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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Methods for the Automated Determination of Sustained Maximum Amplitudes in Oscillating Signals

Machine condition monitoring has been proven to reduce machine downtime and increase productivity. The state-of-the-art research uses vibration monitoring for tasks such as maintenance and tool wear prediction. A less explored aspect is how vibration monitoring might be used to monitor equipment sensitive to vibration. In a manufacturing environment, one example of where this might be needed is in monitoring the vibration of optical linear encoders used in high-precision machine tools and coordinate measuring machines. Monitoring the vibration of sensitive equipment presents a unique case for vibration monitoring because an accurate calculation of the maximum sustained vibration is needed, as opposed to extracting trends from the data. To do this, techniques for determining sustained peaks in vibration signals are needed. Here, this work fills this gap by formalizing and testing methods for determining sustained vibration amplitudes. The methods are tested on simulated signals based on experimental data. Results show that processing the signal directly with the novel Expire Timer method produces the smallest amounts of error on average under various test conditions. Additionally, this method can operate in real-time on streaming vibration data.

Industrial Internet of Things↗
NASA NTRS2018

Optimal Control Prediction Method for Control Allocation

This paper proposes a novel prediction method for online optimal control allocation that extends the volume of moments achievable with the Moore-Penrose generalized inverse to the entire Attainable Moment Set. This method formulates the control allocation problem using selected basis vectors and associated gains which reduces the optimization problem dimensions and provides physical insight into the resulting optimal solutions. The proposed algorithm finds the entire family of unique optimal control solutions along the desired moment vector from the origin to the boundary of the Attainable Moment Set. Numerical results for the Moore-Penrose prediction method show that the unique minimal controls obtained yield the desired moment with near machine precision accuracy while maintaining control effectors within specified position limits. This method has been fully validated against the unique solution obtained on the boundary of the Attainable Moment Set using the Durham Direct Allocation method. Minimal control solutions obtained for moments in the interior of the Attainable Moment Set, similarly yield the desired moment to near machine precision while providing control solutions that are smaller (i.e. 2-norm) than solutions found with traditional control allocation algorithms (e.g. interior point methods) applied to the minimal control problem. Numerical simulations using a Matlab® autocoded executable (MEX) for the representative real world problem of 3-moments with 20 individual control effectors and prescribed control position limits show a mean computation speed of approximately 125 Hz which is sufficient to enable real-time flight allocation.

Acheson, Michael J.↗
NASA NTRS2019

Efficient computation of optimal low thrust gravity perturbed orbit transfers

We have developed a new method for solving low-thrust fuel-optimal orbit transfer problems in the vicinity of a large body (planet or asteroid), considering a high-fidelity spherical harmonic gravity model. The algorithm is formulated via the indirect optimization method, leading to a two-point boundary value problem (TPBVP). We make use of a hyperbolic tangent smoothing law for performing continuation on the thrust magnitude to reduce the sharpness of the control switches in early iterations and thus promote convergence. The TPBVP is solved using the method of particular solutions (MPS) shooting method and Picard-Chebyshev numerical integration. Application of Picard-Chebyshev integration affords an avenue for increased efficiency that is not available with step-by-step integrators. We demonstrate that computing the particular solutions with only a low-fidelity force model greatly increases the efficiency of the algorithm while ultimately achieving near machine precision accuracy. A salient feature of the MPS is that it is parallelizable, and thus further speedups are available. It is also shown that, for near Earth orbits and over a small number of en-route revolutions around the Earth, only the zonal perturbation terms are required in the costate equations to obtain a solution that is accurate to machine precision and optimal to engineering precision. The proposed framework can be used for trajectory design around small asteroids and also for orbit debris rendezvous and removal tasks.

Junkins, John L.↗
NASA NTRS2008

Compression After Impact Testing of Sandwich Structures Using the Four Point Bend Test

For many composite laminated structures, the design is driven by data obtained from Compression after Impact (CAI) testing. There currently is no standard for CAI testing of sandwich structures although there is one for solid laminates of a certain thickness and lay-up configuration. Most sandwich CAI testing has followed the basic technique of this standard where the loaded ends are precision machined and placed between two platens and compressed until failure. If little or no damage is present during the compression tests, the loaded ends may need to be potted to prevent end brooming. By putting a sandwich beam in a four point bend configuration, the region between the inner supports is put under a compressive load and a sandwich laminate with damage can be tested in this manner without the need for precision machining. Also, specimens with no damage can be taken to failure so direct comparisons between damaged and undamaged strength can be made. Data is presented that demonstrates the four point bend CAI test and is compared with end loaded compression tests of the same sandwich structure.

