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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 307 records · Page 17

CECE: A Deep Throttling Demonstrator Cryogenic Engine for NASA's Lunar Lander

As one of the first technology development programs awarded under NASA's Vision for Space Exploration, the Pratt & Whitney Rocketdyne (PWR) Deep Throttling, Common Extensible Cryogenic Engine (CECE) program was selected by NASA in November 2004 to begin technology development and demonstration toward a deep throttling, cryogenic Lunar Lander engine for use across multiple human and robotic lunar exploration mission segments with extensibility to Mars. The CECE program leverages the maturity and previous investment of a flight-proven hydrogen/oxygen expander cycle engine, the RL10, to develop and demonstrate an unprecedented combination of reliability, safety, durability, throttlability, and restart capabilities in a high-energy, cryogenic engine. NASA Marshall Space Flight Center and NASA Glenn Research Center personnel were integral design and analysis team members throughout the requirements assessment, propellant studies and the deep throttling demonstrator elements of the program. The testbed selected for the initial deep throttling demonstration phase of this program was a minimally modified RL10 engine, allowing for maximum current production engine commonality and extensibility with minimum program cost. In just nine months from technical program start, CECE Demonstrator No. 1 engine testing in April/May 2006 at PWR's E06 test stand successfully demonstrated in excess of 10:1 throttling of the hydrogen/oxygen expander cycle engine. This test provided an early demonstration of a viable, enabling cryogenic propulsion concept with invaluable system-level technology data acquisition toward design and development risk mitigation for both the subsequent CECE Demonstrator No. 2 program and to the future Lunar Lander Design, Development, Test and Evaluation effort.

Giuliano, Victor J.↗

CECE: Expanding the Envelope of Deep Throttling in Liquid Oxygen/Liquid Hydrogen Rocket Engines For NASA Exploration Missions

As one of the first technology development programs awarded by NASA under the Vision for Space Exploration, the Pratt & Whitney Rocketdyne (PWR) Deep Throttling, Common Extensible Cryogenic Engine (CECE) program was selected by NASA in November 2004 to begin technology development and demonstration toward a deep throttling, cryogenic engine supporting ongoing trade studies for NASA s Lunar Lander descent stage. The CECE program leverages the maturity and previous investment of a flight-proven hydrogen/oxygen expander cycle engine, the PWR RL10, to develop technology and demonstrate an unprecedented combination of reliability, safety, durability, throttlability, and restart capabilities in a high-energy cryogenic engine. The testbed selected for the deep throttling demonstration phases of this program was a minimally modified RL10 engine, allowing for maximum current production engine commonality and extensibility with minimum program cost. Three series of demonstrator engine tests, the first in April-May 2006, the second in March-April 2007 and the third in November-December 2008, have demonstrated up to 13:1 throttling (104% to 8% thrust range) of the hydrogen/oxygen expander cycle engine. The first two test series explored a propellant feed system instability ("chug") environment at low throttled power levels. Lessons learned from these two tests were successfully applied to the third test series, resulting in stable operation throughout the 13:1 throttling range. The first three tests have provided an early demonstration of an enabling cryogenic propulsion concept, accumulating over 5,000 seconds of hot fire time over 27 hot fire tests, and have provided invaluable system-level technology data toward design and development risk mitigation for the NASA Altair and future lander propulsion system applications. This paper describes the results obtained from the highly successful third test series as well as the test objectives and early results obtained from a fourth test series conducted over March-May 2010

Giuliano, Victor J.↗

Predictive Efficiency Modeling for Lithium-Ion Cells at Various Relative Charge and Discharge C Rates for Electrified Powertrain Flight Demonstration

The Electrified Powertrain Flight Demonstration (EPFD) project aims to enhance battery efficiency by studying various Lithium-Ion (Li-ion) cell types. These cells are analyzed under different charging and discharging rates (C rates) to simulate a range of scenarios. As the EPFD project focuses on developing a sustainable hybrid/electric aircraft, it is essential to evaluate the efficiency, energy density, and weight of various battery cells. This ensures safety, reliability and optimal travel distance of the aircraft.

