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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 NTRS1985

Active magnetic bearings for optimum turbomachinery design

The design and shop test results are given for a high speed eight stage centrifugal compressor supported by active magnetic bearings. A brief summary of the rotor dynamics analysis is presented with specific attention given to design considerations for optimum rotor stability. The concerns for retrofit of magnetic bearings in existing machinery are discussed with supporting analysis of a four stage centrifugal compressor. Recommendations are given on design and analysis requirements for successful machinery operation of either retrofit or new design turbomachinery.

Hustak, J.↗
NASA NTRS1985

Design and Fabrication of the NASA Decoupler Pylon for the F-16 Aircraft, Addendum 2

The decoupler pylons which were originally designed and assembled with bushings in the pivot joints were retrofitted with roller bearings. This retrofit, the supporting analyses and the fixture tests of the modified pylons are reported in this document. The loads and stress analysis was directed toward the redesigned parts which were the pylon links and pins. The loads and stress analysis indicates that the pylons with the bearing installation have reduced capacity with respect to the bushing design. Fixture tests of the redesigned pylons were conducted in the GD/FW facility. Breakout friction tests and vibration tests were conducted. The tests show that the joint friction is approximately one-half the level with bearings as compared with the bushing installation. The vibration test data was used to tune the pylon mathematical simulation and this revised pylon simulation was used to recompute airplane modes of vibration. These computed modes of vibration were used in complete airplane symmetric and antisymmetric flutter and aeroservoelastic analyses.

Clayton, J. D.↗
NASA NTRS1986

Report on holographic tests at S-band and K-band on the DSS-63 64 metre antenna

High resolution holographic tests were carried out on DSS-63 at S-band and K-band during May l985. These tests followed a mechanical retrofit which involved the addition of structural bracing to the backing structure. Geosynchronous satellite beacons were used as sources for the tests. At a resolution of 0.4m the S-band and K-band tests revealed rms deviations of the surface to be 2.73mm and 1.53mm, respectively. The difference between these two results is thought to be due mainly to contamination of the S-band surface error map by expected and generally predictable subreflector diffraction effects. The S-band map is also known to be contaminated by diffraction from the subreflector support struts and has a higher noise level than the K-band map. A list of corrections to be applied to the reflector panels is derived from the K-band map. These corrections are predicted to reduce the rms deviation from 1.53mm to 0.86mm at 0.4m resolution. Comparison with results obtained before the mechanical retrofit suggests the major effect of the added structural bracing to be reduction of a third order deformation of the reflector about its axis.

Godwin, M. P.↗
NASA NTRS1993

Active magnetic bearings applied to industrial compressors

The design and shop test results are given for a high-speed eight-stage centrifugal compressor supported by active magnetic bearings. A brief summary of the basic operation of active magnetic bearings and the required rotor dynamics analysis are presented with specific attention given to design considerations for optimum rotor stability. The concerns for retrofits of magnetic bearings in existing machinery are discussed with supporting analysis of a four-stage centrifugal compressor. The current status of industrial machinery in North America using this new support system is presented and recommendations are given on design and analysis requirements for successful machinery operation of either retrofit or new design turbomachinery.

Kirk, R. G.↗
NASA NTRS1999

Demonstration of an Ultra-Short Channel Metal Monolith Catalytic Reactor for Trace Contaminant Control Applications

The International Space Station (ISS) Trace Contaminant Control Subassembly (TCCS) design is based upon proven, highly reliable technology. However, because its core unit operations rely upon expendable activated charcoal and an indirectly heated high temperature catalyst, annual logistics mass, crew time, and power consumption requirements are significant. To address this situation, a unique catalytic reactor design has been developed which is suitable for retrofit into the TCCS's high temperature catalytic oxidizer (HTCO) assembly. The unique design, which employs a metallic, ultra-short channel length monolith (USCM) catalyst substrate, was tested in a flight-like TCCS HTCO assembly to investigate its performance characteristics. Test results indicate that retrofitting the TCCS with a USCM-based catalytic reactor is feasible and that it may provide significant reductions in logistics mass, crew time, and power consumption. Savings indicated by test results are up to 81% for annual logistics, 56% for crew time, and 77% for startup transient duration. In addition, its demonstrated ability to operate in a power saving mode provides up to a 43% savings in average power consumption. A summary of the USCM demonstration test objectives, approach, results, and specific benefits to the TCCS's process economics are presented,

