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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS2004

Sabatier Carbon Dioxide Reduction Assembly Development for Closed Loop Water Recovery

The Sabatier Carbon Dioxide Reduction System (CRA) offers water recovery on a long duration space mission to reduce water resupply. Currently, NASA Johnson Space Center (JSC), NASA Marshall Space Flight Center (MSFC), Hamilton Sundstrand Space Systems International, Inc. (HSSSI), and Southwest Research Institute (SWRI) are working together to develop a Sabatier CRA for the International Space Station (ISS). This effort is being funded by the Office of Biological and Physical Research (Code U)/Advanced Life Support program which is administered by NASA JSC. The Sabatier CRA is the next step in closing the oxygen life support loop on future space missions. The Sabatier reaction combines the waste carbon dioxide (recovered from crew metabolism) with waste hydrogen (a byproduct of electrolysis to produce oxygen) to produce water and methane (CH4). On ISS, the methane would be vented overboard, however the methane can be utilized for propulsion during a planetary exploration mission. Based on a crew size of 7-equivalent people, the Sabatier CRA can produce as much a 2000 lb/year water. Use of the Sabatier CRA will significantly reduce the amount of water that needs to be resupplied to the ISS on a yearly basis, at a tremendous cost saving to the program. Additionally, by recycling this additional water, the Sabatier CRA enables additional launch capacity for science experiments to be brought up to the ISS. The NASA/Industry team noted above has been working to reduce technical risks associated with the Sabatier CRA system. To date the technical risks have been considerably reduced, bringing the Technology Readiness Level (TRL) from TRL 4 to TRL 5/6. In doing so, the team has developed the system schematic, system models, control scheme, produced engineering development unit (EDU) hardware, performed limited integration testing of the EDU's and verified system modeling through testing. Additionally, the system schematic has been evaluated for failure modes and hazards and had a successful technical review by the NASA Safety Board. The current focus is now related to development of the water/methane phase separator, liquid sensor and CO2 compressor piston seal life. The overall goal of the current effort is to bring the system up to a TRL6 by the end of GFY04. Although the Sabatier CRA is not currently baselined for use on the ISS, its benefits are significant enough such that volume within the Oxygen Generation System rack has been reserved for future installation. The value of the water the CRA recover will allow NASA the additional crew time and payload needed to pursue its mission of scientific research.

Smith, Frederick↗
NASA NTRSDate not supplied

Attitude Control Approach for Solar Cruiser, a Large, Deep Space Solar Sail

Solar Cruiser is a small satellite Technology Demonstration Mission (TDM) to mature solar sail propulsion technology using a solar sail larger than 1600 square meters, demonstrating performance as a propulsion system and a stable pointing platform for science observations in an artificial halo orbit sunward of the Sun-Earth Lagrange Point 1 (sub-L1). For the “sailcraft” to meet mission objectives, there are several unique attitude control challenges that the Attitude Determination and Control System (ADCS) must overcome. Large disturbance torques, primarily due to sail deformations coupled with off-sun pointing angles, make it more difficult to maintain adequate controls performance and manage accumulated momentum on the control actuators. The large-amplitude, low-frequency flexible body modes of the sail, in concert with noisy sensors and actuators, make it challenging to mitigate control-structure interactions and maintain fine pointing capabilities. Stability and control performance during sail deployment is complicated by rapidly and widely varying inertias. The Solar Cruiser ADCS effectively addresses these challenges using a simple, traditional control system – including momentum management actuators that use bang-bang control to constrain internal accumulated momentum, a low-pass controls filter and an attitude determination Kalman Filter (KF) that blends multiple star tracker solutions, and a reaction wheel assembly (RWA) with controller gains tuned to specific configurations or inertias. Solar Cruiser’s attitude control approach, and lessons learned from its development, establishes a state of the art of high value to future solar sail missions and other small spacecraft with large deployable structures operating in deep space.

solar sail↗
NASA NTRSDate not supplied

Attitude Control Approach for Solar Cruiser, a Large, Deep Space Solar Sail

Solar Cruiser is a small satellite Technology Demonstration Mission (TDM) to mature solar sail propulsion technology using a solar sail larger than 1600 square meters, demonstrating performance as a propulsion system and a stable pointing platform for science observations in an artificial halo orbit sunward of the Sun-Earth Lagrange Point 1 (sub-L1). For the “sailcraft” to meet mission ob- jectives, there are several unique attitude control challenges that the Attitude De- termination and Control System (ADCS) must overcome. Large disturbance tor- ques, primarily due to sail deformations coupled with off-sun pointing angles, make it more difficult to maintain adequate controls performance and manage accumulated momentum on the control actuators. The large-amplitude, low- frequency flexible body modes of the sail, in concert with noisy sensors and ac- tuators, make it challenging to mitigate control-structure interactions and main- tain fine pointing capabilities. Stability and control performance during sail de- ployment is complicated by rapidly and widely varying inertias. The Solar Cruiser ADCS effectively addresses these challenges using a simple, traditional control system – including momentum management actuators that use bang- bang control to constrain internal accumulated momentum, a low-pass controls filter and an attitude determination Kalman Filter (KF) that blends multiple star tracker solutions, and a reaction wheel assembly (RWA) with controller gains tuned to specific configurations or inertias. Solar Cruiser’s attitude control ap- proach, and lessons learned from its development, establishes a state of the art of high value to future solar sail missions and other small spacecraft with large de- ployable structures operating in deep space.