Battery↗

Variability in the high energy gamma ray emission from Cyg X-3 over a two-year period (1983 - 1984) at E 4 x 10(11) eV

Cygnus X-3 is observed to emit gamma rays with energies in excess of 4 x 10 to the 11th power eV during two out of 9 observational categories over an 18 month time span. The emissions are observed at the 0.6 phase of the characteristic 4.8 hr light curve for this binary system. We estimate a peak flux at phase 0.6 of 5 x 10 to the minus 10th power photons cm-2s-1 at a software threshold of 8 x 10 to the 11th power eV for Oct/Nov 1983. A flux for the June 84 effect cannot be reliably calculated at present due to lack of Monte Carlo simulations for the energy range and spectral region. For the other 7 observational categories the observations are consistent with zero source emission. The light curve would appear to be variable on a time scale of a couple of weeks at these categories. Selection of compact images in accordance with Monte Carlo simulations combined with empirical optimization techniques have led to an enriched gamma ray light curve for the Oct/Nov 1983 data. Selection on the basis of shower orientation, however, has not led to any notable enhancement of the gamma ray content. Individual Cherenko images can be reliably sorted on an event by event basis into either proton-induced or photon-induced showers.

Cawley, M. F.↗

Development of a breadboard design of a high-performance, high-reliability switching regulator

A comparison of two potential conversion methods, the series inverter and the inductive energy transfer (IET) conversion technique, is presented. The investigations showed that a characteristic of the series inverter circuit (high equalizing current values in each half cycle) could not be accomplished with available components, and the investigations continued with the IET circuit only. An IET circuit system was built with the use of computer-aided design in a 2, 4, and 8 stage configuration, and these stages were staggered 180, 90, and 45 degrees, respectively. All stages were pulsewidth modulated to regulate over an input voltage range from 200 to 400 volts dc at a regulated output voltage of 56 volts. The output power capability was 100 to 500 watts for the 2 and 8 stage configuration and 50 to 250 watts for the 4 stage configuration. Equal control of up to eight 45 degree staggered stages was accomplished through the use of a digital-to-analog control circuit. Equal power sharing of all stages was achieved through a new technique using an inductively coupled balancing circuit. Conclusions are listed.

Lindena, S. J.↗

Test Hardware Design for Flightlike Operation of Advanced Stirling Convertors (ASC-E3)

NASA Glenn Research Center (GRC) has been supporting development of the Advanced Stirling Radioisotope Generator (ASRG) since 2006. A key element of the ASRG project is providing life, reliability, and performance testing of the Advanced Stirling Convertor (ASC). For this purpose, the Thermal Energy Conversion branch at GRC has been conducting extended operation of a multitude of free-piston Stirling convertors. The goal of this effort is to generate long-term performance data (tens of thousands of hours) simultaneously on multiple units to build a life and reliability database. The test hardware for operation of these convertors was designed to permit in-air investigative testing, such as performance mapping over a range of environmental conditions. With this, there was no requirement to accurately emulate the flight hardware. For the upcoming ASC-E3 units, the decision has been made to assemble the convertors into a flight-like configuration. This means the convertors will be arranged in the dual-opposed configuration in a housing that represents the fit, form, and thermal function of the ASRG. The goal of this effort is to enable system level tests that could not be performed with the traditional test hardware at GRC. This offers the opportunity to perform these system-level tests much earlier in the ASRG flight development, as they would normally not be performed until fabrication of the qualification unit. This paper discusses the requirements, process, and results of this flight-like hardware design activity.