Perry, J. L↗
NASA NTRS1998

Friction Stir Welding of Large Scale Cryogenic Tanks for Aerospace Applications

The Marshall Space Flight Center (MSFC) has established a facility for the joining of large-scale aluminum cryogenic propellant tanks using the friction stir welding process. Longitudinal welds, approximately five meters in length, have been made by retrofitting an existing vertical fusion weld system, designed to fabricate tank barrel sections ranging from two to ten meters in diameter. The structural design requirements of the tooling, clamping and travel system will be described in this presentation along with process controls and real-time data acquisition developed for this application. The approach to retrofitting other large welding tools at MSFC with the friction stir welding process will also be discussed.

Russell, Carolyn↗
NASA NTRS1992

Remote maintenance monitoring system

A remote maintenance monitoring system retrofits to a given hardware device with a sensor implant which gathers and captures failure data from the hardware device, without interfering with its operation. Failure data is continuously obtained from predetermined critical points within the hardware device, and is analyzed with a diagnostic expert system, which isolates failure origin to a particular component within the hardware device. For example, monitoring of a computer-based device may include monitoring of parity error data therefrom, as well as monitoring power supply fluctuations therein, so that parity error and power supply anomaly data may be used to trace the failure origin to a particular plane or power supply within the computer-based device. A plurality of sensor implants may be rerofit to corresponding plural devices comprising a distributed large-scale system. Transparent interface of the sensors to the devices precludes operative interference with the distributed network. Retrofit capability of the sensors permits monitoring of even older devices having no built-in testing technology. Continuous real time monitoring of a distributed network of such devices, coupled with diagnostic expert system analysis thereof, permits capture and analysis of even intermittent failures, thereby facilitating maintenance of the monitored large-scale system.

Simpkins, Lorenz G.↗
NASA NTRS2008

Active Management of Flap-Edge Trailing Vortices

The vortex hazard produced by large airliners and increasingly larger airliners entering service, combined with projected rapid increases in the demand for air transportation, is expected to act as a major impediment to increased air traffic capacity. Significant reduction in the vortex hazard is possible, however, by employing active vortex alleviation techniques that reduce the wake severity by dynamically modifying its vortex characteristics, providing that the techniques do not degrade performance or compromise safety and ride quality. With this as background, a series of experiments were performed, initially at NASA Langley Research Center and subsequently at the Berlin University of Technology in collaboration with the German Aerospace Center. The investigations demonstrated the basic mechanism for managing trailing vortices using retrofitted devices that are decoupled from conventional control surfaces. The basic premise for managing vortices advanced here is rooted in the erstwhile forgotten hypothesis of Albert Betz, as extended and verified ingeniously by Coleman duPont Donaldson and his collaborators. Using these devices, vortices may be perturbed at arbitrarily long wavelengths down to wavelengths less than a typical airliner wingspan and the oscillatory loads on the wings, and hence the vehicle, are small. Significant flexibility in the specific device has been demonstrated using local passive and active separation control as well as local circulation control via Gurney flaps. The method is now in a position to be tested in a wind tunnel with a longer test section on a scaled airliner configuration. Alternatively, the method can be tested directly in a towing tank, on a model aircraft, a light aircraft or a full-scale airliner. The authors believed that this method will have significant appeal from an industry perspective due to its retrofit potential with little to no impact on cruise (devices tucked away in the cove or retracted); low operating power requirements; small lift oscillations when deployed in a time-dependent manner; and significant flexibility with respect to the specific devices selected.

