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Results for “prototyping and performance testing”

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 NTRS2013

Investigation of Sideband Index Response to Prototype Gear Tooth Damage

The objective of this analysis was to evaluate the ability of gear condition indicators (CI) to detect contact fatigue damage on spiral bevel gear teeth. Tests were performed in the NASA Glenn Spiral Bevel Gear Fatigue Rig on eight prototype gear sets (pinion/gear). Damage was initiated and progressed on the gear and pinion teeth. Vibration data was measured during damage progression at varying torque values while varying damage modes to the gear teeth were observed and documented with inspection photos. Sideband indexes (SI) and root mean square (RMS) CIs were calculated from the time synchronous averaged vibration data. Results found that both CIs respond differently to varying torque levels, damage levels and damage modes

health monitoring↗
NASA NTRS2017

Computational Modeling of Space Physiology for Informing Spaceflight Countermeasure Design and Predictions of Efficacy

MOTIVATION: Spaceflight countermeasures mitigate the harmful effects of the space environment on astronaut health and performance. Exercise has historically been used as a countermeasure to physical deconditioning, and additional countermeasures including lower body negative pressure, blood flow occlusion and artificial gravity are being researched as countermeasures to spaceflight-induced fluid shifts. The NASA Digital Astronaut Project uses computational models of physiological systems to inform countermeasure design and to predict countermeasure efficacy.OVERVIEW: Computational modeling supports the development of the exercise devices that will be flown on NASAs new exploration crew vehicles. Biomechanical modeling is used to inform design requirements to ensure that exercises can be properly performed within the volume allocated for exercise and to determine whether the limited mass, volume and power requirements of the devices will affect biomechanical outcomes. Models of muscle atrophy and bone remodeling can predict device efficacy for protecting musculoskeletal health during long-duration missions. A lumped-parameter whole-body model of the fluids within the body, which includes the blood within the cardiovascular system, the cerebral spinal fluid, interstitial fluid and lymphatic system fluid, estimates compartmental changes in pressure and volume due to gravitational changes. These models simulate fluid shift countermeasure effects and predict the associated changes in tissue strain in areas of physiological interest to aid in predicting countermeasure effectiveness. SIGNIFICANCE: Development and testing of spaceflight countermeasure prototypes are resource-intensive efforts. Computational modeling can supplement this process by performing simulations that reduce the amount of necessary experimental testing. Outcomes of the simulations are often important for the definition of design requirements and the identification of factors essential in ensuring countermeasure efficacy.

biomedical data↗
NASA NTRS1989

Development of an adsorption compressor for use in cryogenic refrigeration

A new compressor with no moving parts has been developed which is able to supply a source of high-pressure gas to a Joule-Thompson based cryogenic refrigerator. The compressor relies on a newly implemented combination of high-surface-area Saran carbon (sorbent) and krypton gas (working fluid). In addition, an integral gas-gap heat switch is used to provide improved overall efficiency. A prototype compressor has been designed, built, and tested as a part of the Jet Propulsion Laboratory effort in sorption refrigeration. Performance data from the prototype unit described here demonstrate successful compressor performance and good agreement with theoretical predictions.

Schember, Helen R.↗
NASA NTRS1972

Design and fabrication of prototype system for early warning of impending bearing failure

Ball bearing performance tests run on several identical ball bearings under a variety of load, speed, temperature, and lubrication conditions are reported. Bearing temperature, torque, vibration, noise, strain, cage speed, etc., were monitored to establish those measurements most suitable as indicators of ball bearing health. Tape records were made under steady-state conditions of a variety of speeds and loads. Sample sections were selected for narrowband spectral analysis with a real time analyzer. An artificial flow was created across the inner race surface of one bearing using an acid etch technique to produce the scratch. Tape records obtained before and after established a characteristic frequency response that identifies the presence of the flow. The signals found most useful as indicators of performance degradation were ultrasonic outputs.

Broderick, J. J.↗
DOE OSTI2024

CRADA Number NFE-21-08879 with Hempitecture Inc. (CRADA Final Report)

Participant is a company that was founded on the idea that sustainable materials can help build a better world. These materials can build a better world by preserving our health, saving energy, and storing carbon dioxide. Participant is at a critical juncture where it has significant sales and manufacturing capabilities that can bring innovative, low-carbon, hemp-based building products to market at scale in the United States, but the company has lacked the time and resources to conduct new product development and testing. At Innovation Crossroads, Participant plans to prototype, test, and develop its product roadmap while obtaining necessary performance and impact measurements of its hemp building products for commercialization. Coming into Innovation Crossroads, only one of Participant’s products has commercial sales, HempWool®. Investments are currently being made to add manufacturing capacity in the United States and to provide Participant with the capability to expand its product line throughout the building envelope.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Polar Bear™ – Innovative Capture of Storage Tank Vapors

