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DOE OSTI2024

Vacuum-assisted extrusion to reduce internal porosity in large-format additive manufacturing

Large-scale 3D printing of polymer composite structures has gained popularity and seen extensive use over the last decade. Much of the research related to improving the mechanical properties of 3D-printed parts has focused on exploring new materials and optimizing print parameters to improve geometric control and minimize voids between printed beads. However, porosity at the microstructural level (within the printed bead) has been much less studied although it is almost universally observed at levels of 4 %-10 % when using fiber reinforced materials. This study introduces a vacuum-assist approach that minimizes internal porosity by removing ambient air from the interstitial space between pellets in the hopper and acts as a negative pressure vent for gases that evolve during the initial stages of single-screw extrusion. Vacuum-assisted extrusion was able to reduce porosity below 2 % across a wide range of processing parameters, moisture content, fiber reinforcements, and printing platforms. Specifically, when printing on a large-format extruder (Strangpresse Model-30), the vacuum-assisted extrusion reduced internal porosity by 35–75 % compared to conventional non-vacuum extrusion, and only pores with length scale > 2 microns are affected. The success of this approach prompted the design of a patent-pending continuous vacuum hopper relevant for large-scale 3D printing on commercial systems.

36 MATERIALS SCIENCE↗

NASA NTRS2013

A Mission Concept: Re-Entry Hopper-Aero-Space-Craft System on-Mars (REARM-Mars)

Future missions to Mars that would need a sophisticated lander, hopper, or rover could benefit from the REARM Architecture. The mission concept REARM Architecture is designed to provide unprecedented capabilities for future Mars exploration missions, including human exploration and possible sample-return missions, as a reusable lander, ascend/descend vehicle, refuelable hopper, multiple-location sample-return collector, laboratory, and a cargo system for assets and humans. These could all be possible by adding just a single customized Re-Entry-Hopper-Aero-Space-Craft System, called REARM-spacecraft, and a docking station at the Martian orbit, called REARM-dock. REARM could dramatically decrease the time and the expense required to launch new exploratory missions on Mars by making them less dependent on Earth and by reusing the assets already designed, built, and sent to Mars. REARM would introduce a new class of Mars exploration missions, which could explore much larger expanses of Mars in a much faster fashion and with much more sophisticated lab instruments. The proposed REARM architecture consists of the following subsystems: REARM-dock, REARM-spacecraft, sky-crane, secure-attached-compartment, sample-return container, agile rover, scalable orbital lab, and on-the-road robotic handymen.

Davoodi, Faranak↗

DOE OSTI1995

Nuclear Safety [Vol. 36, No. 2, July-December 1995]

