hours. The leak rates of the silicone elastomer S0383-70 seals were quantified and compared to samples that received no radiation. Each lot contained six samples and statistical t-tests were used to determine the separate and combined influences of exposure to the two wavelength ranges. A comparison of the mean leak rates of samples exposed to 115-165 nm wavelength radiation to the control specimens showed no difference, suggesting that spectrum was not damaging. The 230-500 nm wavelength appeared to be damaging, as the mean leak rates of the specimens exposed to that range of wavelengths, and those exposed to the combined 115-165 nm and 230-500 nm spectrums, were significantly different from the leak rates of the control specimens. Most importantly, the test articles exposed to both wavelength spectrums exhibited mean leak rates two orders of magnitude larger than any other exposed specimens, which suggested that both wavelength spectrums are important when simulating the orbital environment.

leakage↗
NASA NTRS1983

Measuring Small Leak Holes

Hole sizes deduced from pressure measurements. Measuring apparatus consists of pitot tube attached to water-filled manometer. Compartment tested is pressurized with air. Pitot probe placed at known distance from leak. Dynamic pressure of jet measured at that point and static pressure measured in compartment. Useful in situations in which small leaks are tolerable but large leaks are not.

Koch, D. E.↗
NASA NTRS2001

Reusable Solid Rocket Motor Nozzle Joint-4 Thermal Analysis

This study provides for development and test verification of a thermal model used for prediction of joint heating environments, structural temperatures and seal erosions in the Space Shuttle Reusable Solid Rocket Motor (RSRM) Nozzle Joint-4. The heating environments are a result of rapid pressurization of the joint free volume assuming a leak path has occurred in the filler material used for assembly gap close out. Combustion gases flow along the leak path from nozzle environment to joint O-ring gland resulting in local heating to the metal housing and erosion of seal materials. Analysis of this condition was based on usage of the NASA Joint Pressurization Routine (JPR) for environment determination and the Systems Improved Numerical Differencing Analyzer (SINDA) for structural temperature prediction. Model generated temperatures, pressures and seal erosions are compared to hot fire test data for several different leak path situations. Investigated in the hot fire test program were nozzle joint-4 O-ring erosion sensitivities to leak path width in both open and confined joint geometries. Model predictions were in generally good agreement with the test data for the confined leak path cases. Worst case flight predictions are provided using the test-calibrated model. Analysis issues are discussed based on model calibration procedures.

Clayton, J. Louie↗
DOE OSTI2024

Solid-State Mixed-Potential Electrochemical Sensors for Natural Gas Leak Detection and Quality Control (Final Technical Report)

Mitigation of methane emissions are a critical factor to limiting the impact of the natural gas industry on global climate change. Throughout the period of 2020-2024, the University of New Mexico and its commercialization partner and subcontractor, SensorComm Technologies, Inc. (SCT), have worked together to develop a low-cost Artificial Intelligence (AI)-driven Internet of Things (IoT)-based multi-gas sensor platform for methane emissions detection. In the final year of the project, we extended this work to include hydrogen detection in support of a transition to a hydrogen economy where hydrogen could be transported through existing natural gas infrastructure. Mixed potential electrochemical sensors were first prototyped by ceramic additive manufacturing and then transitioned to conventional ceramic manufacturing tape casting and screen-printing technologies in preparation for mass production. Demonstrated limits of detection of 5 ppm of methane in natural gas and 1 ppm of hydrogen were measured. These limits of detection are among the lowest of solid-state electrochemical sensors that have been reported in the literature or available in the industry. Machine learning algorithms were developed to identify natural gas mixtures with > 98% accuracy level and quantify methane concentrations at 97% accuracy. The presence of hydrogen could also be identified, and its concentration quantified at these accuracy levels. These algorithms were optimized for running on portable computing hardware which enabled > 1 Hz processing rates. A portable packaged IoT system was integrated with the electrochemical sensor in collaboration with SCT. The package consists of readout electronics with < 1 mV resolution, sensor temperature control, and data transmission over cellular wireless and/or Wi-Fi networks. Field testing was performed in two rounds at Colorado State University’s Methane Emissions Technology Evaluation Center (CSU METEC). The first round of testing demonstrated successful measurements of methane from an underground natural gas leak of 20 standard liters per minute (SLPM), which agreed with previously published literature using more sophisticated and expensive analytical equipment. The second round of testing showed that an above ground leak of 2 SLPM of hydrogen could be detected at 32 ft. This project has resulted in six published peer reviewed journal articles, over ten presentations at professional conferences, and one full patent application filed in 2023. Future work on this project includes increased sensitivity, higher production yields, and applications in the hydrogen safety and flare emissions monitoring spaces.