solar sail↗
NASA NTRS2013

Cu-Cr-Nb-Zr Alloy for Rocket Engines and Other High-Heat- Flux Applications

Rocket-engine main combustion chamber liners are used to contain the burning of fuel and oxidizer and provide a stream of high-velocity gas for propulsion. The liners in engines such as the Space Shuttle Main Engine are regeneratively cooled by flowing fuel, e.g., cryogenic hydrogen, through cooling channels in the back side of the liner. The heat gained by the liner from the flame and compression of the gas in the throat section is transferred to the fuel by the liner. As a result, the liner must either have a very high thermal conductivity or a very high operating temperature. In addition to the large heat flux (>10 MW/sq m), the liners experience a very large thermal gradient, typically more than 500 C over 1 mm. The gradient produces thermally induced stresses and strains that cause low cycle fatigue (LCF). Typically, a liner will experience a strain differential in excess of 1% between the cooling channel and the hot wall. Each time the engine is fired, the liner undergoes an LCF cycle. The number of cycles can be as few as one for an expendable booster engine, to as many as several thousand for a reusable launch vehicle or reaction control system. Finally, the liners undergo creep and a form of mechanical degradation called thermal ratcheting that results in the bowing out of the cooling channel into the combustion chamber, and eventual failure of the liner. GRCop-84, a Cu-Cr-Nb alloy, is generally recognized as the best liner material available at the time of this reporting. The alloy consists of 14% Cr2Nb precipitates in a pure copper matrix. Through experimental work, it has been established that the Zr will not participate in the formation of Laves phase precipitates with Cr and Nb, but will instead react with Cu to form the desired Cu-Zr compounds. It is believed that significant improvements in the mechanical properties of GRCop-84 will be realized by adding Zr. The innovation is a Cu-Cr-Nb-Zr alloy covering the composition range of 0.8 to 8.1 weight percent Cr, 0.7 to 7.2 weight percent Nb, 0.1 to 1.5 weight percent Zr, and balance Cu. The alloy combines two known strengthening mechanisms - dispersion strengthening by Cr2Nb precipitates (GRCop-84), and precipitation strengthening by CuxZr (AMZIRC) - to produce a synergistic increase in the capabilities of the alloy with the goal of achieving properties greater than either of the methods could achieve alone. The anticipated advantages of the alloy are higher strength at temperatures up to 700 C, improved creep strength, and significantly higher LCF lives relative to GRCop-84. The thermal expansion, thermal conductivity, and processing of the alloy are anticipated to remain largely unchanged relative to GRCop-84.

Ellis, David L.↗
DOE OSTI2022

Optimization of WAAM Process to Produce AUSC Components with Increased Service Life

Additive manufacturing has the potential to revolutionize industrial hardware and unlock efficiency gains through the fabrication of geometries and architectures not possible by conventional processing. Wire Arc Additive manufacturing (WAAM) process is a class of directed energy deposition process enabling higher build rate and allowing custom wire feedstock allowing spatial variation of microstructure. The larger spot size and lower speed creates a larger melt pool, reducing residual stress and often time creating directional/columnar microstructure for Ni-superalloy. The use of flexible platform provides freedom in deposition strategy, which can accommodate complex substrates, including feature addition onto existing structures, non-flat layers, and repair methods. However, the certification of the final component needs to match the strength requirement. Hence, the quality of the component produced is stringently monitored to avoid buildup of residual stress, cracks, porosity and to reduce detrimental segregated phases commonly observed during alloy solidification. Simulation plays a huge role in predicting the melt pool dimension and can be used to optimize the process parameter. Similar development is also required to perform physics-based modeling of microstructural development in WAAM that can predict the microstructural features during solidification and can be used to optimize the process more effectively. To move toward this goal, Raytheon Technologies Research Center together with Siemens worked to create a set of computational tools to control the process parameters, enable on-line measurements and acquisition with feedback to the optimized process parameters, and eventually track material evolution through each step of the additive process. Computational fluid dynamics is used for accurate prediction and calibration of the thermal field during WAAM process. and phase field models for microstructure evolution as a function of processing parameters to establish a connection between additive parameters and the final microstructure. Here we report cellular automata (CA) model development to predict the dendritic microstructure evolution with surface and bulk nuclei for single track and multiple layers. The CA model was developed to account for secondary element addition and predict segregation, local melting, and latent heat release as well as prediction of Euler angles from orientation information and validated against experiments. This framework was utilized to tailor spatially-varying composition in a part by appropriately controlling the microstructure evolution during the additive process. Functionally graded Haynes 282 alloy with high Cr content at the surface was tested for oxidation and mechanical properties. An advanced physics-based reaction-diffusion model predicting the simultaneous creation of chromium oxide and alumina is developed and validated to extend life expectancy of the WAAM manufactured high temperature part. A machine-learning data-driven framework establishing the process-structure relationship from a dataset of real microstructure images and corresponding process history data has been developed and implemented in the NX Siemens design system. The digital twin configuration along with the tool path generation enabled prediction of WAAM component buildup time and the techno-economic analysis provided a favorable option for all 4 cases with 15-40% cost reduction.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS2019