Greenblatt, David↗
NASA NTRS2011

A Focus on Cryogenic Engineering for the Primordial Inflation Polarization Explorer (PIPER) Mission

Cryogenic engineering involves design and modification of equipment that is used under boiling point of nitrogen which is 77 K. The focus of this paper will be on the design of hardware for cryogenic use and a retrofit that was done to the main laboratory cryostat used to test flight components for the Primordial Inflation Polarization Explorer balloon-borne mission. Data from prior tests showed that there was a superfluid helium leak and a total disassemble of the cryostat was conducted in order to localize and fix the leak. To improve efficiency new fill tubes and clamps with modifications were added to the helium tank. Upon removal of the tank, corrosion was found on the flange face that connects to the helium cold plate and therefore had to be fully replaced and copper plated to prevent future corrosion. Indium seals were also replaced for the four fill tubes, a helium level sensor, and the nitrogen and helium tanks. Four additional shielded twisted pairs of cryogenic wire and a wire harness for the Superconducting Quantum Interference Devices (SQUIDs) were added. Finally, there was also design work done for multiple pieces that went inside the cryostat and a separate probe used to test the SQUIDs. Upon successful completion of the cryostat upgrade, tests were run to check the effectiveness and stability of the upgrades. The post-retrofit tests showed minor leaks were still present and due to this, superfluidity has still not been attained. As such there could still be a possibility of a superfluid leak appearing in the future. Regardless, the copper plating on the helium tank has elongated the need to service it by three to five years.

Rosas, Rogelio↗
NASA NTRS2012

Design and Performance of a Wideband Radio Telescope

The Goldstone Apple Valley Radio Telescope (GAVRT) is an outreach project, a partnership involving NASA's Jet Propulsion Laboratory (JPL), the Lewis Center for Educational Research (LCER), and the Apple Valley Unified School District near the NASA Goldstone deep space communication complex. This educational program currently uses a 34-meter antenna, DSS12, at Goldstone for classroom radio astronomy observations via the Internet. The current program utilizes DSS12 in two narrow frequency bands around S-band (2.3 GHz) and X-band (8.45 GHz), and is used by a training program involving a large number of secondary school teachers and their classrooms. To expand the program, a joint JPL/LCER project was started in mid-2006 to retrofit an additional existing 34-meter beam-waveguide antenna, DSS28, with wideband feeds and receivers to cover the 0.5-to- 14-GHz frequency bands. The DSS28 antenna has a 34-meter diameter main reflector, a 2.54-meter subreflector, and a set of beam waveguide mirrors surrounded by a 2.43-meter tube. The antenna was designed for high power and a narrow frequency band around 7.2 GHz. The performance at the low end of the frequency band desired for the educational program would be extremely poor if the beam waveguide system was used as part of the feed system. Consequently, the 34-meter antenna was retrofitted with a tertiary offset mirror placed at the vertex of the main reflector. The tertiary mirror can be rotated to use two wideband feeds that cover the 0.5-to-14-GHz band. The earlier designs for both GAVRT and the DSN only used narrow band feeds and consequently, only covered a small part of the S- and X-band frequencies. By using both a wideband feed and wideband amplifiers, the entire band from 0.5 to 14 GHz is covered, expanding significantly the science activities that can be studied using this system.

Weinreb, Sander↗
NASA NTRS2012

Expanding AirSTAR Capability for Flight Research in an Existing Avionics Design

The NASA Airborne Subscale Transport Aircraft Research (AirSTAR) project is an Unmanned Aerial Systems (UAS) test bed for experimental flight control laws and vehicle dynamics research. During its development, the test bed has gone through a number of system permutations, each meant to add functionality to the concept of operations of the system. This enabled the build-up of not only the system itself, but also the support infrastructure and processes necessary to support flight operations. These permutations were grouped into project phases and the move from Phase-III to Phase-IV was marked by a significant increase in research capability and necessary safety systems due to the integration of an Internal Pilot into the control system chain already established for the External Pilot. The major system changes in Phase-IV operations necessitated a new safety and failsafe system to properly integrate both the Internal and External Pilots and to meet acceptable project safety margins. This work involved retrofitting an existing data system into the evolved concept of operations. Moving from the first Phase-IV aircraft to the dynamically scaled aircraft further involved restructuring the system to better guard against electromagnetic interference (EMI), and the entire avionics wiring harness was redesigned in order to facilitate better maintenance and access to onboard electronics. This retrofit and harness re-design will be explored and how it integrates with the evolved Phase-IV operations.