03 NATURAL GAS↗
NASA NTRS2019

Advanced Cryogenic Insulation Systems

New materials in recent decades have enabled advances in thermal insulation systems for storage and transfer of cryogens. To preserve the cold and achieve efficient cryogenic systems, a combination of materials, testing, and engineering is required. The total heat leak into any cryogenic assembly is comprised of three main parts: 1) heat leak through the insulation, 2) heat leak through the support structures, and 3) heat leak attributed to piping penetrations and feedthroughs (and their negative effects on the insulation). This "cold triangle" approach provides a basis for evaluating performance benefits of new materials and analyzing the cost effectiveness in overall system design. Provided are thermophysical data for aerogels, aerogel composites, novel multilayered composites, and glass bubbles for standard test conditions of 293 K and 78 K under conditions from high vacuum to ambient pressure. Examples of cryogenic storage tanks show the relative importance of both insulation and structural materials for achieving designs of highest energy efficiency.

Multilayer Insulation↗
NASA NTRS1972

Space simulation experiments on reaction control system thruster plumes

A space simulation procedure was developed for studying rocket plume contamination effects using a 5-pound bipropellant reaction control system thruster. Vacuum chamber pressures of 3 x 10 to the minus 5 torr (70 miles altitude) were achieved with the thruster firing in pulse trains consisting of eight pulses (50 msec on, 100 msec off, and seven minutes between pulse trains). The final vacuum was achieved by cooling all vacuum chamber surfaces to liquid helium temperature and by introducing a continuous argon leak of 48 std. cc/sec into the test chamber. An effort was made to simulate propellant system flow dynamics corresponding to actual spacecraft mission use. Fast time response liquid flow rate measurements showed that large variations occurred in the ratio of oxidizer to fuel flow for pulse-on times up to 120 msec. These variations could lead to poor combustion efficiency and the production of contamination.

Cassidy, J. F.↗
NASA NTRS1972

Space simulation experiments on reaction control system thruster plumes.

A space simulation procedure was developed for studying rocket plume contamination effects using a 5-lb bipropellant reaction control system thrustor. Vacuum chamber pressures of 0.00003 torr (70 miles altitude) were achieved with the thrustor firing in pulse trains consisting of eight pulses - 50 msec on, 100 msec off, and seven minutes between pulse trains. The final vacuum was achieved by cooling all vacuum chamber surfaces to liquid-helium temperature and by introducing a continuous argon leak of 48 std. cc/sec into the test chamber. Fast time response liquid flow rate measurements showed that large variations occurred in the ratio of oxidizer to fuel flow for pulse-on times up to 120 msec. These variations could lead to poor combustion efficiency and the production of contamination.

Cassidy, J. F.↗
NASA NTRS2011

ITCS Test Strip Development and Certification

Internal coolant loops used for International Space Station thermal control must be periodically monitored for system health, including pH, biocide levels and any indication of ammonia. The presence of ammonia, possible via a microleak in the interface between the internal and external thermal control systems, could be a danger to the crew. The Internal Thermal Control System (ITCS) Sampling Kit uses test strips as a colorimetric indicator of pH and concentrations of biocide and free ammonia. This paper describes the challenges in designing an ammonia colorimetric indicator in a variable pH environment, as well as lessons learned, ultimately resulting in a robust test strip to indicate a hazardous ammonia leak.