Nettles, Alan T.↗
NASA NTRS2007

Micro Machining Enhances Precision Fabrication

Advanced thermal systems developed for the Space Station Freedom project are now in use on the International Space Station. These thermal systems employ evaporative ammonia as their coolant, and though they employ the same series of chemical reactions as terrestrial refrigerators, the space-bound coolers are significantly smaller. Two Small Business Innovation Research (SBIR) contracts between Creare Inc. of Hanover, NH and Johnson Space Center developed an ammonia evaporator for thermal management systems aboard Freedom. The principal investigator for Creare Inc., formed Mikros Technologies Inc. to commercialize the work. Mikros Technologies then developed an advanced form of micro-electrical discharge machining (micro-EDM) to make tiny holes in the ammonia evaporator. Mikros Technologies has had great success applying this method to the fabrication of micro-nozzle array systems for industrial ink jet printing systems. The company is currently the world leader in fabrication of stainless steel micro-nozzles for this market, and in 2001 the company was awarded two SBIR research contracts from Goddard Space Flight Center to advance micro-fabrication and high-performance thermal management technologies.

Source record↗
DOE OSTI2024

A Particle-in-Cell Method for Plasmas with a Generalized Momentum Formulation, Part II: Enforcing the Lorenz Gauge Condition

In a previous paper Christlieb et al. (A particle-in-cell method for plasmas with a generalized momentum formulation, part I: Model formulation, 2024), we developed a new particle-in-cell (PIC) method for the relativistic Vlasov–Maxwell system in which the electromagnetic fields and the equations of motion for the particles were cast in terms of scalar and vector potentials through a Hamiltonian formulation. This new method evolved the potentials under the Lorenz gauge using integral equation methods. New methods to construct spatial derivatives of the potentials that converge at the same rates as the fields were also presented. The new particle method was compared against standard explicit discretizations, including the well-known FDTD-PIC method, for a range of applications involving sheaths and particle beams. Here, this paper extends this new class of methods by focusing on the enforcement the Lorenz gauge condition in both exact and approximate forms using co-located meshes. A time-consistency property of the proposed field solver for the vector potential form of Maxwell’s equations is established, which is shown to preserve the equivalence between the semi-discrete Lorenz gauge condition and the analogous semi-discrete continuity equation. Using this property, we present three methods to enforce a semi-discrete gauge condition. The first method introduces an update for the continuity equation that is consistent with the discretization of the Lorenz gauge condition. Both the finite difference and spectral implementations satisfy this discrete gauge condition to machine precision. The second approach we propose enforces a semi-discrete continuity equation using the boundary integral solution to the field equations. The potential benefit of this approach is that it eliminates spatial derivatives that appear on the particle data, namely the current density, which is often calculated by linear combinations of low-order spline basis functions. This method is ideally suited to boundary integral equation methods that invert multi-dimensional operators without dimensional splitting techniques and will be the subject of future work. The third approach introduces a gauge correcting method that makes direct use of the gauge condition to modify the scalar potential and uses local maps for both the charge and current densities. This results in a gauge error, as the maps do not enforce the continuity equation. The vector potential coming from the current density is taken to be exact, and using the Lorenz gauge, we compute a correction to the scalar potential that makes the two potentials satisfy the gauge condition. This method also enforces the gauge condition to machine precision. We demonstrate two of the proposed methods in the context of periodic domains. Problems defined on bounded domains, including those with complex geometric features remain an ongoing effort. However, this work shows that it is possible to design computationally efficient methods that can effectively enforce the Lorenz gauge condition in a non-staggered PIC formulation.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS1988

Holding Irregularly Shaped Parts For Machining

Part with complicated, irregular outside contours clamped for precise machining of internal passages with aid of simple method. Exterior of part cast in Rigidex, or equivalent epoxy. Forms wall to be clamped. Interior of part machined to finish of 125 microinches or finer. When machining finished, epoxy melted away by heating part to 200 degree F.