Laughter, Sean A.↗
NASA NTRS2015

An Investigation of Interval Management Displays

NASA's first Air Traffic Management (ATM) Technology Demonstration (ATD-1) was created to transition the most mature ATM technologies from the laboratory to the National Airspace System. One selected technology is Interval Management (IM), which uses onboard aircraft automation to compute speeds that help the flight crew achieve and maintain precise spacing behind a preceding aircraft. Since ATD-1 focuses on a near-term environment, the ATD-1 flight demonstration prototype requires radio voice communication to issue an IM clearance. Retrofit IM displays will enable pilots to both enter information into the IM avionics and monitor IM operation. These displays could consist of an interface to enter data from an IM clearance and also an auxiliary display that presents critical information in the primary field-of-view. A human-in-the-loop experiment was conducted to examine usability and acceptability of retrofit IM displays, which flight crews found acceptable. Results also indicate the need for salient alerting when new speeds are generated and the desire to have a primary field of view display available that can display text and graphic trend indicators.

Swieringa, Kurt A.↗
NASA NTRS2024

Wilson Corners, Solid Waste Management Unit 001(SWMU 01) 2023 Annual Long-Term Monitoring Report

This report presents a summary of the long-term monitoring (LTM) activities that occurred in 2023 at Wilson Corners, Solid Waste Management Unit 001, at Kennedy Space Center (KSC), Florida. Annual LTM of groundwater is being conducted at the site. Based on results from groundwater sampling activities performed during the 2019 through 2020 LTM reporting period and the 2020 and 2021 DPT groundwater sampling, it was determined that the LTM sampling plan was no longer meeting the goal of LTM because delineation was not verified and the installation of an air sparge (AS) system to treat the area of the High Concentration Plume was recommended. The AS System was installed in late 2022 and early 2023. System start-up activities were initiated in April 2023. Following system startup, several site wells required retrofitting to equip wellheads for withstanding the air pressure released from air sparge wells during system operation. Some site wells also required repair or abandonment, and replacement. Survey of location and top-of-casing of newly installed monitoring wells was combined with scheduled AS system survey activities and was completed in January 2024. The activities presented in this report include the February and April 2023 LTM monitoring well installations; March and April 2023 LTM and performance monitoring well water level gauging and sampling; November 2023 LTM well retrofits and repairs; a summary of December 2023 LTM well abandonments and installations (complete site well abandonment activities will be presented under a separate cover); and January 2024 LTM well survey. During the March and April 2023 sampling events, the low-flow sampling method was used, and samples were analyzed for a select list of volatile organic compounds. In March 2023, groundwater flow for the site was generally to the west was generally consistent with historical observations at the site. The Low Concentration Plume (LCP) continues to extend both horizontally and vertically beyond the terminal depth of the current monitoring well network. Data, inclusive of the 2023 LTM and baseline performance monitoring sampling events, indicate that the LCP encompasses an estimated 19.5 acres, compared to the 2021 LCP footprint, inclusive of the 2020 and 2021 DPT sampling events of 20.7 acres. The vertical extent of VOCs was historically delineated by monitoring wells screened greater than 48 feet below land surface (bls). The results from the three vertical extent monitoring wells screened below 48 feet bls that were sampled during the 2023 LTM indicate that groundwater vinyl chloride concentrations in these three wells are greater than the GCTL. As presented in the 2021 Long-Term Monitoring Report (NASA 2022), the KSCRT agreed to delay deeper investigations in this area to prevent the creation of additional pathways for vertical migration. Based on groundwater sampling activities performed in 2023, recommendations are to perform the next annual LTM sampling event, scheduled for April 2024 and to conduct quarterly performance monitoring of the AS System. The current selection of monitoring wells in the recommended 2024 LTM plan will provide an adequate data set for monitoring groundwater plume behavior; however, the LTM monitoring well network will be evaluated and refined based on 2024 LTM and year one performance monitoring data.