Polar Bear™ is a patented technology developed by the Energy & Environmental Research Center (EERC) to capture storage tank vapors and eliminate methane emissions from upstream oil- and gas-producing facilities. Sparked by early commercial investment, the EERC licensed the technology and extended the intellectual property to storage tanks. Polar Bear™ is uniquely engineered and adapted to individual lower-producing facilities where there is otherwise no economic alternative for capturing tank vapors. A high number of small producing oil and gas wells are distributed across the country. The aggregate contributes to a significant volume of emissions. Because of the lack of economy of scale, gas volumes from these facilities are typically not recovered and contribute to methane emissions. Polar Bear™ provides a fit-for-purpose compression solution that addresses cost by reducing complexity with respect to conventional vapor recovery units and eliminating oil changes. Unique to Polar Bear™ is the capability to separate oxygenated gas from storage tank vapors. Storage tanks are designed to “breathe,” allowing gas to enter and escape during internal level and temperature changes. This infiltration of air into the tank headspace imparts undesirable oxygen content with respect to pipeline gathering. Polar Bear™ separates the vapor stream, allowing oxygen-rich gas to be used as fuel on-site while recovering the liquids-rich portion of the gas where oxygen content is minimized. A prototype system was tested to verify process models, evaluate operational performance, and advance the technology readiness level from 5 to 6. Results provide a good match between experimental measurements and process models, indicating the models are useful for future scale-up and field design. Various mixtures of nitrogen and liquefied petroleum gas were tested to understand the mass balance of nitrogen and how it relates to the potential control of oxygen content. Findings indicate that less than 2000 ppm of oxygen is likely to remain in the liquid portion of the gas in field applications. The research and development prepare the technology for field implementation to eliminate routine and fugitive methane emissions from storage tanks.

02 PETROLEUM↗
DOE OSTI2025

Design, Fabrication and Concept for the Surface Treatment of the SRF Cavity Prototype for the CLIC Damping Rings

The Compact Linear Collider (CLIC) Damping Rings (DRs) need to generate ultra-low emittance bunches to achieve high luminosity in CLIC. This requires many wiggler magnets with big energy loss which is compensated by the Radio Frequency (RF) system. The resulting strong beam loading transients lead to a challenging design for the RF system. A novel SRF cavity at 2 GHz with an ultra-low R/Q parameter of below 1 Ω is proposed to minimize the transient beam loading effects below acceptable level. The design and fabrication of the bulk Nb prototype based on turning from a single piece of Nb and EB welding is presented. Moreover, conceptual study of the system for cavity surface treatment to achieve the highest surface magnetic field which is the main goal of the prototype cold test is described as well. To enable excellent performance in this cavity, we plan to apply the 75/120C modified low temperature bake in combination with the cold electropolishing process. This surface treatment approach has been shown to consistently deliver high accelerating gradients and improved quality factors in TESLA-shaped 1.3 GHz SRF cavities. By adapting and implementing this process for the 2 GHz ultra-low R/Q design, we aim to maximize the achievable surface magnetic field while minimizing residual resistance and field emission. This treatment strategy will be critical for demonstrating that the cavity can meet the demanding performance requirements of the CLIC damping ring RF system under high beam loading conditions.

Bafia, Daniel P. [Fermilab]↗
DOE OSTI2025

Coal-derived graphene materials for industrial applications

The project (Award DE-FEO-0032274), led by Iowa State University in collaboration with the University of Wyoming, sought to improve the production and utility of graphene oxide (GO), reduced graphene oxide (rGO), and related advanced materials from coal char. The three overall objectives of this project were: 1) to improve production of graphene oxide using Powder River Basin (PRB) coal as feedstock; 2) to continue testing and improvement of a hard carbon sodium-ion battery prototype and test device; and 3) to determine properties and performance of concrete using GO and rGO as a concrete additive or cement replacement.

01 COAL, LIGNITE, AND PEAT↗
NASA NTRS1974

Absolute pressure transducers for space shuttle and orbiter propulsion and control systems

A preliminary design was completed, reviewing of such subjects as: the trade studies for media isolation and one sensor vs. two sensors for two bridges; compensation resistors; unit design; hydrogen embrittlement; sealing techniques and test station design. A design substantiation phase was finished, consisting of testing of a prototype unit and fabrication technique studies. A cryogenic test station was implemented and prototype sensor cells were fabricated, sensors assembled, and cryogenic tests performed.

