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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 sources NASA NTRS DOE OSTI

NASA NTRS2008

Ground Handling of Batteries at Test and Launch-site Facilities

Ground handling of flight as well as engineering batteries at test facilities and launch-site facilities is a safety critical process. Test equipment interfacing with the batteries should have the required controls to prevent a hazardous failure of the batteries. Test equipment failures should not induce catastrophic failures on the batteries. Transportation requirements for batteries should also be taken into consideration for safe transportation. This viewgraph presentation includes information on the safe handling of batteries for ground processing at test facilities as well as launch-site facilities.

Jeevarajan, Judith A.↗

DOE OSTI2025

Understanding the impacts of inorganic species in woody biomass for preprocessing and pyrolysis–A review

Woody biomass represents an abundant resource for sustainable biofuels, biochemicals, and bioproducts. Technologies for converting woody biomass have been established for decades, and research consistently highlights the critical role of inorganic species and ash plays in feedstock handling and conversion processes, including equipment plugging, corrosion, and catalyst deactivation. A thorough understanding of the variability, transport behavior, and downstream impact of inorganic species in woody biomass is essential for defining feedstock quality specifications and developing effective management strategies for conversion processes. This review compiles critical information in five main sections: 1) inorganic species concentration in woody biomass, based on anatomical fractions and their sources of variability; 2) technique features for quantifying inorganic elemental chemical analysis; 3) impacts of inorganic species on biomass preprocessing; 4) impacts of inorganic species on pyrolysis, and 5) mitigation strategies. Additionally, this review explores future challenges and opportunities in addressing the impacts of inorganic species on biomass quality. These insights aim to support the sustainable development of the biomass-to-bioenergy pipeline and ensure high-quality lignocellulosic feedstocks for efficient downstream conversions. The findings offer valuable guidance to policy makers, industry stakeholders, and researchers in developing effective strategies for managing inorganic species in woody biomass and fostering the sustainable processes for lignocellulosic biorefineries.

09 BIOMASS FUELS↗

DOE OSTI2025

RCBC Automatic Monitoring and Control Recommendations

The recompression closed Brayton cycle (RCBC) test rig at the Sandia Brayton Laboratory provides a development platform to accelerate the commercialization of key technologies for supercritical CO 2 (sCO 2 ) closed loop Brayton cycles. The test rig enables testing to gain experience and confidence with new technologies, equipment, and processes, and automating monitors and controls will enhance Sandia’s ability to perform the types and amounts of testing needed. This report identifies candidates for automatic monitoring and control to ensure the loop remains within design limits and minimize risk to equipment due to off-normal events or conditions.

42 ENGINEERING↗

NASA NTRS2007

Automated Hybridization of X-ray Absorber Elements-A Path to Large Format Microcalorimeter Arrays

In the design of microcalorimeters, it is often desirable to produce the X-ray absorber separately from the detector element. In this case, the attachment of the absorber to the detector element with the required thermal and mechanical characteristics is a major challenge. In such arrays, the attachment has been done by hand. This process is not easily extended to the large format arrays required for future X- ray astronomy missions such as the New x-ray Telescope or NeXT. In this paper we present an automated process for attaching absorber tiles to the surface of a large-scale X-ray detector array. The absorbers are attached with stycast epoxy to a thermally isolating polymer structure made of SU-8. SU-8 is a negative epoxy based photo resist produced by Microchem. We describe the fabrication of the X-ray absorbers and their suspension on a handle die in an adhesive matrix. We describe the production process for the polymer isolators on the detector elements. We have developed a new process for the alignment, and simultaneous bonding of the absorber tiles to an entire detector array. This process uses equipment and techniques used in the flip-chip bonding industry and approaches developed in the fabrication of the XRS-2 instrument. XRS-2 was an X-ray spectrometer that was launched on the Suzaku telescope in July 10, 2005. We describe the process and show examples of sample arrays produced by this process. Arrays with up to 300 elements have been bonded. The present tests have used dummy absorbers made of Si. In future work, we will demonstrate bonding of HgTe absorbers.