King Linnea↗
DOE OSTI2024

Field Study of 120-volt Heat Pump Water Heaters in the Big Easy

To meet long-term goals for reducing carbon emissions and lessen the impacts of climate change, the U.S. plans to decarbonize its building stock, which includes the replacement of fossil fuel-burning end uses with energy efficient electric alternatives. As part of this strategy, the replacement of fossil fuel water heaters with heat pump water heaters (HPWH) has the potential to avoid substantial carbon emissions. An estimated 10-15 million single-family homes with fossil fuel water heaters do not have the electrical panel capacity to install a 240-volt, 30-amp HPWH. For these homes, a technology recently introduced to the market, the 120-volt plug-in HPWH, can provide energy efficient electrification of water heating without an expensive panel and wiring retrofit. This paper presents the results of an ongoing 120-volt HPWH field study conducted in 17 homes in New Orleans, LA. Key installation scenarios are profiled for retrofitting from gas-fired water heaters to 120-volt HPWHs, accounting for space, air volume, air temperature, condensate drainage, and electrical. Each HPWH had its surrounding air temperature, relative humidity, inlet and outlet water temperature, flow, and energy consumption monitored. Using these data, hot water delivery and energy efficiency performance were analyzed based on home characteristics. Hot water run outs were investigated to understand how hot water usage, inlet water temperature, and surrounding air temperature impact the HPWH’s ability to meet load. From these results, best practices for 120-volt HPWH siting, sizing, and installation were developed. In addition, results are explored further to add insight for electrification policies and product development.

heat pump water heater, 120-volt, Residential buil↗
DOE OSTI2024

Economic and Jobs Impacts of Point-Source Carbon Capture in Cement Industry – Case Study

The cement industry accounts for an estimated 8% of global CO2 emissions, which surpasses that of the entire aviation sector. In contrast with other industries, where CO2 emissions can be drastically reduced via electrification or fuels substitution, cement production releases CO2 as part of its process, during the calcination of carbonates to yield oxides. Thus, point-source carbon capture has become a key technology in the cement industry’s decarbonization. Apart from the expected environmental benefits, point-source carbon capture in the cement industry can yield important economic benefits and create jobs. The objective of this study was to perform a preliminary assessment of the economic and workforce impacts associated with the construction and operation of a point-source carbon capture retrofit of an existing cement production facility, using as a basis the data from a front-end engineering design (FEED) study to install a 3.9 million metric tons per year (Mtpy) CO2 capture facility at Holcim Ste Genevieve cement plant in Missouri, United States of America. The advanced carbon capture technology used in this FEED study was Air Liquide’s Cryocap™ FG carbon capture technology. The study evaluated the direct, indirect, and induced economic impacts of the construction, operation, and maintenance activities of the project over its lifespan. It also covered how the project will generate new jobs, their nature, and quantity, along with strategies to prepare the workforce. To perform this study, construction, operation, and maintenance cost estimates, as well as construction and operation staffing plans from the FEED study were input into IMPLAN version 7.5 software, licensed by IMPLAN Group LLC (Huntersville, VC), to predict the direct, indirect and induced economic impacts of the project using industry multipliers from the software. Additionally, recruitment strategies were developed for hiring individuals who belong to groups that are historically underserved or underrepresented, as well as anticipated recruitment of workers from the local community (whether training will be required or if the skills are associated with an existing labor force). The analysis estimated that the construction and operation of the carbon capture at Holcim Ste. Genevive will result in over 24 thousand work-years of job opportunities, close to USD 10 billion of economic impacts, including over USD 460 million of tax revenue. These results encompass the direct, indirect, and induced effects. A strategy to maximize hiring from the project and neighboring counties was developed, leveraging training agreements with local trade groups and universities. The result of this study can be used for a strategic preliminary assessment of the potential regional economic and job impacts of retrofitting existing cement plants with point source carbon systems, and its methodology can be replicated to individual projects to aid in planning and workforce development.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2025

From Theory to Practice: Feasibility Study of a Thermal Microgrid at a DoD Installation: Preprint