Nuclear Safety is a journal that covers significant issues in the field of nuclear safety. Its primary scope is safety in the design, construction, operation, and decommissioning of nuclear power reactors worldwide and the research and analysis activities that promote this goal, but it also encompasses the safety aspects of the entire nuclear fuel cycle, including fuel fabrication, spent-fuel processing and handling, and nuclear waste disposal, the handling of fissionable materials and radioisotopes, and the environmental effects of all these activities. Table of Contents for this issue follows. THE CHORNOBYL ACCIDENT: 195 The Chornobyl Accident Revisited, Part III: Chernobyl Source Term Release Dynamics and Reconstruction of Events During the Active Phase, A. R. Sich; GENERAL SAFETY CONSIDERATIONS: 218 Second ANS Workshop on the Safety of Soviet-Designed Nuclear Power Plants, R. A. Bari; 234 Elements of a Nuclear Criticality Safety Program, C. M. Hopper; 243 Rickover, Excellence, and Criticality Safety Programs, R. E. Wilson; ACCIDENT ANALYSIS: 249 Transient Analysis of the PIUS Advanced Reactor Design with the TRAC-PF1/MOD2 Code, B. E. Boyack, J. L Steiner, S. C. Harmony, H. J. Stumpf, and J. F. Lime; 278 The Hierarchy-By-Interval Approach to Identifying Important Models that Need Improvement in Severe-Accident Simulation Codes, T. J. Heames, M. Khatib-Rahbar, J. E. Kelly, R. P. Jenks-Johnson, and Y.-S. Chen; 290 RELAP5/MOD3 Code Coupling Model, R. P. Martin; 299 Missiles Caused by Severe Pressurized-Water Reactor Accidents, R. Krieg; DESIGN FEATURES: 310 Validation of COMMIX with Westinghouse AP-600 PCCS Test Data, J. G. Sun, T. H. Chien, J. Ding, and W T. Sha; ENVIRONMENTAL EFFECTS: 321 Spent Nuclear Fuel Characterization for a Bounding Reference Assembly for the Receiving Basin for Off-Site Fuel, S. D. Kahook, R. L. Garrett, L. R. Canas, and M J. Beckum; OPERATING EXPERIENCES: 332 Reactor Shutdown Experience, Compiled by J. W. Cletcher; U.S. NUCLEAR REGULATORY COMMISSION INFORMATION AND ANALYSES: 335 Reactor Coolant System Blowdown at Wolf Creek on September 17, 1994, J. V. Kauffman and S. L. Israel; RECENT DEVELOPMENTS: 344 Reports, Standards, and Safety Guides, D. S. Oueener; 349 Proposed Rule Changes as of June 30, 1995; ANNOUNCEMENTS: 320 Symposium on Acceptability of Risk From Radiation—Application to Manned Space Flight; 320 24th DOE/NRC Nuclear Air Cleaning and Treatment Conference; 361 Radiation Biology and Radiation Protection— Modern Developments and Tendencies in Radiation Biology; 362 1997 IEEE Sixth Conference on Human Factors and Power Plants; 354 The Authors; 360 Reviewers of Nuclear Safety, Vol. 36.

05 NUCLEAR FUELS↗

DOE OSTI1995

Nuclear Safety [Vol. 36, No. 2, July-December 1995]

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS2019

Missions to Triton and Pluto using a Hopper Vehicle with In-Situ Refueling

The Triton Hopper is a NASA Innovative Advanced Concepts (NIAC) project to design a mission to not merely land, but repeatedly fly across the surface of Triton, utilizing the volatile surface ices (primarily nitrogen) as propellant for a radioisotope-heated thermal rocket engine to launch across the surface and explore all the moon's varied terrain. An engineering design study of the vehicle and mission was done. With a calculated range of 20 km per hop, equator-to-pole mobility can be achieved over a primary mission duration of 2 years. Using Nuclear Electric Propulsion for the transfer vehicle, the same concept can be applied for a mission to the surface of Pluto.

Landis, Geoffrey A.↗

NASA NTRS1978

Engineering Model 8-cm Thruster System

Development of an Engineering Model 8-cm Mercury Ion Thruster System for Satellite Control has been successfully completed. This system operates at a specific impulse in excess of 2600 sec, produces a thrust of 5 mN with a total input power of 165 W; it has a dry mass of 16.6 kg and a mercury-propellant-reservoir capacity of 8.75 kg. This paper summarizes the development work, the system characteristics and performance, and the testing undertaken to verify the design.

Herron, B. G.↗

NASA NTRS1989

Lunar base and Mars base design projects

The space design classes at the University of Texas at Austin undertook seven projects in support of the NASA/USRA advanced space design program during the 1988-89 year. A total of 51 students, including 5 graduate students, participated in the design efforts. Four projects were done within the Aerospace Engineering (ASE) design program and three within the Mechanical Engineering (ME) program. Both lunar base and Mars base design efforts were studied, and the specific projects were as follows: Lunar Crew Emergency Rescue Vehicle (ASE); Mars Logistics Lander Convertible to a Rocket Hopper (ME); A Robotically Constructed Production and Supply Base on Phobos (ASE); A Mars/Phobos Transportation System (ASE); Manned Base Design and Related Construction Issues for Mars/Phobos Mission (ME); and Health Care Needs for a Lunar Colony and Design of Permanent Medical Facility (ME).