SPARROW: Steam Propelled Autonomous Retrieval Robot for Ocean Worlds

The Steam Propelled Autonomous Retrieval Robot (SPARROW) for Ocean Worlds was a Phase I mission concept study funded under the NASA NIAC program. This report represents the findings of that study and recommendations for future work. SPARROW, envisioned as a soccer ball-sized payload to a primary lander mission, is a propulsively hopping robot for the exploration of Europa's rugged, icy surface. A multi-thruster, passively gimballed robot within a protective, spherical shell, SPARROW is able to freely rotate, self-right, and tumble over chaotic terrains. Europa's abundant surface ice would be harvested as an in situ propellant source. The principal objective of SPARROW is to increase the science return of a Europa landed asset by enabling access to distal, spatially distributed geologic units. The design of mobility systems for Europa is challenging, due in part to its almost entirely unconstrained surface topography and strength. Images returned by Voyager and Galileo yielded resolutions on the order of hundreds of meters per pixel, with localized regions reaching 6 meters per pixel—still far larger than a typical rover. A key benefit of SPARROW's hopping, impact-tolerant design, is that it eliminates the need for a priori information regarding terrain topography and surface strength; no surface reaction forces are required for motion. In this context, SPARROW is believed to be entirely terrain agnostic. In this report we detail the results of three study objectives: i) to quantify the energy required to collect surface ice, change its phase, and maintain propellant temperature, ii) to identify control and estimation strategies that enable SPARROW to successfully reach, and return from, regions of scientific interest, and iii) to characterize the impact of SPARROW's range on likely science return. Five water-based propellant architectures are presented alongside their mass, power, and volume requirements. Monte Carlo simulations of SPARROW hopping and tumbling over 1 km of glacial ice are summarized, characterizing SPARROW's sensitivity to uncertainty in: initial pose, thrust profile, and vehicle-terrain interaction. A science traceability matrix is presented, which details the effect of sortie range on three science goals: constraining Europa's evolutionary morphology, assessing sub-surface ocean habitability, and searching for life and/or biosignatures.

Autonomous↗
NASA NTRS2000

Vehicle Dynamics due to Magnetic Launch Propulsion

The field of Magnetic Levitation Lind Propulsion (MagLev) has been around for over 30 years, primarily in high-speed rail service. In recent years, however, NASA has been looking closely at MagLev as a possible first stage propulsion system for spacecraft. This approach creates a variety of new problems that don't currently exist with the present MagLev trains around the world. NASA requires that a spacecraft of approximately 120,000 lbs be accelerated at two times the acceleration of gravity (2g's). This produces a greater demand on power over the normal MagLev trains that accelerate at around 0.1g. To be able to store and distribute up to 3,000 Mega Joules of energy in less than 10 seconds is a technical challenge. Another problem never addressed by the train industry and, peculiar only to NASA, is the control of a lifting body through the acceleration of and separation from the MagLev track. Very little is understood about how a lifting body will react with external forces, Such as wind gusts and ground effects, while being propelled along on soft springs such as magnetic levitators. Much study needs to be done to determine spacecraft control requirements as well as what control mechanisms and aero-surfaces should be placed on the carrier. Once the spacecraft has been propelled down the track another significant event takes place, the separation of the spacecraft from the carrier. The dynamics involved for both the carrier and the spacecraft are complex and coupled. Analysis of the reaction of the carrier after losing, a majority of its mass must be performed to insure control of the carrier is maintained and a safe separation of the spacecraft is achieved. The spacecraft angle of attack required for lift and how it will affect the carriage just prior to separation, along with the impacts of around effect and aerodynamic forces at ground level must be modeled and analyzed to define requirements on the launch vehicle design. Mechanisms, which can withstand the expected forces and allow the spacecraft to separate at the desired time must be developed. Modeling and analysis of the full-scale system must be developed to derive the requirements for design of the separation mechanisms. A description of several MagLev demonstrators will be presented and the testing and analysis to model the demonstrators will be included.