Bolta, J. J.↗
NASA NTRS1975

Fluid infusion system

Development of a fluid infusion system was undertaken in response to a need for an intravenous infusion device operable under conditions of zero-g. The initial design approach, pursued in the construction of the first breadboard instrument, was to regulate the pressure of the motive gas to produce a similar regulated pressure in the infusion liquid. This scheme was not workable because of the varying bag contact area, and a major design iteration was made. A floating sensor plate in the center of the bag pressure plate was made to operate a pressure regulator built into the bellows assembly, effectively making liquid pressure the directly controlled variable. Other design changes were made as experience was gained with the breadboard. Extensive performance tests were conducted on both the breadboard and the prototype device; accurately regulated flows from 6 m1/min to 100 m1/min were achieved. All system functions were shown to operate satisfactorily.

Hammond, J. C.↗
NASA NTRS1977

Electric prototype power processor for a 30cm ion thruster

An electrical prototype power processor unit was designed, fabricated and tested with a 30 cm mercury ion engine for primary space propulsion. The power processor unit used the thyristor series resonant inverter as the basic power stage for the high power beam and discharge supplies. A transistorized series resonant inverter processed the remaining power for the low power outputs. The power processor included a digital interface unit to process all input commands and internal telemetry signals so that electric propulsion systems could be operated with a central computer system. The electrical prototype unit included design improvement in the power components such as thyristors, transistors, filters and resonant capacitors, and power transformers and inductors in order to reduce component weight, to minimize losses, and to control the component temperature rise. A design analysis for the electrical prototype is also presented on the component weight, losses, part count and reliability estimate. The electrical prototype was tested in a thermal vacuum environment. Integration tests were performed with a 30 cm ion engine and demonstrated operational compatibility. Electromagnetic interference data was also recorded on the design to provide information for spacecraft integration.

Biess, J. J.↗
NASA NTRS1984

Air intakes for a probative missile of rocket ramjet

The methods employed to test air intakes for a supersonic guided ramjet powered missile being tested by ONERA are described. Both flight tests and wind tunnel tests were performed on instrumented rockets to verify the designs. Consideration as given to the number of intakes, with the goal of delivering the maximum pressure to the engine. The S2, S4, and S5 wind tunnels were operated at Mach nos. 1.5-3 for the tests, which were compartmentalized into fuselage-intake interaction, optimization of the intake shapes, and the intake performance. Tests were performed on the length and form of the ogive, the presence of grooves, the height of traps in the boundary layer, the types and number of intakes and the lengths and forms of diffusers. Attention was also given to the effects of sideslip, effects of the longitudinal and circumferential positions of the intakes were also examined. Near optimum performance was realized during Mach 2.2 test flights of the prototype rockets.

Laruelle, G.↗
NASA NTRS2005

Surface Sampling System for Low-Gravity Missions

SpaceWorks has identified several sampling missions that could benefit from the technology developed under this project. Requirements were established for the surface sampling system. SpaceWorks teamed with Virginia Tech to identify and select a baseline adhesive suitable for the surface sampling system. SpaceWorks identified Solimide foam as the baseline substrate material. SpaceWorks conducted extensive testing to characterize the performance of the substrate/adhesive combination. A prototype version of the sampler head was designed and built by SpaceWorks.

Preble, Jeffrey C.↗
NASA NTRS2010

NASA's Soil Moisture Active and Passive (SMAP) Mission

The Soil Moisture Active-Passive (SMAP) Mission is one of the first Earth observation satellites being formulated by NASA in response to the 2007 National Research Council s Decadal Survey. SMAP will make global measurements of soil moisture at the Earth's land surface and its freeze-thaw state. These measurements will allow significantly improved estimates of water, energy and carbon transfers between the land and atmosphere. Soil moisture measurements are also of great importance in assessing flooding and monitoring drought. Knowledge gained from SMAP observations can help mitigate these natural hazards, resulting in potentially great economic and social benefits. SMAP observations of soil moisture and freeze/thaw timing over the boreal latitudes will also reduce a major uncertainty in quantifying the global carbon balance and help to resolve an apparent missing carbon sink over land. The SMAP mission concept will utilize an L-band radar and radiometer sharing a rotating 6-meter mesh reflector antenna flying in a 680 km polar orbit with an 8-day exact ground track repeat aboard a 3-axis stabilized spacecraft to provide high-resolution and high-accuracy global maps of soil moisture and freeze/thaw state every two to three days. In addition, the SMAP project will use these surface observations with advanced modeling and data assimilation to provide estimates of deeper root-zone soil moisture and net ecosystem exchange of carbon. SMAP recently completed its Phase A Mission Concept Study Phase for NASA and transitioned into Phase B (Formulation and Detailed Design). A number of significant accomplishments occurred during this initial phase of mission development. The SMAP project held several open meetings to solicit community feedback on possible science algorithms, prepared preliminary draft Algorithm Theoretical Basis Documents (ATBDs) for each mission science product, and established a prototype algorithm testbed to enable testing and evaluation of the performance of candidate algorithms. SMAP conducted an Applications Workshop in September 2009 to coordinate with potential application users interested in the mission data. A draft Applications Plan describing the Project s planned outreach to potential applications users has been prepared and will be updated during Phase B. SMAP made a significant evaluation of the potential terrestrial radio frequency interference (RFI) source environment and established radiometer and radar flight hardware and ground processing mitigation approaches. SMAP finalized its science orbit and orbit injection approach to optimize launch mass and prepared launch and commissioning scenarios and timeline. A science data communications approach was developed to maximize available science data volume to improve science margins while maintaining moderately short data product latencies to support many potential applications using existing ground assets and with minimum impact to the flight system. SMAP developed rigid multi-body and flexible body dynamics and control models and system designs for the 6-meter rotating instrument reflector-boom assembly (RBA) and flight system to confirm pointing and control performance, and devised strategies to efficiently implement on-orbit balancing if needed. Industry partners were selected for the spin mechanism assembly (SMA) and RBA. Preliminary designs for the radar and radiometer were initiated, including constructing breadboards of key assemblies.