Hilton, Burt W.↗
NASA NTRSDate not supplied

Students Solving Problems for ISS and Beyond: Inspiring the Next-Generation

Students Solving Problems for ISS and Beyond: Inspiring the Next-Generation Session Title: Students Solving Problems for ISS and Beyond: Inspiring the Next-Generation Session Description: NASA High school students United with NASA to Create Hardware (HUNCH) mission is to empower and inspire students through a Project-Based Learning program where 7-12 grade students learn 21st century skills and can launch their careers through participation in the design and fabrication of real-world valued products for NASA. With six different tracks consisting of Design & Prototype, Culinary Challenge, Softgoods, Precision Machining, Software, and Video Challenge, students are given the opportunity to create solutions for the International Space Station (ISS), the Moon, and beyond. Many projects are requested by the Crew to help ease living conditions, giving students the opportunity to make an impact on the lives of Astronauts. Other projects come directly from NASA and its partners. Join our session to learn how NASA is working with teachers across the country to mentor the next generation of scientists and engineers to solve some of NASA’s greatest challenges. Learning Outcomes: 1. Describe the NASA HUNCH Program, including the program objectives, goals, and strategic partnerships for middle school and high school outreach and advocacy efforts. 2. Identify the innovative strategies NASA is using to work with middle and high school students to solve real-world problems 3. Use the knowledge gained to inspire the next generation of scientists and engineers Session Track: Advocacy & Outreach Specialized Focus Area: Women in Government and Military Learning Level: Foundational Session Format: Listen & Learn Speaker Qualifications: 1. Deboshri Sadhukhan • Current Job Title: Deputy Project Manager • Topic Experience (years of experience related to proposed topic): 1-5 years • Biography: Deboshri Sadhukhan is an engineer for NASA Glenn Research Center (GRC). She has worked on numerous projects — from International Space Station (ISS) fluid technologies, to Orion European Service Module propulsion, to planetary science missions and other game-changing technologies. Her roles have ranged from Project Manager to System Safety Lead. She currently serves as a GRC Regional Mentor for the High school students United with NASA to Create Hardware (HUNCH) program. She also serves as Deputy Project Manager for an ISS payload and Safety & Mission Assurance Lead for a Radioisotope Power Systems project. In these roles, she oversees each phase of a project from beginning to end and provides leadership to increase the reliability, maintainability and system safety of hardware and personnel throughout the system life cycle. She holds a Bachelor of Science in Electrical Engineering from The University of Akron. 2. Nancy Hall • Current Job Title: Project Manager • Topic Experience: 20+ years • Biography: Nancy Rabel Hall earned a B.S. degree in Space Sciences from Florida Institute of Technology and a M.S. degree in Mechanical Engineering from the University of Toledo. She has been at NASA Glenn for over 30 years. She has led several International Space Station experiments that studied how the behavior of fluids and fluid systems behave differently in microgravity as compared to here on Earth. She is also the High school students United with NASA to Create Hardware (HUNCH) project manager, a program that allows students to design and fabricate hardware and softgoods for NASA as well as participate in a culinary and video challenge. She enjoys talking to the public and students about the work being done at NASA as well as showing students how math and science can be fun. She is an amateur radio operator, enjoys playing golf, and reading science fiction and fantasy books.

HUNCH↗
DOE OSTI2025

Design and Construction of a High-Resolution Hodoscope for the GlueX Experiment with High-Statistics Analysis of the p0, ¿, and ¿1 Photoproduction Cross Sections from the RadPhi Experiment