Amos, J.↗

DOE OSTI2021

Flow and Arching of Biomass Particles in Wedge-Shaped Hoppers

Poor understanding of the flow behavior of granular biomass material poses great challenges for the bioenergy industry, as the equipment functioning time is significantly reduced by handling issues like screw feeder clogging and hopper arching. In this work, the flow behavior of loblolly pine chips, including the mass flow rate and the critical outlet width, in a wedge-shaped hopper is investigated by combining physical experiments and numerical simulations. Comprehensive characterization of the flow response affected by the two material attributes (initial packing, particle density) and the three operational parameters (hopper outlet width, hopper inclination, and surcharge) is conducted. The results show that the hopper outlet width linearly controls the mass flow rate while the hopper inclination angle controls the critical outlet size. The packing determines whether the flow is smooth or surging, and the surcharge-induced compaction creates flow impedance. The magnitude of these influences varies from a slender hopper with a low inclination angle to a flat-bottom silo. These findings provide guidance for hopper operation in the material handling industry and shed light on the construction of a novel design method for material handling equipment in biorefineries.

09 BIOMASS FUELS↗

DOE OSTI2023

Hybrid Solar System (Final Scientific/Technical Report)

GTI Energy (GTI) teamed with the University of California at Merced (UCM) to scaleup the hybrid solar system (HSS) technology for demonstrating its performance at the US Gypsum (USG) plant in Plaster City, California. The technology integrates two-stage concentrating solar collector with matching particle thermal transport and storage (TSS) system to deliver cost-effective, and on-demand distributed high temperature industrial process heat up to 600°C with solar thermal, in this case to a gypsum kettle, to reduce its fuel use and carbon footprint. Current solar technologies, which reach these temperatures, are not distributable (towers) or cost-effective (dish). The research team developed a conceptual system design for host site retrofit, including preliminary heat balance, process flow diagram, particle to process heat exchanger and equipment placements at the site. Subsequently, parallel efforts were carried out at UCM to design, build and test a 12 m long commercial scale prototype concentrating thermal-only collector system and at GTI to design, build and test a matching 650°C capable particle TTS system. The nominal 50 kWth collector consists of a parabolic trough and three 4 m long two-stage receivers in series. Prior to on-sun testing, a 4 m long receiver was fabricated and successfully tested at 650 °C in a laboratory setting for 100 hrs of continuous operation showing less than 15% radiation loss. A 7 m wide x 17 m long parabolic trough was then installed at UCM for on-sun testing of the 12 m long receiver, and concurrently several 4 m long receivers were built. The optics of the parabolic trough were calibrated, and on-sun test were carried out on 12 m long receivers. During tests, the intense solar radiation (53x) caused the absorber tubes in the receivers to bend, reducing the overall optical efficiency. To address the bending issue, a self-consistent algorithm that includes ray tracing, thermal and deformation models was developed to perform thermal stress analysis on absorbers for parabolic solar collectors. Results obtained with this algorithm showed a dramatic rise in deformation as absorber tube length increases. A combined efficiency parameter that includes the occluded area for the mounts was developed to obtain an optimized tube length obtained. Based on the results, a length of 2.7 m for the absorber + 0.2 m for the coupler was chosen to minimize any bending and optimize optical efficiency while maintaining ease of mounting. The associated particle TTS system was designed, built and successfully tested at GTI. It includes storage, receiving and lock hoppers and piping that simulates the transfer of captured solar energy to an actual industrial furnace. Tests over 77 charge-discharge cycles demonstrated <2% particle degradation, with no problematic particle accumulations and no flow interruptions. The piping pressure drop was about 5 psi. The team also worked with Stanley Consultants (Stanley) to prepare conceptual and preliminary engineering packages to facilitate follow-on development and commercialization efforts. These include process and instrumentation diagram’s (P&ID’s), general arrangements, electrical one-line, project definitions document, equipment data sheets, schedule, and construction cost estimate for 2 MWth system. Updated HSS technology commercialization and customer engagement plans and detailed costs and evaluated market trade-offs and manufacturing.