Advanced district thermal energy systems, also known as thermal microgrids, can electrify and decarbonize urban districts in a highly efficient way, but adoption of such systems, especially in the US, has been slow. Thermal microgrids use a network circulating water at near-ambient (60-80 degree F) (15- 25 degree C) temperatures, and water-source heat pumps at connected buildings to boost or lower the temperature for space conditioning and domestic hot water. Addressing challenges related to retrofits of existing buildings for integration with such systems, as well as quantifying the benefits of different configurations, will be key to unlocking the full potential of thermal microgrids for energy savings, decarbonization, and resiliency. This paper will do that, by reporting on preliminary results from a feasibility study of a thermal microgrid, and illustrating the process of conceptual design to seek the best possible performance, within the many constraints of existing buildings. The feasibility study focuses on a cluster of existing buildings, including a grocery store, big box style retail store, motel, and clinic, at a US Department of Defense installation in Germany. The study will assess the performance of a pilot-scale thermal microgrid serving those buildings, in terms of energy, emissions, and life cycle cost, and assess practical considerations (such as building retrofits and scalability) for future implementation. A significant opportunity exists for waste heat recovery from refrigeration at the grocery store (more than offsetting the entire building s space heating load in terms of waste heat availability), and modeling of the proposed thermal microgrid will assess the benefits of the waste heat integration. The moderate operating temperatures of thermal microgrids facilitate the integration of waste heat from a variety of sources, and the networks allow waste heat to be shared amongst buildings in proximity. Along with results on expected energy and emissions performance, as well as waste heat integration, the paper will assess implications of load diversity on system performance. The paper will also discuss the process of evaluating existing building HVAC systems for compatibility with a thermal microgrid, including the feasibility of lower heating hot water temperatures compatible with currently-available water-to-water heat pumps. The cluster of buildings under consideration in this study has much in common with commercial buildings in the United States. The process of and results from this feasibility study can inform assessment of the potential for thermal microgrids in other locations and help unlock the benefits of such systems for decarbonization and energy savings.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Integrating Safety, Security, and Nuclear Operations for Advanced Reactors

The traditional separation between safety, security, and operations teams has created significant barriers to achieving optimal outcomes. When security considerations are introduced late in the design process, they often conflict with already-established architectural, operational, or engineering parameters. Retrofitting security measures can lead to increased costs, schedule delays, and compromises in security effectiveness. For instance, the need to retrofit physical barriers or surveillance systems often results in trade-offs that could have been avoided with earlier input from security professionals. Delayed integration can also affect regulatory processes and result in licensing delays. Security reviews conducted at later stages frequently identify gaps that necessitate significant redesign efforts, impacting not only scope, schedule, and budget, but also adding risk and lowering stakeholder confidence in the project. This paper aims to address these challenges by identifying practical opportunities for integrating security considerations seamlessly with design and operations teams throughout the entire lifecycle of nuclear facilities—from conceptual design to commissioning and beyond. The research emphasizes the value of early and continuous collaboration among stakeholders to ensure that security measures are robust, operationally effective, and cost-efficient. By examining case studies, analyzing past incidents, and leveraging best practices from other high-security industries, this study highlights actionable strategies for bridging the gap between safety, security, and operations teams.

Zineddin, Dr. Z. [ORNL] (ORCID:0009000848740725)↗
DOE OSTI2024

Assessing the impacts of air-sealing on the sizing, operation, and economic feasibility of ground-source heat pumps for electrifying single-family houses in the US

According to recent studies and reports, in single-family houses (SFHs), air-sealing can significantly lower the thermal loads for space heating and cooling. Thus, air-sealing in SFHs could reduce the required size and cost of ground source heat pump (GSHP) systems for electrifying SFHs. Here, this study investigated the costs and benefits of integrating air-sealing with GSHPs for retrofitting existing SFHs when compared with air-source heat pumps. A whole building energy simulation tool integrated with an advanced design tool for modeling ground heat exchangers was used to calculate changes in required GSHP capacity, total borehole length, and building energy consumption with and without air-sealing in SFHs in 16 US climatic regions. The results from this study showed that reducing outdoor air infiltration from 0.8 air changes per hour (ACH) to the minimum ventilation requirement (0.35 ACH) can significantly reduce borehole length (up to 55 %), GSHP capacity (up to 48 %), and total heating electricity reduction, especially in cold climates (up to 44 %). The results also showed that for airtight homes (0.03 ACH infiltration) with a direct outdoor air system, the minimum required borehole length, GSHP capacity, and total heating electricity consumption can be reduced up to 70 %, 68 %, and 67 %, respectively, when compared with SFHs with 0.8 ACH infiltration. Moreover, the life cycle cost analysis showed that air-sealing in conjunction with a GSHP is more profitable than replacing the existing system with an air-source heat pump, even without any incentives for most climatic regions in the US (except for some hot regions).

15 GEOTHERMAL ENERGY↗