Differential cross sections for forward-angle photoproduction of p0, ¿, and ¿ 1 pseudoscalar mesons were measured using data from the RadPhi experiment conducted in Hall B at Jef ferson Lab. RadPhi utilized a tagged bremsstrahlung photon beam incident on a stationary 9Be target, with a detector system configured to trigger on a recoil proton in coincidence with multiple neutral showers in the calorimeter. Events were reconstructed and subjected to kinematic constraints, with background suppressed via sideband subtraction guided by Monte Carlo modeling of background contributions. Cross sections were extracted over the photon energy range 4.4– 5.4 GeV and binned in invariant momentum transfer t, providing measurements from one of the first high-statistics experiments of forward ¿ and ¿1 pro duction from a nuclear target at these energies. Acceptance corrections were applied using a detailed GEANT-based simulation of the detector geometry and response. The resulting cross sections are consistent with 2020 CLAS results, when scaled by the number of protons in beryllium, and show broad agreement with other data and theoretical models. In parallel, a high-resolution photon tagger detector, the Tagger Microscope (TAGM), was designed, constructed, and commissioned for the GlueX experiment in Hall D at Jefferson Lab. The TAGM was developed to provide high-rate tagging capability in the coherent bremsstrahlung peak by detecting post-bremsstrahlung electrons across a one GeV range along the focal plane of the tagging spectrometer. The detector consists of a 5ˆ102 array of 2ˆ2 mm2 square BCF-20 plastic scintillating fibers thermally fused to BCF-98 light guide fibers optically coupled to silicon photomultipliers. These fibers are mounted in a precision machined framework enabling fine positional adjustments to maintain precise alignment with post-bremsstrahlung electron trajectories, while ensuring mechanical rigidity, thermal stability, optical isolation, minimal inactive area, and radiation shielding for electronics. The construction effort involved extensive testing of fiber quality, light transmission, thermal fusing, radiation hardness, and defect analysis using SEM and EDX techniques. Following its installation and commissioning, the TAGM became a critical component of the GlueX beamline, enabling high-rate tagging essential for studies of hybrid mesons and gluonic ex citations.

McIntyre, James [Univ. of Connecticut, Storrs, CT ↗
NASA NTRS1980

Cryogenic machining of polyurethane foam

Low-density foam can be machined precisely while frozen. Liquid nitrogen cools foam and aluminum heat sink prior to machining. Heat sink keeps part frozen during entire machining operation.

Moshey, E. A.↗
NASA NTRS2009

NASA SBIR Subtopic S2.04 "Advanced Optical Components"

The primary purpose of this subtopic is to develop and demonstrate technologies to manufacture ultra-low-cost precision optical systems for very large x-ray, UV/optical or infrared telescopes. Potential solutions include but are not limited to direct precision machining, rapid optical fabrication, slumping or replication technologies to manufacture 1 to 2 meter (or larger) precision quality mirror or lens segments (either normal incidence for uv/optical/infrared or grazing incidence for x-ray). An additional key enabling technology for UV/optical telescopes is a broadband (from 100 nm to 2500 nm) high-reflectivity mirror coating with extremely uniform amplitude and polarization properties which can be deposited on 1 to 3 meter class mirror.

Stahl, H. Philip↗
DOE OSTI2022

ALDWP Operational Highlights 2021

The Weapons Pit production manufacturing team completed pit build 21-1 assembly operations on December 23, 2020. This build utilized all essential flow sheet steps and included the second -01 long tube cut off extension and welding activity. This is the best build produced in the MC4597-01 pit program to date. Final out-of-line operations, non-destructive evaluation, and radiography was completed during the week of January 4. Depending on the results from high energy radiography, this pit will be considered to be a candidate for CERT-02 and shipment to Lawrence Livermore National Laboratory in support of pit certification. It is notable that this build was completed while concurrently making Plutonium (Pu) metal, producing additional castings, machining Pu parts for Build 22, completing disassembly of two pits, supporting Nightshade B Pu target characterization, and precision machining of Jasper certification base plates.

42 ENGINEERING↗
DOE OSTI2025

Harvesting Reactor Pressure Vessel Beltline Material from the Decommissioned Zion Nuclear Power Plant Unit 1