Moseley, S.↗

NASA NTRS2019

Improved Processing Techniques for Inclusion-Free Steel for Bearing and Mechanical Component Applications

High hardness, high carbide powder metallurgy tools steels such as M62 enable the operation of ball bearings at extremely high load and stress levels. Operation under such conditions increases the potential for rolling contact fatigue failure attributed to ceramic particle inclusions. To address this challenge, industry has sought steel made from ever increasing levels of cleanliness but the results have been uneven owing to the random nature of the occurrence of material flaws. One common approach is to rely upon careful ingot inspections prior to bearing manufacture. By selecting the cleanest portion of an ingot, it is expected that bearings relatively free from material flaws will result. This approach is not always successful because detrimental flaws that exist deep within an ingot can pass inspection undetected potentially causing subsequent failure. Recent efforts to commercialize an intermetallic material, 60NiTi, for rolling element bearings demonstrates a pathway to produce bearing steel that is free from unwanted ceramic particle inclusions. In this paper, the process used to make bearing grade ceramic-free NiTi alloys is described and applied to steelmaking. At its core, the NiTi process differs from steel making in one key aspect. NiTi alloys are made from elementally pure starting materials that are melted, blended and processed in equipment absolutely free from exposure to oxygen and ceramics ensuring a ceramic particle-free product. In contrast, the predominant method to make bearing steel is to employ a successive series of purification steps to reduce contamination levels below required thresholds. This paper describes the processes developed and applied to high carbide tool steel, M62. The resulting material and microstructures are evaluated and compared to M62 prepared by conventional powder metallurgy techniques. It is hoped that the application of materials manufacturing techniques used for fracture sensitive ceramics and intermetallic materials like NiTi can provide a pathway to Ultra-Clean, Ceramic-Inclusion free steels for rolling element bearings and other failure critical applications.

Steel↗

NASA NTRS1985

Future heavy duty trucking engine requirements

Developers of advanced heavy duty diesel engines are engaged in probing the opportunities presented by new materials and techniques. This process is technology driven, but there is neither assurance that the eventual users of the engines so developed will be comfortable with them nor, indeed, that those consumers will continue to exist in either the same form, or numbers as they do today. To ensure maximum payoff of research dollars, the equipment development process must consider user needs. This study defines motor carrier concerns, cost tolerances, and the engine parameters which match the future projected industry needs. The approach taken to do that is to be explained and the results presented. The material to be given comes basically from a survey of motor carrier fleets. It provides indications of the role of heavy duty vehicles in the 1998 period and their desired maintenance and engine performance parameters.

Strawhorn, L. W.↗

NASA NTRS1995

Development of replicated optics for AXAF-1 XDA testing

Advanced optical systems for applications such as grazing incidence Wolter I x-ray mirror assemblies require extraordinary mirror surfaces in terms of fine finish and surface figure. The impeccable mirror surface is on the inside of the rotational mirror form. One practical method of producing devices with these requirements is to first fabricate an exterior surface for the optical device then replicate that surface to have the inverse component with lightweight characteristics. The replicated optic is not better than the master or mandrel from which it is made. This task identifies methods and materials for forming these extremely low roughness optical components. The objectives of this contract were to (1) prepare replication samples of electroless nickel coated aluminum, and determine process requirements for plating XDA test optic; (2) prepare and assemble plating equipment required to process a demonstration optic; (3) characterize mandrels, replicas and test samples for residual stress, surface contamination and surface roughness and figure using equipment at MSFC and; (4) provide technical expertise in establishing the processes, procedures, supplies and equipment needed to process the XDA test optics.

Engelhaupt, Darell↗

NASA NTRS1992

Ramp Technology and Intelligent Processing in Small Manufacturing

To address the issues of excessive inventories and increasing procurement lead times, the Navy is actively pursuing flexible computer integrated manufacturing (FCIM) technologies, integrated by communication networks to respond rapidly to its requirements for parts. The Rapid Acquisition of Manufactured Parts (RAMP) program, initiated in 1986, is an integral part of this effort. The RAMP program's goal is to reduce the current average production lead times experienced by the Navy's inventory control points by a factor of 90 percent. The manufacturing engineering component of the RAMP architecture utilizes an intelligent processing technology built around a knowledge-based shell provided by ICAD, Inc. Rules and data bases in the software simulate an expert manufacturing planner's knowledge of shop processes and equipment. This expert system can use Product Data Exchange using STEP (PDES) data to determine what features the required part has, what material is required to manufacture it, what machines and tools are needed, and how the part should be held (fixtured) for machining, among other factors. The program's rule base then indicates, for example, how to make each feature, in what order to make it, and to which machines on the shop floor the part should be routed for processing. This information becomes part of the shop work order. The process planning function under RAMP greatly reduces the time and effort required to complete a process plan. Since the PDES file that drives the intelligent processing is 100 percent complete and accurate to start with, the potential for costly errors is greatly diminished.