Carrigan, Caitlin↗
NASA NTRS2008

Affect of Air Leakage into a Thermal-Vacuum Chamber on Helium Refrigeration Heat Load

NASA s Johnson Space Center (JSC) Building 32 houses two large thermal-vacuum chambers (Chamber A and Chamber B). Within these chambers are liquid nitrogen shrouds to provide a thermal environment and helium panels which operate at 20K to provide cryopumping. Some amount of air leakage into the chambers during tests is inevitable. This causes "air fouling" of the helium panel surfaces due to the components of the air that adhere to the panels. The air fouling causes the emittance of the helium panels to increase during tests. The increase in helium panel emittance increases the heat load on the helium refrigerator that supplies the 20K helium for those panels. Planning for thermal-vacuum tests should account for this increase to make sure that the helium refrigerator capacity will not be exceeded over the duration of a test. During a recent test conducted in Chamber B a known-size air leak was introduced to the chamber. Emittance change of the helium panels and the affect on the helium refrigerator was characterized. A description of the test and the results will be presented.

Garcia, Sam↗
DOE OSTI2025

Evaluation of a 5kW Solid Oxide Electrolysis Cell Stack

Solid oxide electrolysis cells (SOECs) are a developing technology for hydrogen production. They are promising due to their utilization of thermal energy to reduce their electricity consumption. The Department of Energy (DOE) has set goals to reduce the price per kilogram of hydrogen, and Idaho National Laboratory (INL) is conducting research to develop and demonstrate advanced methods and technologies to achieve making hydrogen a more affordable, efficient, and sustainable energy source. In this project, INL is collaborating with a vendor to evaluate and validate the design of a 5kW SOEC stack. The test aims to demonstrate a safe startup, operation, and shutdown on INL’s 5kW test stand, providing third-party validation in a different environment. A successful 50-hour test with stable hydrogen production will pave the way for a subsequent 1000-hour test. This project emphasized learning about electrolysis and the various support systems, referred to as balance of plant (BOP) equipment. These systems required modification while swapping to the vendor 5kW SOEC stack, most prominently the furnace door design and the controls system. It also included gaining skills in creating computer-aided design (CAD) drawings for the new door while using available materials and ensuring it met high-temperature requirements. Upon completion of modifications to the test stand, the SOEC will be test-fitted with respective wiring and piping. Instrumentation and piping will be checked for leaks and quality. This must be completed before the vendor’s engineers arrive to observe the test plan, startup, and a collection of 50 hours of data. The vendor’s engineers will ensure their stack performed sufficiently in the 50-hour test to enable the progression to a 1000-hour test.

08 - HYDROGEN↗
NASA NTRSDate not supplied

Development and characterization of the Capillary DirectINJECT System

The DirectINJECT Project was initiated to create a reliable in-line dosing system for delivering a concentrated silver ion biocide solution into spacecraft potable water. Three dosing systems, including a miniature peristaltic pump, a multi-piston pump, and a differential pressure-driven capillary tube, were quickly prototyped and tested. Although the peristaltic and multi-piston pump systems met the desired flow rate range, the capillary system showed the most promise and was chosen for further development. In FY23, the Capillary DirectINJECT dosing system underwent extensive testing with a nominal injection rate of 1.0 μl/min into varying backpressure conditions. A Primary DirectINJECT System with triplicate testbeds was employed for long-term testing, and auxiliary systems like the Secondary DirectINJECT System and Leak Testbed were developed to characterize specific components and investigate various phenomena related to the dosing system. Parameters such as flow rates, reservoir pressures, and temperature were monitored throughout the testing campaigns.

DirectINJECT↗
NASA NTRS1994

Space Station Freedom NiH2 cell testing program

Testing for the Space Station Freedom Nickel Hydrogen Cell Test Program began in 1990 at Crave Division, Naval Surface Warfare Center. The program has included receipt inspection, random vibration, acceptance, characterization, and life cycle testing of Ni-H2 cells in accordance with the NASA LeRC Interagency Order C-31001-J. A total of 400 Ni-H2 cells have been received at NAVSURFWARCENDIV Crane from three separate manufacturers; Yardney Technical Products (Yardney), Eagle Picher Industries (Eagle Picher), and Gates Energy Products (Gates). Of those, 308 cells distributed among 39 packs have undergone life cycle testing under a test regime simulating low earth orbit conditions. As of 30 September 1993, there are 252 cells assembled into 32 packs still on life cycle test. Since the beginning of the program, failed cells have been detected in all phases of testing. The failures include the following; seven 65 AmpHr and 81 AmpHr Yardney cells were found to be leaking KOH on receipt, one 65 AmpHr Eagle Picher cell failed the acceptance test, one 65 AmpHr Gates cell failed during the characterization test, and six 65 AmpHr Gates cells failed the random vibration test. Of the 39 life cycle packs, testing on seven packs, 56 cells, has been suspended because of low end of discharge voltages. All of the failed life cycle packs were cycled at 60% depth of discharge.