Galaboff, Zachary J.↗
NASA NTRS2019

SPARROW: A Steam Propelled Autonomous Retrieval Robot for Ocean Worlds

This paper presents the results of a NIAC Phase I study into the use of a propulsively hopping robot for the exploration of Europa’s rugged, icy surface. Named the“Steam Propelled Retrieval Robot for Ocean Worlds,” SPARROW is a multi-thruster robot passively gimballed within a protective, spherical shell, which enables it to freely rotate, self-right, and tumble over chaotic terrains. SPARROW is envisioned as a soccerball-sized payload to a primary lander mission. Europa’s abundant surface ice would be harvested as an in situ propellant source. The principal objective of SPARROW would be to increase the science return of a Europa landed asset by enabling access to distal, spatially distributed geologic units. The design of mobility systems for Europa is challenging, due in part to its almost entirely unconstrained surface topography and strength. Images returned by Voyager and Galileo yielded resolutions on the order of hundreds of meters per pixel, with localized regions reaching 6 meters per pixel—still far larger than a typical rover. A key benefit of SPARROW’s hopping, impact-tolerant design, is that it eliminates the need for a piori information on the terrain topography and surface strength; no surface reaction forces are required for motion. In this context, SPARROW is entirely terrain agnostic. In this paper we detail the results of three study objectives: i) to quantify the energy required to collect surface ice, change its phase, and maintain propellant temperature, ii) to identify control and estimation strategies that enable SPARROW to successfully reach, and return from, regions of scientific interest, and iii) to characterize the impact of SPARROW’s range on likely science return. Five water-based propellant architectures are presented alongside their mass, power, and volume requirements. Monte Carlo simulations of SPARROW hopping and tumbling over 1 km of glacial ice are summarized, characterizing SPARROW’s sensitivity to uncertainty in: initial conditions, thrust control, and cage-terrain interaction. Finally, a science traceability matrix is presented, which details the effect of sortie range on three science goals: constraining Europa’s evolutionary morphology, assessing sub-surface ocean habitability, and searching for life and/or biosignatures.

Phillips, Cynthia↗
NASA NTRS2002

Overview of the High Performance Antiproton (HiPAT) Experiment

The annihilation of matter with antimatter represents the highest energy density of any known reaction, producing 10(exp 8) MJ/g, approximately 10 orders of magnitude more energy per unit mass than chemical based combustion. To take the first step towards using this energy for propulsion applications the NASA MSFC Propulsion Research Center (PRC) has initiated a research activity examining the storage of low energy antiprotons. Storage was identified as a key enabling technology since it builds the experience base necessary to understand the handling of antiprotons for virtually all utilization and high-density storage concepts. To address this need, a device referred to as the High Performance Antiproton Trap (HiPAT) is under development at the NASA MSFC PRC. The HiPAT is an electromagnetic system (Penning-Malmberg design) consisting of a 4 Tesla superconductor, a high voltage confinement electrode system (operation up to 20 KV), and an ultra high vacuum test section (operating in the 10(exp -12) torr range). The system was designed to be portable with an ultimate goal of maintaining 10(exp 12) charged particles with a half-life of 18 days. Currently, this system is being experimentally evaluated using normal matter ions which are cheap to produce and relatively easy to handle. These normal ions provide a good indication of overall trap behavior, with the exception of assessing annihilation losses. The ions are produced external to HiPAT using two hydrogen ion sources, with adjustable beam energy and current. Ion are transported in a beam line and controlled through the use of electrostatic optics. These optics serve to both focus and gate the incoming ions, providing microsecond-timed pulses that are dynamically captured by cycling the HiPAT electric containment field like a 'trap door'. The layout of this system more closely simulates the operations expected at an actual antiproton production facility where 'packets' of antiprotons with pulse widths measured in 100's of nanoseconds could be provided. Initial dynamic capture experiments have been performed with both trap and ton source system functioning at approximately 10% of maximum levels, minimizing the potential for extraneous effects. Dynamic trapping techniques demonstrated the successful capture of millions of hydrogen ions with good agreement with the predicted loading based on the timing sequence, trap electric field, and ion beam current. These techniques will be expanded to examine multiple shot capture or 'stacking' to increase the total number of ions stored within HiPAT.