Oriti, Salvatore M.↗

Test Hardware Design for Flight-Like Operation of Advanced Stirling Convertors

NASA Glenn Research Center (GRC) has been supporting development of the Advanced Stirling Radioisotope Generator (ASRG) since 2006. A key element of the ASRG project is providing life, reliability, and performance testing of the Advanced Stirling Convertor (ASC). For this purpose, the Thermal Energy Conversion branch at GRC has been conducting extended operation of a multitude of free-piston Stirling convertors. The goal of this effort is to generate long-term performance data (tens of thousands of hours) simultaneously on multiple units to build a life and reliability database. The test hardware for operation of these convertors was designed to permit in-air investigative testing, such as performance mapping over a range of environmental conditions. With this, there was no requirement to accurately emulate the flight hardware. For the upcoming ASC-E3 units, the decision has been made to assemble the convertors into a flight-like configuration. This means the convertors will be arranged in the dual-opposed configuration in a housing that represents the fit, form, and thermal function of the ASRG. The goal of this effort is to enable system level tests that could not be performed with the traditional test hardware at GRC. This offers the opportunity to perform these system-level tests much earlier in the ASRG flight development, as they would normally not be performed until fabrication of the qualification unit. This paper discusses the requirements, process, and results of this flight-like hardware design activity.

Oriti, Salvatore M.↗

Damage tolerance certification methodology for composite structures

An advanced certification methodology was developed for composite structures to include the effects of impact damage. The methodology has the capability to determine the reliability of impact damaged structure at any prescribed load level and impact threat, which may be specified in terms of impact energy or C-scan damage area. In addition, the methodology can also calculate the allowable impact threat level at a given applied load and specified reliability. The developed damage tolerance certification methodology was demonstrated on the F/A-18 inner wing. The results of the methodology demonstration showed that the F/A-18 inner wing has excellent damage tolerance capability.

Kan, Han Pin↗

A Hybrid Power Management (HPM) Based Vehicle Architecture

Society desires vehicles with reduced fuel consumption and reduced emissions. This presents a challenge and an opportunity for industry and the government. The NASA John H. Glenn Research Center (GRC) has developed a Hybrid Power Management (HPM) based vehicle architecture for space and terrestrial vehicles. GRC's Electrical and Electromagnetics Branch of the Avionics and Electrical Systems Division initiated the HPM Program for the GRC Technology Transfer and Partnership Office. HPM is the innovative integration of diverse, state-of-the-art power devices in an optimal configuration for space and terrestrial applications. The appropriate application and control of the various power devices significantly improves overall system performance and efficiency. The basic vehicle architecture consists of a primary power source, and possibly other power sources, providing all power to a common energy storage system, which is used to power the drive motors and vehicle accessory systems, as well as provide power as an emergency power system. Each component is independent, permitting it to be optimized for its intended purpose. This flexible vehicle architecture can be applied to all vehicles to considerably improve system efficiency, reliability, safety, security, and performance. This unique vehicle architecture has the potential to alleviate global energy concerns, improve the environment, stimulate the economy, and enable new missions.

Eichenberg, Dennis J.↗

Frequency stabilization in injection controlled pulsed CO2 lasers

Longitudinal mode selection by injection has been demonstrated as a viable technique for tailoring a TEA-CO2 laser with pulse energies of a Joule or greater to fit the requirements of a coherent lidar transmitter. Once reliable generation of single-longitudinal-mode (SLM) pulses is obtained, one can study the intrapulse frequency variation and attempt to determine the sources of frequency sweeping, or chirp. These sources include the effect of the decaying plasma, the thermal gradient due to the energy dissipation associated with the laser mechanism itself, and the pressure shift of the center frequency of the laser transition. The use of the positive-branch unstable resonator as an efficient means of coupling a discharge with transverse spatial dimensions of the order of centimeters to an optical cavity mode introduces another concern: namely, what can be done to emphasize transverse mode discrimination in an unstable resonator cavity while maintaining high coupling efficiency. These issues are briefly discussed in the paper, and representative experimental examples are included.

Menzies, Robert T.↗

NASA Utilization of Space Nuclear Systems for Robotic and Human Exploration Missions: Response to EO 13972: Promoting Small Nuclear Reactors for National Defense and Space Exploration