The decommissioning of the Zion Nuclear Power Plant (NPP) provided a unique opportunity to harvest and study service-aged reactor pressure vessel (RPV) beltline materials. This work, conducted through the U.S. Department of Energy’s Light Water Reactor Sustainability (LWRS) Program, aims to improve the understanding of radiation-induced embrittlement to support extended nuclear plant operations. Material segments containing the Linde 80 flux, wire heat 72105 (WF-70) beltline weld and the A533B Heat B7835-1 base metal, obtained from the intermediate shell region with a peak fluence of 0.7 × 10 19 n/cm 2 (E > 1.0 MeV), were extracted, cut into blocks, and machined into test specimens for mechanical and microstructural characterization. The segmentation process involved oxy-propane torch-cutting, followed by precision machining using wire saws and electrical discharge machining (EDM). A chemical composition analysis confirmed the expected variations in alloying elements, with copper levels being notably higher in the weld metal. The harvested specimens enable a detailed evaluation of through-wall embrittlement gradients, a comparison with the existing surveillance data, and the validation of predictive embrittlement models. This study provides critical data for assessing long-term reactor vessel integrity, informing aging-management strategies, and supporting regulatory decisions to extend the life of nuclear plants. This article is a revised and expanded version of a paper entitled, “Current Status of the Characterization of RPV Materials Harvested from the Decommissioned Zion Unit 1 Nuclear Power Plant”, PVP2017-65090, which was accepted and presented at the ASME 2017 Pressure Vessels and Piping Conference, Waikoloa, HI, USA, 16–20 July 2017.

harvesting beltline material↗
NASA NTRS1983

Ferrofluid Would Seal Linear-Motion Valve

Proposed valve employs ferrofluid to make tight seal. Seal requires no precisely machined parts, and hand lapping of valve seats are unnecessary. Magnetic fluid fills gap between shaft and annular pole piece in chamber wall. Precise shaft fit is not necessary.

Chandler, J. A.↗
DOE OSTI2024

Robust Iterative Method for Symmetric Quantum Signal Processing in All Parameter Regimes

Here, this paper addresses the problem of solving nonlinear systems in the context of symmetric quantum signal processing (QSP), a powerful technique for implementing matrix functions on quantum computers. Symmetric QSP focuses on representing target polynomials as products of matrices in SU(2) that possess symmetry properties. We present a novel Newton’s method tailored for efficiently solving the nonlinear system involved in determining the phase factors within the symmetric QSP framework. Our method demonstrates rapid and robust convergence in all parameter regimes, including the challenging scenario with ill-conditioned Jacobian matrices, using standard double precision arithmetic operations. For instance, solving symmetric QSP for a highly oscillatory target function α cos(1000x) (polynomial degree ≈ 1433) takes 6 iterations to converge to machine precision when α = 0.9, and the number of iterations only increases to 18 iterations when α = 1 – 10 -9 with a highly ill-conditioned Jacobian matrix. Leveraging the matrix product state structure of symmetric QSP, the computation of the Jacobian matrix incurs a computational cost comparable to a single function evaluation. Moreover, we introduce a reformulation of symmetric QSP using real-number arithmetics, further enhancing the method’s efficiency. Extensive numerical tests validate the effectiveness and robustness of our approach, which has been implemented in the QSPPACK software package.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS2015