Martin, James J.↗
DOE OSTI2022

Detailed chemistry modeling of rotating detonations with dilute n -heptane sprays and preheated air

Utilization of liquid fuels is crucial to enabling commercialization of rotating detonation engines (RDE) in the near future. In this study, Eulerian-Lagrangian simulations are conducted for rotating detonative combustion with dilute n-heptane sprays and preheated air. Two-dimensional flattened configuration is used and a skeletal chemical mechanism with 44 species and 112 elementary reactions for n-heptane combustion is adopted. The flow structure, droplet distribution, and thermochemical parameters in the refill zone are first analyzed. It is shown that the mixture in the refill zone is heterogeneous, including evaporating droplets, vapor, and air. When the total temperature is below 950 K, the average equivalence ratio increases with the total temperature. When it is higher than 950 K, the average equivalence ratio is almost constant. Subsequently, the chemical explosive mode analysis is applied to identify the controlling reactions and dominant combustion modes in the fuel refill zone and reaction fronts. Results demonstrate that the initiation reaction (R104: n-C 7 H 16 + O 2 2-C 7 H 15 + HO 2 ) and low-temperature reaction (R107: RO 2 R'O 2 H) are dominant in the upstream and downstream of the refill zone, respectively. The intermediate species from low-temperature chemistry, R'O 2 H, is found to be important for the chemical explosive mode in the undetonated mixture. The influence of species diffusion and dispersed droplets is further analyzed. Results show that vapor autoignition facilitated by droplet evaporation occurs in the refill zone. Finally, the effects of the air total temperature on the detonation propagation speed and RDE propulsion performance are investigated. Further, it is found that the detonation propagation speed and specific impulse increase with air total temperature. The total pressure ratio first increases and then decreases as the air total temperature increases. Moreover, when the total temperature of the preheated air is above 1,300 K, the effects of low-temperature chemistry are negligible.

33 ADVANCED PROPULSION SYSTEMS↗
NASA NTRS2017

Near Earth Asteroid Scout Solar Sail Thrust and Torque Model

The Near Earth Asteroid (NEA) Scout is a solar sail mission whose objective is to scout at least one Near Earth Asteroid to help prepare for human missions to Near Earth Asteroids. NEA Scout will launch as a secondary payload on the first SLS-Orion mission. NEA Scout will perform a small trim maneuver shortly after deploy from the spent SLS upper stage using a cold gas propulsion system, but from that point on will depend entirely on the solar sail for thrust. As such, it is important to accurately characterize the thrust of the sail in order to achieve mission success. Additionally, the solar sail creates a relatively large solar disturbance torque that must be mitigated. For early mission design studies a flat plate model of the solar sail with a fixed center of pressure was adequate, but as mission concepts and the sail design matured, greater fidelity was required. Here we discuss the progress to a three-dimensional sail model that includes the effects of tension and thermal deformation that has been derived from a large structural Finite Element Model (FEM) developed by the Langley Research Center. We have found that the deformed sail membrane affects torque relatively much more than thrust; a flat plate model could potentially model thrust well enough to close mission design studies, but a three-dimensional solar sail is essential to control system design. The three-dimensional solar sail model revealed that thermal deformations of unshielded booms would create unacceptably large solar disturbance torques. The original large FEM model was used in control and mission simulations, but was resulted in simulations with prohibitive run times. This led us to adapt the Generalized Sail Model (GSM) of Rios-Reyes. A design reference sail model has been baselined for NEA Scout and has been used to design the mission and control system for the sailcraft. Additionally, since NEA Scout uses reaction wheels for attitude pointing and control, the solar torque model is essentially to successfully design the NEA Scout momentum management control system. We have also updated the estimate of diffusivity used for the aluminized sail material based on optical testing of wrinkled sail material. The model presented here represents the current state of the art of NASA's ability to model solar sail thrust and torque.

Heaton, Andy↗
NASA NTRS2024

Reliable Ignition of LOX-LCH4 Propellants

No cryogenic Reaction Control System (RCS) has ever flown in space. Cryogenic propellants are baselined by HLS and CLPS partners and are the key use case for future ISRU manufactured propellants. A reliable LOX/LCH 4 RCS is an enabling technology for human Lunar and Mars exploration. In previous thermal vacuum (<275 F, <10 torr) testing at NASA GRC Plum Brook, the team uncovered anomalous LOX/LCH4 engine ignition phenomena where flame kernels quenched at these ultra cold hardware temperatures, leading to many pulses where the engines would not light. In 2022, the project was able to recreate the no light condition with an upgraded Frost-Mint test stand at JSC. This project implemented test stand improvements and procured propellants and follow on engine components for a hot fire campaign beginning in November 2024 which will attempt to ignite the RCS engine at ultra cold vacuum conditions by modifying the engine mixture ratio. New modeling techniques were implemented to account for past no lights and are an enabling method to make lunar surface go no go predictions based on hardware conditions. This was enabled by significant improvements to the Frost Mint system, which reduced moisture build up and leaks, increased propellant availability, leading to more attempts at thermal vacuum hot-fires.