Space Nuclear Systems (SNS) technology development offers a wide range of capabilities to support NASA’s current and future missions. Executive Order (EO) 13972, “Promoting Small Modular Reactors for National Defense and Space Exploration” [1], issued 5 January 2021, directs NASA to define requirements for NASA utilization of nuclear energy systems for human and robotic exploration missions through 2040 and analyze the costs and benefits of such requirements.” Although it is premature to define requirements and cost for future exploration missions that have not yet been formulated, this report describes planned objectives and missions by 2040 that are enabled or enhanced by nuclear systems while taking into account a number of unique considerations for nuclear energy in the space environment. Nuclear energy systems are enabling for space missions and critical capabilities where conventional forms of energy production are impractical or impossible due to mass constraints, mission duration, or distance from the Sun. Space nuclear technologies available or in development for use by 2040 utilize radioisotope decay or nuclear fission and fall into three categories: heat, power, and propulsion. Current applications utilize radioisotope power systems that provide consistent and reliable performance in the sub-kilowatt power range. More advanced SNS can enable new mission objectives where high energy density solutions are critical, or where access to solar solutions is prohibitive. Higher power radioisotope and fission systems are under development within NASA for a wide variety of human exploration and science mission applications. Planned missions designed to use radioisotope systems include Dragonfly, a rotorcraft that will explore the surface of Titan, and Persephone, a mission concept for a Pluto orbiter. Nuclear fission systems have the key advantage of providing significantly higher power, lower mass solutions from tens to even thousands of kilowatts. Fission power is enabling to a sustained human presence on the Moon and developing a robust lunar economy. Fission propulsion is enabling for missions within and beyond cis-lunar space. This report examines NASA-envisioned mission applications and associated performance needs for SNS over the next twenty years leading to 2040 along with the unique technical considerations posed by space nuclear technology development. This includes engineering and operational logistics for ground handling, thermal management, survival of the space environment, operational safety, power requirements, and service longevity. Safety to the public, the NASA work force, and agency assets remains a top priority for NASA and particular attention is given to this aspect in the design, hardware assembly, ground operation, launch, and mission operation of an SNS. NASA relies on the Department of Energy as nuclear authority and its legacy of rigorous safety procedures as standards for ground development, test, transportation, and launch site operation. The principal concern is preventing unintended radiological release to the public or environment. Radioisotope system experience has established processes, including ground operation, transportation, and launch, that are considered directly applicable to emerging fission systems; however, fission systems have unique design needs that impact the safety and performance requirements. High efficiency power conversion from both fission and radioisotope systems requires high operating temperatures necessitating both passive and active thermal management to maintain safe and nominal operating conditions. Effective cooling and waste heat rejection have special considerations for space applications, whether in zero-g or reduced gravity. Fluid and heat transfer within the reactor system is not anticipated to be impacted by reduced or zero-g environments. Cryogenic working fluids and propellant supplies utilized in some space nuclear applications will need low mass, high capacity cryocoolers to meet the long-term storage and near zero-boiloff needs. Integrated, high power density SNS capable of being packaged in a single vehicle is a key consideration for NASA. Due to concerns for complexity and reliability, in space reactor assembly and reactor refueling are not current design considerations. Expanding into a new era for space exploration depends on mass-efficient, high-energy solutions to power deep-space vehicles, operate in harsh environments, and increase mission flexibility. NASA nuclear technology investments are targeting power for surface operations and propulsion for fast-transit, deep-space missions, all with the ability to reliably operate without the need for repair or refueling. NASA’s goals, enabled by nuclear technologies, provide for exciting advances in scientific objectives and human exploration, ushering in a new space age that enables a human presence on bodies beyond our Earth.

nuclear↗

Ultrasonic detection of flaws in fusion butt welds

Reliable and accurate Delta technique, a nondestructive ultrasonics method, uses redirection of energy to detect randomly oriented imperfections in fusion butt welds. Data on flaws can be read from either an oscilloscope or a printout.

Cross, B. T.↗

An overview of fatigue failures at the Rocky Flats Wind System Test Center

Potential small wind energy conversion (SWECS) design problems were identified to improve product quality and reliability. Mass produced components such as gearboxes, generators, bearings, etc., are generally reliable due to their widespread uniform use in other industries. The likelihood of failure increases, though, in the interfacing of these components and in SWECS components designed for a specific system use. Problems relating to the structural integrity of such components are discussed and analyzed with techniques currently used in quality assurance programs in other manufacturing industries.