03 NATURAL GAS↗

NASA NTRS2009

Component and System Sensitivity Considerations for Design of a Lunar ISRU Oxygen Production Plant

Component and system sensitivities of some design parameters of ISRU system components are analyzed. The differences between terrestrial and lunar excavation are discussed, and a qualitative comparison of large and small excavators is started. The effect of excavator size on the size of the ISRU plant's regolith hoppers is presented. Optimum operating conditions of both hydrogen and carbothermal reduction reactors are explored using recently developed analytical models. Design parameters such as batch size, conversion fraction, and maximum particle size are considered for a hydrogen reduction reactor while batch size, conversion fraction, number of melt zones, and methane flow rate are considered for a carbothermal reduction reactor. For both reactor types the effect of reactor operation on system energy and regolith delivery requirements is presented.

Linne, Diane L.↗

NASA NTRS1976

Development of an 8-cm engineering model thruster system

Electric propulsion has been shown to offer major advantages over the techniques currently employed for the control of earth satellites. For a user to realize these advantages, however, requires the availability of a proven, operationally flight-ready propulsion system. Currently an Engineering Model of an 8-cm ion thruster propulsion system is under development. The system includes the thruster unit with its associated reservoir, thruster gimbaling subsystem, and power processing unit. This paper describes the EM System with special emphasis on hardware design and system performance.

Herron, B. G.↗

NASA NTRS1969

High-efficiency boost regulator design for planetary spacecraft.

High efficiency boost regulator design and tests for planetary spacecraft, considering input and output voltages

Hopper, D. J.↗

NASA NTRS2013

Microgravity Storage Vessels and Conveying-Line Feeders for Cohesive Regolith

Under microgravity, the usual methods of placing granular solids into, or extracting them from, containers or storage vessels will not function. Alternative methods are required to provide a motive force to move the material. New configurations for microgravity regolith storage vessels that do not resemble terrestrial silos, hoppers, or tanks are proposed. The microgravity-compatible bulk-material storage vessels and exit feed configurations are designed to reliably empty and feed cohesive material to transfer vessels or conveying ducts or lines without gravity. A controllable motive force drives the cohesive material to the exit opening(s), and provides a reliable means to empty storage vessels and/or to feed microgravity conveying lines. The proposed designs will function equally well in vacuum, or inside of pressurized enclosures. Typical terrestrial granular solids handling and storage equipment will not function under microgravity, since almost all such equipment relies on gravity to at least move material to an exit location or to place it in the bottom of a container. Under microgravity, there effectively are no directions of up or down, and in order to effect movement of material, some other motive force must be applied to the material. The proposed storage vessels utilize dynamic centrifugal force to effect movement of regolith whenever material needs to be removed from the storage vessel. During simple storage, no dynamic motion or forces are required. The rotation rate during emptying can be controlled to ensure that material will move to the desired exit opening, even if the material is highly cohesive, or has acquired an electrostatic charge. The general concept of this Swirl Action Utilized for Centrifugal Ejection of Regolith (SAUCER) microgravity storage unit/dynamic feeder is to have an effective slot-hopper (based on the converging angles of the top and bottom conical section of the vessel) with an exit slot around the entire periphery of the SAUCER. The basic shape of such a unit is like two Chinese straw hats (douli) - one upside down, on the bottom, and another on top; or two wokpans, one upright on the bottom and another inverted on top, with a small gap between the upright and inverted pans or hats (around the periphery). A stationary outer ring, much like an unmounted bicycle tire, surrounds the gap between the two coaxial, nearly conical pieces, forming the top and bottom of the unit.