Propulsion↗
NASA NTRS2000

Affordable, Robust Ceramic Joining Technology (ARCJoinT) Given 1999 R and D 100 Award

Advanced ceramics and fiber-reinforced ceramic matrix composites with high strength and toughness, good thermal conductivity, thermal shock resistance, and oxidation resistance are needed for high-temperature structural applications in advanced high-efficiency and high-performance engines, space propulsion components, and land-based systems. The engineering designs of these systems require the manufacturing of large parts with complex shapes, which are either quite expensive or impossible to fabricate. In many instances, it is more economical to build complex shapes by joining together simple geometrical shapes. Thus, joining has been recognized as an enabling technology for the successful utilization of advanced ceramics and fiber-reinforced composite components in high-temperature applications. However, such joints must retain their structural integrity at high temperatures and must have mechanical strength and environmental stability comparable to those of the bulk materials. In addition, the joining technique should be robust, practical, and reliable. ARCJoinT, which is based on the reaction-forming approach, is unique in terms of producing joints with tailorable microstructures. The formation of joints by this approach is attractive since the thermomechanical properties of the joint interlayer can be tailored to be very close to those of the base materials. In addition, high-temperature fixturing is not needed to hold the parts at the infiltration temperature. The joining process begins with the application of a carbonaceous mixture in the joint area, holding the items to be joined in a fixture, and curing at 110 to 120 C for 10 to 20 min. This step fastens the pieces together. Then, silicon or a silicon alloy in tape, paste, or slurry form is applied around the joint region and heated to 1250 to 1425 C (depending on the type of infiltrant) for 10 to 15 min. The molten silicon or silicon-refractory metal alloy reacts with carbon to form silicon carbide with controllable amounts of silicon and other phases as determined by the alloy composition. Joint thickness can be readily controlled through adjustments of the properties of the carbonaceous paste and the applied fixturing force. The photograph shows various shapes of silicon-carbide-based ceramics and fiberreinforced composites that have been joined using ARCJoinT. Thermomechanical and thermochemical characterization of joints is underway for a wide variety of silicon-carbidebased advanced ceramics and fiber-reinforced composites under the hostile environments that will be encountered in engine applications. ARCJoinT, which was developed by researchers at the NASA Glenn Research Center at Lewis Field, received R&D Magazine's prestigious R&D 100 Award in 1999.

Singh, Mrityunjay↗
NASA NTRS2008

NASA Tech Briefs, November 2008

Topics covered include: Digital Phase Meter for a Laser Heterodyne Interferometer; Vision System Measures Motions of Robot and External Objects; Advanced Precipitation Radar Antenna to Measure Rainfall From Space; Wide-Band Radar for Measuring Thickness of Sea Ice; Vertical Isolation for Photodiodes in CMOS Imagers; Wide-Band Microwave Receivers Using Photonic Processing; L-Band Transmit/Receive Module for Phase-Stable Array Antennas; Microwave Power Combiner/Switch Utilizing a Faraday Rotator; Compact Low-Loss Planar Magic-T; Using Pipelined XNOR Logic to Reduce SEU Risks in State Machines; Quasi-Optical Transmission Line for 94-GHz Radar; Next Generation Flight Controller Trainer System; Converting from DDOR SASF to APF; Converting from CVF to AAF; Documenting AUTOGEN and APGEN Model Files; Sequence History Update Tool; Extraction and Analysis of Display Data; MRO DKF Post-Processing Tool; Rig Diagnostic Tools; MRO Sequence Checking Tool; Science Activity Planner for the MER Mission; UAVSAR Flight-Planning System; Templates for Deposition of Microscopic Pointed Structures; Adjustable Membrane Mirrors Incorporating G-Elastomers; Hall-Effect Thruster Utilizing Bismuth as Propellant; High-Temperature Crystal-Growth Cartridge Tubes Made by VPS; Quench Crucibles Reinforced with Metal; Deep-Sea Hydrothermal-Vent Sampler; Mars Rocket Propulsion System; Two-Stage Passive Vibration Isolator; Improved Thermal Design of a Compression Mold; Enhanced Pseudo-Waypoint Guidance for Spacecraft Maneuvers; Altimetry Using GPS-Reflection/Occultation Interferometry; Thermally Driven Josephson Effect; Perturbation Effects on a Supercritical C7H16/N2 Mixing Layer; Gold Nanoparticle Labels Amplify Ellipsometric Signals; Phase Matching of Diverse Modes in a WGM Resonator; WGM Resonators for Terahertz-to-Optical Frequency Conversion; Determining Concentration of Nanoparticles from Ellipsometry; Microwave-to-Optical Conversion in WGM Resonators; Four-Pass Coupler for Laser-Diode-Pumped Solid-State Laser; Low-Resolution Raman-Spectroscopy Combustion Thermometry; Temperature Sensors Based on WGM Optical Resonators; Varying the Divergence of Multiple Parallel Laser Beams; Efficient Algorithm for Rectangular Spiral Search; Algorithm-Based Fault Tolerance Integrated with Replication; Targeting and Localization for Mars Rover Operations; Terrain-Adaptive Navigation Architecture; Self-Adjusting Hash Tables for Embedded Flight Applications; Schema for Spacecraft-Command Dictionary; Combined GMSK Communications and PN Ranging; System-Level Integration of Mass Memory; Network-Attached Solid-State Recorder Architecture; Method of Cross-Linking Aerogels Using a One-Pot Reaction Scheme; An Efficient Reachability Analysis Algorithm.