Testing of an Arcjet Thruster with Capability of Direct-Drive Operation

Electric thrusters typically require a power processing unit (PPU) to convert the spacecraft provided power to the voltage-current that a thruster needs for operation. Testing has been initiated to study whether an arcjet thruster can be operated directly with the power produced by solar arrays without any additional conversion. Elimination of the PPU significantly reduces system-level complexity of the propulsion system, and lowers developmental cost and risk. The work aims to identify and address technical questions related to power conditioning and noise suppression in the system and heating of the thruster in long-duration operation. The apparatus under investigation has a target power level from 400-1,000 W. However, the proposed direct-drive arcjet is potentially a highly scalable concept, applicable to solar-electric spacecraft with up to 100's of kW and beyond. A direct-drive electric propulsion system would be comprised of a thruster that operates with the power supplied directly from the power source (typically solar arrays) with no further power conditioning needed between those two components. Arcjet thrusters are electric propulsion devices, with the power supplied as a high current at low voltage; of all the different types of electric thruster, they are best suited for direct drive from solar arrays. One advantage of an arcjet over Hall or gridded ion thrusters is that for comparable power the arcjet is a much smaller device and can provide more thrust and orders of magnitude higher thrust density (approximately 1-10 N/sq m), albeit at lower I(sub sp) (approximately 800-1000 s). In addition, arcjets are capable of operating on a wide range of propellant options, having been demonstrated on H2, ammonia, N2, Ar, Kr, Xe, while present SOA Hall and ion thrusters are primarily limited to Xe propellant. Direct-drive is often discussed in terms of Hall thrusters, but they require 250-300 V for operation, which is difficult even with high-voltage solar arrays. The arcjet requires under 100 V, which is more in-line with what is easily possible with a solar array. Direct-drive of an electric propulsion system confers the advantage of reducing or eliminating the power processing unit (PPU) that is typically needed to convert the spacecraft-provided power to the voltage and current needed for thruster operation. Since the PPU is typically the most expensive piece of an electric thruster system, from both a fabrication and qualification standpoint, its elimination offers the potential for major reductions in system cost and risk. The design of the arcjet built for this effort was based on previous low power (1 kW class) arcjets. It has a precision machined 99.95% pure tungsten anode which also serves as the nozzle. The anode constrictor region is 1 mm (0.040-in) diameter and 1 mm (0.040-in) long. The cathode is a tungsten welding electrode doped with LaO2; its tip was precision ground to a 30◦ angle ending in a blunt end. The two electrodes are separated by a boron-nitride insulator which also serves as the propellant injection manifold; it ends in six small holes which introduce the propellant gas in the diverging section of the nozzle, directly adjacent to the cathode. The electrodes and insulator are housed in a stainless-steel outer-body, with a Macor insulator at the mid-plane to provide thermal isolation between the front and back halves of the device. The gas seals were made using Grafoil gaskets. Figure 1A shows the assembled thruster in the vacuum chamber; figure 1B shows the thruster in operation on argon at a flow rate of 676 sccm (20 mg/s). Initial testing was conducted in a 3.5-ft diameter vacuum chamber; the ultimate pressure reached during quasi-steady operation of the thruster was about 330 millitorr. The thruster was powered with a high-current, 0-100A, 15 kW power supply. The discharge was initiated with a high-voltage (approximately 10 kV) spark initiator that was isolated from the supply by a stack of diodes. The testing indicated that an operating point exists within the I-V characteristics that is compatible with direct-drive solar-electric operation; for a flow rate of 20 mg/s (argon) the arc could be sustained at a voltage of about 20 V and a current of 25 A (500W).

Martin, Adam K.↗
NASA NTRS2015

Direct Drive Solar-Powered Arcjet Thruster

Electric thrusters typically require a power processing unit (PPU) to convert the spacecraft-provided power to the voltage and current that a thruster needs for operation. NASA Marshall Space Flight Center has initiated fundamental studies on whether an arcjet thruster can be operated directly with the power produced by solar arrays without any additional conversion. Elimination of the PPU significantly reduces system-level complexity of the propulsion system, and lowers developmental cost and risk. The proposed work will aim to refine the proof-of-concept presently being assembled and begin to identify and address technical questions related to power conditioning and noise suppression in the system, and heating of the thruster in long-duration operation. The apparatus proposed for investigation has a target power level of 400 to 1,000 W. The proposed direct-drive arcjet is potentially a highly scalable concept, applicable to spacecraft with up to hundreds of kilowatts and beyond. The design of the arcjet built for this effort was based on previous low power (1 kW class) arcjets.1-3 It has a precision machined 99.95% pure tungsten anode that also serves as the nozzle with a 0.040-in- (1-mm-) diameter, 0.040-in-long constrictor region. An additional anode with a 0.020-in- (0.5-mm-) diameter, 0.020-inlong constrictor region was purchased, but has not yet been used. The cathode is a 0.125-in-diameter tungsten welding electrode doped with lanthum-oxygen; its tip was precision ground to a 308deg angle and terminates in a blunt end. The two electrodes are separated by a boron-nitride insulator that also serves as the propellant manifold; it ends in six small holes which introduce the propellant gas in the diverging section of the nozzle, directly adjacent to the cathode. The electrodes and insulator are housed in a stainless-steel outer body, with a Macor insulator at the mid-plane to provide thermal isolation between the front and back halves of the device. The gas seals were made using Grafoil gaskets. Figure 1(a) shows the assembled thruster; figure 1(b) shows the thruster in the vacuum chamber with electrical and propellant connections.

Polzin, Kurt↗