Rentz, Richard E.↗

NASA NTRS1997

Methyl Chloroform Elimination from the Production of Space Shuttle Sold Rocket Motors

Thiokol Space Operations manufactures the Reusable Solid Rocket Motors used to launch America's fleet of Space Shuttles. In 1989, Thiokol used more than 1.4 Mlb of methyl chloroform to produce rocket motors. The ban placed by the Environmental Protection Agency on the sale of methyl chloroform had a significant effect on future Reusable Solid Rocket Motor production. As a result, changes in the materials and processes became necessary. A multiphased plan was established by Thiokol in partnership with NASA's Marshall Space Flight Center to eliminate the use of methyl chloroform in the Reusable Solid Rocket Motor production process. Because of the extensive scope of this effort, the plan was phased to target the elimination of the majority of methyl chloroform use (90 percent) by January 1, 1996, the 3 Environmental Protection Agency deadline. Referred to as Phase I, this effort includes the elimination of two large vapor degreasers, grease diluent processes, and propellant tooling handcleaning using methyl chloroform. Meanwhile, a request was made for an essential use exemption to allow the continued use of the remaining 10 percent of methyl chloroform after the 1996 deadline, while total elimination was pursued for this final, critical phase (Phase II). This paper provides an update to three previous presentations prepared for the 1993, 1994, and 1995 CFC/Halon Alternative Conferences, and will outline the overall Ozone Depleting Compounds Elimination Program from the initial phases through the final testing and implementation phases, including facility and equipment development. Processes and materials to be discussed include low-pressure aqueous wash systems, high-pressure water blast systems- environmental shipping containers, aqueous and semi-aqueous cleaning solutions, and bond integrity and inspection criteria. Progress toward completion of facility implementation and lessons learned during the scope of the program, as well as the current development efforts and basic requirements of future methyl chloroform handcleaning elimination, will also be outlined.

Golde, Rick P.↗

NASA NTRS1998

Predictive Models for Semiconductor Device Design and Processing

The device feature size continues to be on a downward trend with a simultaneous upward trend in wafer size to 300 mm. Predictive models are needed more than ever before for this reason. At NASA Ames, a Device and Process Modeling effort has been initiated recently with a view to address these issues. Our activities cover sub-micron device physics, process and equipment modeling, computational chemistry and material science. This talk would outline these efforts and emphasize the interaction among various components. The device physics component is largely based on integrating quantum effects into device simulators. We have two parallel efforts, one based on a quantum mechanics approach and the second, a semiclassical hydrodynamics approach with quantum correction terms. Under the first approach, three different quantum simulators are being developed and compared: a nonequlibrium Green's function (NEGF) approach, Wigner function approach, and a density matrix approach. In this talk, results using various codes will be presented. Our process modeling work focuses primarily on epitaxy and etching using first-principles models coupling reactor level and wafer level features. For the latter, we are using a novel approach based on Level Set theory. Sample results from this effort will also be presented.

Meyyappan, Meyya↗

NASA NTRS1993

Lunar-base construction equipment and methods evaluation

A process for evaluating lunar-base construction equipment and methods concepts is presented. The process is driven by the need for more quantitative, systematic, and logical methods for assessing further research and development requirements in an area where uncertainties are high, dependence upon terrestrial heuristics is questionable, and quantitative methods are seldom applied. Decision theory concepts are used in determining the value of accurate information and the process is structured as a construction-equipment-and-methods selection methodology. Total construction-related, earth-launch mass is the measure of merit chosen for mathematical modeling purposes. The work is based upon the scope of the lunar base as described in the National Aeronautics and Space Administration's Office of Exploration's 'Exploration Studies Technical Report, FY 1989 Status'. Nine sets of conceptually designed construction equipment are selected as alternative concepts. It is concluded that the evaluation process is well suited for assisting in the establishment of research agendas in an approach that is first broad, with a low level of detail, followed by more-detailed investigations into areas that are identified as critical due to high degrees of uncertainty and sensitivity.