Source record↗
DOE OSTI2022

Numerical and experimental investigation of the flame kernel growth in a methane/air mixture near the lean flammability limit

Lean combustion has the potential to improve the thermal efficiency of spark-ignition engines, but it faces the significant challenge of increased cycle-to-cycle variation due to low mixture reactivity and unstable flame dynamics. Computational fluid dynamics (CFD) employing predictive models can guide engine design and optimize operating strategies for lean combustion. However, ignition and combustion models have rarely been validated at fuel-lean conditions, and a fundamental understanding of the early flame kernel growth process is also lacking for a successful sub-model development. Here, the present study develops a numerical simulation framework used to investigate early flame kernel growth in methane/air mixtures. A nanosecond-pulsed discharge (NPD) approach is employed to effectively decouple the flame kernel growth from the electrical discharge due to their difference in timescales, and equivalence ratios near the experimentally measured lean flammability limit (LFL) are selected to focus on challenging mixture conditions. Three numerical investigations, such as the choice of turbulence modeling, grid size, and grid control strategies, are examined to match both LFL and flame kernel structure measured from experiments. It is demonstrated that a quasi-direct numerical simulation (QDNS) with a fixed grid embedding of 10 μm can predict the LFL as φ CFD =0.61 and match the displacement speed of the kernel’s boundary marked in schlieren images. To predict the LFL and flame kernel shape, a fine grid (Δ≤12.5 μm) is needed to capture the consumption of formaldehyde (CH 2 O) in kernel’s reaction branches attached to the anode, and adaptive mesh refinement is replaced with the fixed embedding due to loss of simulation accuracy. Also, it is found that a large-eddy simulation (LES) using the Dynamic Structure model is not suitable for the NPD-induced flame kernel simulation because artificial sub-grid turbulent kinetic energy induced by shock dynamics alters the flow velocity calculation, resulting in divergence of LES from QDNS. Lastly, the simulation well matches the experimental data for the flame kernel evolution in three mixture conditions (φ = 0.7, 0.61, 0.55), showing toroidal flame kernel expansion and flame kernel growth/extinction.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Full-Loop Simulation of the Combustion of Biomass in a Circulating Fluidized Bed Combustor

Interest in circulating fluidized bed (CFB) boilers as a power generation technology has skyrocketed in recent years because of several advantages this technology offers over conventional boilers, such as increased gas-solid mixing, which results in higher combustion efficiency, and the ability to use lower rank fuels. CFB combustors are operated at lower temperatures than conventional thermal power generation combustors, thus reducing NO x emissions, while SO 2 emissions can be conveniently controlled through the addition of Ca-based sulfur sorbents within the combustor. This report summarizes the development of a comprehensive computational fluid dynamics (CFD) model for biomass combustion in a 50 kW th CFB combustor employing the multiphase particle-in-cell (PIC) approach in the open-source Multiphase Flow with Interphase eXchanges (MFiX) Software Suite at the U.S. Department of Energy (DOE) National Energy Technology Laboratory (NETL). The experimental combustor was designed, built, and operated at CanmetENERGY, Natural Resources Canada in Ottawa, Canada. This work is the culmination of a multi-year collaboration between NETL and CanmetENERGY. The hydrodynamics in the full loop are validated against cold-flow experiments conducted at CanmetENERGY. To mimic the dense packing in the standpipe in the absence of a collisional model in the MFiX-PIC approach, the ram valve in the return leg is partially closed to obstruct the flow. A combustion reaction scheme was developed that considers the volatiles released by the fuel as a lumped species that fully converts to CO 2 and H 2 O. The so-called enhanced simplified combustion scheme produces an excellent match with experimental data in terms of the species concentrations of CO 2 and O 2 at the outlet and the freeboard, demonstrating the utility of the comprehensive model for a range of flow conditions and operating temperatures. Furthermore, the model can be readily adapted to simulate combustion of a variety of biomass fuels as well as co-fired systems under air and oxy-fuel conditions.