Waldon, C. A.↗

Systems Engineering of Electric and Hybrid Vehicles

Technical paper notes systems engineering principles applied to development of electric and hybrid vehicles such that system performance requirements support overall program goal of reduced petroleum consumption. Paper discusses iterative design approach dictated by systems analyses. In addition to obvious peformance parameters of range, acceleration rate, and energy consumption, systems engineering also considers such major factors as cost, safety, reliability, comfort, necessary supporting infrastructure, and availability of materials.

Kurtz, D. W.↗

Solar-cell interconnect design for terrestrial photovoltaic modules

Useful solar cell interconnect reliability design and life prediction algorithms are presented, together with experimental data indicating that the classical strain cycle (fatigue) curve for the interconnect material does not account for the statistical scatter that is required in reliability predictions. This shortcoming is presently addressed by fitting a functional form to experimental cumulative interconnect failure rate data, which thereby yields statistical fatigue curves enabling not only the prediction of cumulative interconnect failures during the design life of an array field, but also the quantitative interpretation of data from accelerated thermal cycling tests. Optimal interconnect cost reliability design algorithms are also derived which may allow the minimization of energy cost over the design life of the array field.

Mon, G. R.↗

Computational chemistry

With the advent of supercomputers, modern computational chemistry algorithms and codes, a powerful tool was created to help fill NASA's continuing need for information on the properties of matter in hostile or unusual environments. Computational resources provided under the National Aerodynamics Simulator (NAS) program were a cornerstone for recent advancements in this field. Properties of gases, materials, and their interactions can be determined from solutions of the governing equations. In the case of gases, for example, radiative transition probabilites per particle, bond-dissociation energies, and rates of simple chemical reactions can be determined computationally as reliably as from experiment. The data are proving to be quite valuable in providing inputs to real-gas flow simulation codes used to compute aerothermodynamic loads on NASA's aeroassist orbital transfer vehicles and a host of problems related to the National Aerospace Plane Program. Although more approximate, similar solutions can be obtained for ensembles of atoms simulating small particles of materials with and without the presence of gases. Computational chemistry has application in studying catalysis, properties of polymers, all of interest to various NASA missions, including those previously mentioned. In addition to discussing these applications of computational chemistry within NASA, the governing equations and the need for supercomputers for their solution is outlined.

Arnold, J. O.↗

A survey of advanced battery systems for space applications

The results of a survey on advanced secondary battery systems for space applications are presented. The objectives were: to identify advanced battery systems capable of meeting the requirements of various types of space missions, with significant advantages over currently available batteries, to obtain an accurate estimate of the anticipated improvements of these advanced systems, and to obtain a consensus for the selection of systems most likely to yield the desired improvements. Few advanced systems are likely to exceed a specific energy of 150 Wh/kg and meet the additional requirements of safety and reliability within the next 15 years. The few that have this potential are: (1) regenerative fuel cells, both alkaline and solid polymer electrolyte (SPE) types for large power systems; (2) lithium-intercalatable cathodes, particularly the metal ozides intercalatable cathodes (MnO2 or CoO2), with applications limited to small spacecrafts requiring limited cycle life and low power levels; (3) lithium molten salt systems (e.g., LiAl-FeS2); and (4) Na/beta Alumina/Sulfur or metal chlorides cells. Likely technological advances that would enhance the performance of all the above systems are also identified, in particular: improved bifunctional oxygen electrodes; improved manufacturing technology for thin film lithium electrodes in combination with polymeric electrolytes; improved seals for the lithium molten salt cells; and improved ceramics for sodium/solid electrolyte cells.

Attia, Alan I.↗

Innovations in dynamic test restraint systems

Recent launch system development programs have led to a new generation of large scale dynamic tests. The variety of test scenarios share one common requirement: restrain and capture massive high velocity flight hardware with no structural damage. The Space Systems Lab of McDonnell Douglas developed a remarkably simple and cost effective approach to such testing using ripstitch energy absorbers adapted from the sport of technical rockclimbing. The proven system reliability of the capture system concept has led to a wide variety of applications in test system design and in aerospace hardware design.

Fuld, Christopher J.↗