Boles, Walter W.↗

NASA NTRS1991

Systems engineering studies of lunar base construction

Many ingenious concepts have been proposed for lunar base construction, but few systematic studies exist which relate time-consistent lunar base construction technologies and the choice of lunar base approach with the long-term SEI objectives - i.e., lunar indigenous base construction and Mars Exploration equipment development. To fill this gap, CSC has taken a two-pronged approach. First, the Center undertook basic geotechnical investigations of lunar soil, fabrication of a scale prototype of a lunar construction crane, a multi-robot construction team laboratory experiment, and a preliminary design of lunar base structures. Second, during Jun. and Jul. 1991 two lunar base construction systems engineering studies were accomplished - a 'near term lunar base' study, and a 'far-term lunar base' study. The goals of these studies were to define the major lunar base construction research problems in consistent technology/construction frameworks, and to define design requirements for construction equipment such as a lunar crane and a regolith mover. The 'near-term lunar base' study examined three different construction concepts for a lunar base comprised of pre-fabricated, pre-tested, Space Station Freedom-type modules, which would be covered with regolith shielding. Concept A used a lunar crane for unloading and transportation; concept B, a winch and cart; and concept C, a walker to move the modules from the landing site to the base site and assemble them. To evaluate the merits of each approach, calculations were made of mass efficiency measure, source mass, reliability, far-term base mass, Mars base mass, and base assembly time. The model thus established was also used to define the requirements for crane speed and regolith mover m(sup 3)/sec rates. A major problem addressed is how to 'mine' the regolith and stack it over the habitats as shielding. To identify when the cost of using indigenous lunar materials to construct the base exceeds the cost of development and delivery of the equipment for processing lunar materials, a study of construction of a candidate sintered regolith 'far term lunar base' was undertaken. A technique was devised for casting slabs of sintered (basaltic) regolith and assembling these into a hemispherical (or geodesic) dome. The major problem occurs with the inner liner. At 14.7 psi and 20 percent oxygen internal atmosphere, the entire structure is in tension, even with the regolith load. Also, another study has indicated that at 14.7 psi major resupply of air will be needed because of leakage, and astronauts may have to engage in extensive pre-breathing and post-breathing for extravehicular activity (EVA) tasks, thus detracting from useful mission work time. An alternative is to operate part of the base at, say, 5 psi and 70 percent oxygen, or to equip the astronauts with hard suits at 8.3 psi or greater. All of these choices directly influence base design and construction techniques.

Morgenthaler, George W.↗

NASA NTRS1973

Exploration of Mars by Mariner 9 - Television sensors and image processing.

Two cameras equipped with selenium sulfur slow scan vidicons were used in the orbital reconnaissance of Mars by the U.S. Spacecraft Mariner 9 and the performance characteristics of these devices are presented. Digital image processing techniques have been widely applied in the analysis of images of Mars and its satellites. Photometric and geometric distortion corrections, image detail enhancement and transformation to standard map projection have been routinely employed. More specializing applications included picture differencing, limb profiling, solar lighting corrections, noise removal, line plots and computer mosaics. Information on enhancements as well as important picture geometric information was stored in a master library. Display of the library data in graphic or numerical form was accomplished by a data management computer program.

Cutts, J. A.↗

NASA NTRS1994

Reliability analysis in the Office of Safety, Environmental, and Mission Assurance (OSEMA)

The technical personnel in the SEMA office are working to provide the highest degree of value-added activities to their support of the NASA Langley Research Center mission. Management perceives that reliability analysis tools and an understanding of a comprehensive systems approach to reliability will be a foundation of this change process. Since the office is involved in a broad range of activities supporting space mission projects and operating activities (such as wind tunnels and facilities), it was not clear what reliability tools the office should be familiar with and how these tools could serve as a flexible knowledge base for organizational growth. Interviews and discussions with the office personnel (both technicians and engineers) revealed that job responsibilities ranged from incoming inspection to component or system analysis to safety and risk. It was apparent that a broad base in applied probability and reliability along with tools for practical application was required by the office. A series of ten class sessions with a duration of two hours each was organized and scheduled. Hand-out materials were developed and practical examples based on the type of work performed by the office personnel were included. Topics covered were: Reliability Systems - a broad system oriented approach to reliability; Probability Distributions - discrete and continuous distributions; Sampling and Confidence Intervals - random sampling and sampling plans; Data Analysis and Estimation - Model selection and parameter estimates; and Reliability Tools - block diagrams, fault trees, event trees, FMEA. In the future, this information will be used to review and assess existing equipment and processes from a reliability system perspective. An analysis of incoming materials sampling plans was also completed. This study looked at the issues associated with Mil Std 105 and changes for a zero defect acceptance sampling plan.

Kauffmann, Paul J.↗

NASA NTRS1994

Process capability determination of new and existing equipment

The objective of this paper is to illustrate a method of determining the process capability of new or existing equipment. The method may also be modified to apply to testing laboratories. Long term changes in the system may be determined by periodically making new test parts or submitting samples from the original set to the testing laboratory. The technique described has been developed through a series of projects in special topics manufacturing courses and graduate student projects. It will be implemented as a standard experiment in an advanced manufacturing course in a new Manufacturing Engineering program at the University of Wisconsin-Stout campus. Before starting a project of this nature, it is important to decide on the exact question to be answered. In this case, it is desired to know what variation can be reasonably expected in the next part, feature, or test result produced. Generally, this question is answered by providing the process capability or the average value of a measured characteristic of the part or process plus or minus three standard deviations. There are two general cases to be considered: the part or test is made in large quantities with little change, or the process is flexible and makes a large variety of parts. Both cases can be accommodated; however, the emphasis in this report is on short run situations.