Walton, Otis R.↗

NASA NTRS2015

The Hopper: A Wearable Robotic Device Testbed for Micro-Gravity Bone-Loading Proof-of-Concept

Wearable robotic systems are showing increased potential for addressing crew countermeasures needs. Wearable robots offer a compactness, programmability, and eccentric loading capability not present in more conventional exercise equipment. Correspondingly, advancements in the man to machine interface has progressed, allowing for higher loads to be applied directly to the person in new and novel ways. Recently, the X1 exoskeleton, a lower extremity wearable robot originally designed for mobility assistance and rehabilitation, underwent human subject testing to assess its potential as a knee dynamometer. This was of interest to NASA physiologists because currently strength is not assessed in flight due to hardware limitations, and thus there is a poor understanding of the time course of in-flight changes to muscle strength. The study concluded that the X1 compared well with the Biodex, the "gold standard" in terrestrial dynamometry, with coefficients of variation less than 6.0%. In a following study, the X1 powered ankle was evaluated for its efficacy in exercising calf muscles. Current on-orbit countermeasures equipment does not adequately protect the calf from atrophy. The results of this study were also positive (targeted muscle activity demonstrated via comparing pre- and post-exercise magnetic resonance imaging T2 measurements), again showing the efficacy of wearable robotic devices for addressing the countermeasure needs of our astronauts. Based on these successes and lessons learned, the Grasshopper was co-developed between IHMC (Florida Institute for Human and Machine Cognition) and NASA. The Grasshopper, or the Hopper for short, is a wearable robotic device designed to address muscle and bone density loss for astronauts spending extended periods of time in micro-gravity. The Grasshopper connects to the user's torso like a hiking backpack, over the shoulders and around the waist. At the feet are footplates that strap to the user. There are two actuators, one at each "knee" joint, which are capable of high fidelity torque control. Because the Hopper uses motors instead of gravity to create the load on the user, the device is suited for use on space missions. Exercise in zero-gravity conditions is critical to maintain muscle strength and bone mass. In operation, the actuators try to fold up, or collapse, the device, putting a compressive load between the user's feet and torso. This force is similar to carrying a heavy backpack. The user then bends and extends his or her knees, replicating a weightlifting squat exercise. The applied load is precisely controlled by a computer, and can be programmed to simulate gravitation loads or any desired load prescription, such as free-weight squat exercise. It is even possible to perform eccentric exercises, or negatives, without the need for a spotter. Because the hip joints, as well as the spine and long leg bones, are in the applied load path, there is the potential to stimulate bone growth, countering the typical bone loss when astronauts return from extended duration space travel.

Beck, C. E.↗

NASA NTRS2018

Triton Hopper: Exploring Neptune's Captured Kuiper Belt Object

Neptune's moon Triton is a fascinating object, a dynamic moon with an atmosphere, and geysers. Triton is unique in the outer solar system in that it is most likely a captured Kuiper belt object (KBO), a leftover building block of the solar system. When Voyager flew by it was the coldest body yet found in our solar system (33 degrees Kelvin) and had volcanic activity, geysers, and a thin atmosphere. It is covered in ices made from nitrogen, water, and carbon-dioxide, and shows surface deposits of tholins, organic compounds that may be precursor chemicals to the origin of life. Exploring Triton will be a challenge well beyond anything done in previous missions; but the unique environment of Triton also allows some new possibilities for mobility. We developed a conceptual design of a Triton Hopping probe that both analyzes the surface and collects it for use to propel its hops. The Hopper would land near the South Pole in 2040 where geysers have been detected. Depending the details of propulsion chosen the Hopper should be able to jump over 300 kilometers in 60 hops or less, exploring the surface and thin atmosphere on its way. This craft will autonomously carry out detailed scientific investigations on the surface, below the surface (drilling) and in the upper atmosphere to provide unprecedented knowledge of a KBO-turned moon and expanding NASA's existing capabilities in deep space planetary exploration to include Hoppers using different ices for propellant. Triton is roughly 2700 kilometers in diameter with a surface of mostly frozen nitrogen, mostly water ice crust and core of metal and rock. Its gravity is half that of Earth's Moon and its atmosphere is 170,000th of Earth's or 0.3 of Mars.The mission concept studied investigated the full surface and atmospheric phenomenon: chemical composition of surface and near subsurface materials, the thin atmosphere, volcanic and geyser activity. Measurements of all these aspects of Triton's unique environment can only be made through focused in-situ exploration with a well-instrumented craft. And this craft will be provided revolutionary mobility, nearly global, using in-situ ices as propellants. While other concepts have looked at gathering gases at Mars to propel a hopper, long periods of time are needed to gather the thin CO2 atmosphere. Several gases, mainly nitrogen are on the surface in a readily dense ice form and just need to be picked up, vaporized and used for propellant.