09 BIOMASS FUELS↗
NASA NTRS2009

Design Evolution and Verification of the A-3 Chemical Steam Generator

Following is an overview of the Chemical Steam Generator system selected to provide vacuum conditions for a new altitude test facility, the A-3 Test Stand at Stennis Space Center (SSC) in Bay St. Louis, MS. A-3 will serve as NASA s primary facility for altitude testing of the J-2X rocket engine, to be used as the primary propulsion device for the upper stages of the Ares launch vehicles. The Chemical Steam Generators (CSGs) will produce vacuum conditions in the test cell through the production and subsequent supersonic ejection of steam into a diffuser downstream of the J-2X engine nozzle exit. The Chemical Steam Generators chosen have a rich heritage of operation at rocket engine altitude test facilities since the days of the Apollo program and are still in use at NASA White Sands Test Facility (WSTF) in New Mexico. The generators at WSTF have been modified to a degree, but are still very close to the heritage design. The intent for the A-3 implementation is to maintain this heritage design as much as possible, making minimal updates only where necessary to substitute for obsolete parts and to increase reliability. Reliability improvements are especially desired because the proposed system will require 27 generators, which is nine times the largest system installed in the 1960s. Improvements were suggested by the original design firm, Reaction Motors, by NASA SSC and NASA WSTF engineers, and by the A-3 test stand design contractor, Jacobs Technology, Inc. (JTI). This paper describes the range of improvements made to the design to date, starting with the heritage generator and the minor modifications made over time at WSTF, to the modernized configuration which will be used at A-3. The paper will discuss NASA s investment in modifications to SSC s E-2 test facility fire a full-scale Chemical Steam Generator in advance of the larger steam system installation at A-3. Risk mitigation testing will be performed in early 2009 at this test facility to verify that the CSGs operate as expected. The generator which will undergo this testing is of the most recent A-3 configuration, and will be instrumented far in excess of what is normally required for operation. The extra data will allow for easier troubleshooting and more complete knowledge of expected generator performance. In addition, the early testing will give SSC personnel experience in operating the CSG systems, which will expedite the process of installation and activation at A-3. Each Chemical Steam Generator is supported by a complement of valves, instruments, and flow control devices, with the entire assembly called a "module." The generators will be installed in groups of three, historically called "units". A module is so called because of its modular ability to be replaced or serviced without disturbing the other two modules installed on the same unit. A module is pictured in Figure 1, shown with its generator secured by white bands in its shipping (vs. installed) configuration. The heritage system at WSTF is composed of a single unit (three generator modules), pictured in Figure 2 as it was installed in 1965. In contrast, A-3 will have nine units operating in parallel to achieve vacuum conditions appropriate for testing the J-2X engine. Each of the combustors operates in two modes and achieves the so-called "full-steam" mode after all three of its stages ignite. Ignition of the first stage is achieved by exciting a spark plug; the second stage and main stage are lit by the flame front of the previous stage. The main stage burns approximately 97% of the total propellant flow and uses the heat energy to vaporize water into superheated steam. While the main stage remains unlit, the combustor is in so-called "idle" mode. In the WSTF system, this idle mode is not optimized for water usage, and does not need to be, as the water is pumped from a large reservoir. The water supply at A-3 will be contained in tanks with finite volume, so water optimization is preferred for the modnized configuration. Multiple solutions for this issue have been proposed, with the leading concept being a change to the operational definition of "idle mode," with the generator running in a lower heat flux condition.

Kirchner, Casey K.↗
DOE OSTI2024

When and Where Lithium Plating Occurs, Its Correlation with Microstructure Heterogeneity, and the Mechanisms That Initiate and Self-Regulate Electrochemical Heterogeneity (A02-0444)

A microstructure scale electrochemical LIB model was used to investigate lithium plating onset, material non-uniform utilization, and in-plane heterogeneities for an NMC-graphite full cell. Model predicts active material particle surface roughness and size distribution (respectively, non-uniform curvature within and between particles) initiate in-plane heterogeneity, and that particle size heterogeneity at the separator interface controls the lithium plating preferential deposition ("Where"). These in-plane heterogeneities are then exacerbated by through-plane heterogeneities induced at fast charge as electrolyte depletion occurs and concentrates intercalation reaction near the anode-separator interface. Also, magnitude and occurrence of lithium plating is controlled by effective, or macroscale, microstructure parameters ("When"). As local states of charge start to diverge between nearby active material regions, overpotential differences induced by OCP difference kick in and contribute to reduce these SOC local heterogeneities. However, for staged materials such as graphite, with OCP profile alternating between plateaus and varying regions, this balancing mechanism is, respectively, inactive and active. This leads to a dynamic, non-monotonic, in-plane heterogeneity time evolution for state of charge and Faraday current density, for which their respective in-plane heterogeneity magnitude alternates. Such behavior has been modeled both for the whole electrode at the microstructure scale and at the particle scale. In-plane heterogeneities are usually considered to be detrimental, as they result in material non-uniform utilization (i.e., under and over stressed regions) and earlier degradations. However, this work provides a more granular approach as it discriminates between a harmful in-plane heterogeneity (non-uniform curvature) that triggers SOC in-plane heterogeneity, and a beneficial in-plane heterogeneity (Faraday current density) that contributes to reduce SOC in-plane heterogeneity. This work comprehensively explains the mechanisms that initiate, exacerbate, and regulate heterogeneity at the microstructure scale, while providing some design suggestions to reduce both in-plane and through-plane heterogeneities, as summarized in the graphical abstract.

ADVANCED PROPULSION SYSTEMS↗