Mcclelland, H. T.↗

DOE OSTI2026

Performance of Quantum Dot Coatings for Luminescent Solar Concentrating Windows: Cooperative Research and Development Final Report, CRADA Number CRD-16-00640

The two major outcomes from this DOE supported collaboration between UbiQD and NREL were: 1) an expert analysis/modeling of the expected performance and cost of luminescent solar concentrating windows with quantum dot coatings, and 2) critical R&D characterization of materials and device performance analysis using equipment and processes that are too expensive for UbiQD to perform in-house. The latter also included third-party validation of the device performance with an NREL-certified conversion efficiency that was ultimately published. (see ACS Energy Lett. 2018 and recently ACS Appl. Energy Mater. 2020).

14 SOLAR ENERGY↗

DOE OSTI2024

Scaleup and Site-Specific Engineering Design for Global Thermostat Direct Air Capture Technology

The overall goal of the project is completion of an initial design of a commercial-scale, Carbon Capture, Utilization, and Storage Direct Air Capture (CCUS-DAC) plant design at three different sites that captures a net of at least 100,000 tonnes per year (TPY) carbon dioxide (CO 2 ) from the atmosphere and considers compression and conditioning of the captured CO 2 for purpose of pipeline transportation to different geological formation sites for deep well injection and underground storage. In addition to the leading system consisting of a scaled-up Global Thermostat DAC unit, overall plant design includes a combined Heat and Power (CHP) unit integrated with a conventional liquid amine-based carbon capture system (90% capture) and compression facilities. These are considered balance of plant (BOP) systems and are required to provide low carbon-intensity steam and power to the DAC process. A second approach involving provision of DAC units modified to directly capture emissions from the CHP unit was initially assessed as an alternative and it was determined to be less mature than considered approach and not included in the scaled-up plant design efforts. Three geographically diverse continental United States locations were selected to better understand the effect of local/regional ambient conditions on scaled-up DAC system performance and project costs: Bucks, Alabama (hot wet climate), Odessa, Texas (dry hot climate), and Goose Creek, Illinois (mid continental climate). The team focused on initial engineering design activities, including the development of project design criteria, initiation of site-specific studies and investigations, completion of DAC system process and equipment design, and definition of balance of plant (BOP) engineering. The purpose of the activities were to develop Technoeconomic Analysis (TEA), Life-Cycle Analysis (LCA), and Environmental, Health, and Safety (EH&S) analysis, and Business Case Analysis (BCA) to validate that the project engineering and scale-up plans of the DAC systems, at each of the three distinct case studies considered, are technically, economically, and environmentally feasible for commercial-scale operation.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2025

Microscopic Measurement: Need for Nuclear Material Sample Specimen Characterization Capability

The Surveillance, Fabrication, and Off-Site Operations team at Lawrence Livermore National Laboratory is beginning an update to the nuclear material machining lab in Superblock. Plutonium and other nuclear materials tend to accelerate the aging process for equipment and machines that would otherwise be maintainable for long lives. They have their lifespans shortened from deteriorated seals, embrittled polymer components, accelerated corrosion, and damage to electronics from exposure to radioactive materials. The cost of installation of equipment into a glove box (GB) tends to outstrip the cost of the equipment itself. Due to the magnification of cost, the historical approach to equipment installs has been to purchase and install the highest-quality and most robust equipment available to maximize time between failures and updates. To make room for the installation of a new lathe, the inspection GB is being moved to a different location within the machining lab. As part of the overall effort, the equipment within the inspection GB is being revisited. Current measurement capabilities are antiquated and starting to become problematic due to age. Advances in metrology are sought for more comprehensive characterization of scientific samples. This document aims to identify several options for the replacement of current measurement equipment and identify a system for purchase and eventual installation. The intention is not to select the cheapest system, but rather to identify a system that best meets the needs of both the operators and principal investigators (PI). Following the convention of the SYSM-5620 Design Thinking and System Engineering, it was determined that a laser confocal measurement system from Keyence is the most suitable option for our programmatic need. Form factor, capability, and maintainability were considered. Along with stakeholder input, to ensure the best decision for the Nuclear Material Technology Program.

36 MATERIALS SCIENCE↗