low conductivity materials↗

NASA NTRS1977

Feeding the feeder

Too often the equipment used to move difficult to handle powdery material from a hopper to process creates a complex of devices whose end result falls short on good performance...simply because equipment design, in many cases, has not kept up with advanced technological concepts in fine powder handling. The Feeder, being the key to an efficient feed system, must be assured a continuous flow from the storage tank...without bridging, arching, spasmodic flow or uncontrolled flushing. The causes and effects of flow problems are discussed and also solutions are offered based on the combination of theoretical and practical experience.

Kurylchek, A. L.↗

NASA NTRS2016

A Basic Robotic Excavator (the Glenn Digger): Description, Design, and Initial Operation

This paper describes the design, commercial part selections, fabrication, assembly, installation, and initial operation of a two degree of freedom robotic excavator. Colloquially referred to as "the NASA Glenn Digger," it was designed specifically to be mounted onto, and to operate with, the then newly developed Centaur 2 robotic mobility base. The excavator, when mounted to Centaur 2, is designed to scoop loose regolith from the terrain, raise its loaded bucket up and dump the load into a hopper of at least a 1-m-height. The hopper represents the input to a machine that would process the raw material, such as to produce oxygen from lunar regolith as would be required for long-term lunar habitation. This equipment debuted at the annual Research and Technology Studies ("Desert RATS", Ref. 1) event held north of Flagstaff, Arizona, in September of 2010, when the Digger was successfully joined to Centaur 2 and the shoveling articulation was demonstrated. During 2011, the hardware was modified for added strength, strain gauges were added to measure loads, and the controls were improved in preparation for the 2011 Desert RATS event, where additional "field operations" experience was gained.

backhoe↗

NASA NTRS2012

Development of Field Excavator with Embedded Force Measurement

A semi-intelligent excavation mechanism was developed for use with the NASA-built Centaur 2 rover prototype. The excavator features a continuously rotatable large bucket supported between two parallel arms, both of which share a single pivot axis near the excavator base attached to the rover. The excavator is designed to simulate the collection of regolith, such as on the Moon, and to dump the collected soil into a hopper up to one meter tall for processing to extract oxygen. Because the vehicle can be autonomous and the terrain is generally unknown, there is risk of damaging equipment or using excessive power when attempting to extract soil from dense or rocky terrain. To minimize these risks, it is critical for the rover to sense the digging forces and adjust accordingly. It is also important to understand the digging capabilities and limitations of the excavator. This paper discusses the implementation of multiple strain gages as an embedded force measurement system in the excavator's arms. These strain gages can accurately measure and resolve multi-axial forces on the excavator. In order to validate these sensors and characterize the load capabilities, a series of controlled excavation tests were performed at Glenn Research Center with the excavator at various depths and cut angles while supported by a six axis load cell. The results of these tests are both compared to a force estimation model and used for calibration of the embedded strain gages. In addition, excavation forces generated using two different types of bucket edge (straight vs. with teeth) were compared.

Soils↗