Kellogg, Kent↗
NASA NTRS2004

An Evolved Antenna for Deployment on NASA's Space Technology 5 Mission

We present an evolved X - band antenna design and flight prototype currently on schedule to be deployed on NASA's Space Technology 5(ST5) spacecraft. Current methods of designing and optimizing antennas by hand are time and labor intensive, limit complexity and require significant expertise and experience. Evolutionary design techniques can overcome these limitations by searching the design space and automatically finding effective solutions that would ordinarily not be found. The ST5 antenna was evolved to meet a challenging set of mission requirements, most notably the combination of wide beamwidth for a circularly-polarized wave and wide bandwidth.Two evolutionary algorithms were used: one used a genetic algorithm style representation that did not allow branching in the antenna arms: the second used a genetic programming style tree-structured representation that allowed branching in the antenna arms. The highest performance antennas from both algorithms were fabricated and tested and both yielded similar performance. Both were comparable in performance to a hand-designed antenna produced by a contractor for the mission, and so we consider them examples of human-competitive performance by evolutionary algorithms. One of the evolved antenna prototypes is undergoing flight qualification testing.

Lohn, Jason D.↗
NASA NTRSDate not supplied

Trace Contaminant Control Test Bed for Evaluation of TCC Prototypes with Vacuum Regenerable and Non-Regenerable Sorbents

A new Space Suit Exploration Portable Life Support System (xPLSS) is being designed, built, integrated, and tested into the Extra-Vehicular Mobility Unit (xEMU). The Trace Contaminant Control (TCC) system is a component in the oxygen ventilation loop of xPLSS that removes contaminants generated by the crewmembers’ metabolic processes. The primary trace contaminants that must be removed include ammonia (NH3), carbon monoxide (CO), formaldehyde (CH2O), and methyl mercaptan (CH3SH). The current state-of-the-art TCC sorbent is non-regenerable activated carbon. As a non-regenerable sorbent, its use negatively impacts the logistics for future missions. Thus, an ideal solution can be a vacuum-regenerable sorbent integrated with the xPLSS CO2/H2O removal system. To test new designs and sorbents, XploSafe has constructed a recirculating test bed that mimics the environment within the xPLSS by providing concentrations of the trace contaminant analytes generated at the operating temperature, humidity, pressure, and flow rates of the xPLSS. This system can perform regeneration or desorption by exposing the sorbent to a pressure swing from 4.3 psia to <1 torr over approximately 2 minutes. Using this test system, XploSafe evaluated various TCC prototypes constructed using rapid prototyping techniques and identified a process that allows vacuum regenerative TCC designs to be quickly examined for flow, pressure drop, and performance. By using toluene as a segregate for volatile organics, this test system was evaluated using both vacuum regenerable and non-regenerable sorbents to demonstrate the operational effectiveness of these sorbents in maintaining the concentrations of the trace contaminant analytes below the 7-day Spacecraft Maximum Allowable Concentrations.

Nicholas Materer↗
NASA NTRS2000

Production Strategies for Production-Quality Parts for Aerospace Applications

A combination of rapid prototyping processes (3D Systems' stereolithography and Sanders Prototyping's ModelMaker) are combined with gelcasting to produce high quality silicon nitride components that were performance tested under simulated use conditions. Two types of aerospace components were produced, a low-force rocket thruster and a simulated airfoil section. The rocket was tested in a test stand using varying mixtures of H2 and O2, whereas the simulated airfoil was tested by subjecting it to a 0.3 Mach jet-fuel burner flame. Both parts performed successfully, demonstrating the usefulness of the rapid prototyping in efforts to effect materials substitution. In addition, the simulated airfoil was used to explore the possibility of applying thermal/environmental barrier coatings and providing for internal cooling of ceramic parts. It is concluded that this strategy for processing offers the ceramic engineer all the flexibility normally associated with investment casting of superalloys.

Cawley, J. D.↗