Moore, Bruce↗
NASA NTRS2006

Integrated Liquid Bismuth Propellant Feed System

A prototype bismuth propellant feed and control system was constructed and tested. An electromagnetic pump was used in this system to provide fine control of the hydrostatic pressure, and a new type of in-line flow sensor was developed to provide an accurate, real-time measurement of the mass flow rate. High-temperature material compatibility was a driving design requirement for the pump and flow sensor, leading to the selection of macor for the main body of both components. Post-test inspections of both components revealed no cracks or leaking in either. In separate proof-of-concept experiments, the pump produced a linear pressure rise as a function of current that compared favorably with theoretical pump pressure predictions, with a pressure of 10 kPa at 30 A. Flow sensing was successfully demonstrated in a bench-top test using gallium as a substitute liquid metal. A real-time controller was successfully used to control the entire system, simultaneously monitoring all power supplies and performing data acquisition duties.

Polzin, Kurt A.↗
NASA NTRS1966

Silver plating technique seals leaks in thin wall tubing joints

Leaks in thin wall tubing joints are sealed by cleaning and silver plating the hot gas side of the joint in the leakage area. The pressure differential across the silver during hydrostatic test and subsequent use forces the ductile silver into the leak area and seals it.

Blenderman, W. H.↗
DOE OSTI2024

Lifetime extension drop-test of real-world corroded 5 Quart Hagan nuclear material storage container

A 5Qt Hagan container with a 20-year history of nuclear material storage was challenged with three successive drop tests at a height of 3.7 meters. The total mass of the test package was 12.1 kg. The 1st and 2nd drop tests (center of gravity over the container bottom corner but 180 degrees apart on the container bottom face) passed the pre- and post- impact helium leak criterion at less than 1.00E-6 atm-cc/sec (ambient cubic centimeters per second). The 3rd and final test (center of gravity over top corner) failed with a post-impact gross leak of 1.1E-1 atmcc/sec. The RRFMC (Respirable Release Fraction Measurement Chamber) is a drop tower test system that is critical for the sustainability of the SAVY-4000™ series and Hagan-type (NFT Inc. Golden CO) nuclear material storage containers. These are the primary in-use nuclear material storage container types at the Los Alamos National Laboratory TA-55 facility. Results are presented to expand the technical knowledge basis for container lifetime, regarding actual exposure to corrosive gas species on the container inner surfaces. The primary source of general corrosion throughout the container is gaseous hydrogen chloride (HCl). This gas is generated by the degradation of the polyvinylchloride (PVC) bag-out bag. Additionally, in most cases, the nuclear material itself also releases HCl gas (due to residual chemical components associated with the material formation). The RRFMC drop tower gives the end-user the ability record and analyze high-speed video and photography and if needed aerosol mass release measurements. In this report the principal issue is the physical deformation of the 5Qt Hagan container. There were no mass release experiments of test aerosol mass in the present study.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Smartphone application for visualizing building air leakage

Annually, unwanted air leakage through building envelopes accounts for 4 quads of energy consumption in the United States, which translates to about 10% of total building energy consumption. Locating and sealing leakage sites is crucial fordecreasing building energy consumption. Smartphones are ubiquitous and contain sophisticated cameras and highperformance processors that could be employed to visualize air leakage using the background-oriented schlieren imaging technique, making leak detection cheaper and easier. This technique requires a textured and high-contrast background such as a brick or concrete masonry unit wall, a building air leak that has a temperature difference compared with the ambient air, and an imaging system. This work focuses on using smartphones as the imaging system to visualize air leakages. The paper discusses application development and the results of testing to determine leakage visualization performance as a function of leak temperature. The results show that leaks with a temperature difference greater than 16°C compared with the ambient air temperature were visualized using existing smartphones.

Boudreaux, Philip [ORNL] (ORCID:0000000229564665)↗