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Optimization Considerations for Annular Linear Electromagnetic Pumps for Space Nuclear Power and Propulsion

The Need for High Performance Liquid Metal Pumps Testing Power and Efficiency Considerations Liquid metal cooled reactors is one option for space nuclear power for settlements and electric propulsion vehicles (Snap 10 A, SP100, Soviet Topaz reactors) • High heat capacity • High boiling point (NaK~1200K) • Simplified heat transfer loop • Good neutronics Liquid metal EM pumps are desired over conventional pumps owing to lack of seals, bearings elimination of cavitation issues, lower mass and eliminates mechanical impeller • Conduction pumps (typically DC-high current, low voltage; ~5% efficiency) • Induction pumps (typically AC, high efficiency ~40%) Annular linear induction pump is an EM pump with no moving parts and of cylindrical/tubular geometry which makes it straightforward to integrate in conventional piping architectures • Higher inherent reliability • Invented by Einstein and Szilard

ALIP↗

NASA NTRS1981

Advanced Gas Turbine (AGT) powertrain system development for automotive applications

Preliminary layouts were made for the exhaust system, air induction system, and battery installation. Points of interference were identified and resolved by altering either the vehicle or engine designs. An engine general arrangement evolved to meet the vehicle engine compartment constraints while minimizing the duct pressure losses and the heat rejection. A power transfer system (between gasifier and power turbines) was developed to maintain nearly constant temperatures throughout the entire range of engine operation. An advanced four speed automatic transmission was selected to be used with the engine. Performance calculations show improvements in component efficiencies and an increase in fuel economy. A single stage centrifugal compressor design was completed and released for procurement. Gasifier turbine, power turbine, combustor, generator, secondary systems, materials, controls, and transmission development are reported.

Source record↗

NASA NTRS1980

Plastic welder

Low-cost, self-contained, portable welder joins plastic parts by induction heating. Welder is useable in any atmosphere or in vacuum and with most types of thermoplastic; plastic components can be joined in situ. Device is applicable to aerospace industry and in automobile, furniture, and construction industries. Power requirements are easily met by battery or solar energy. In welder, toroidal inductor transfers magnetic flux through thermoplastic to screen. Heated screen causes plastic surface on either side to melt and flow into it to form joint.

Buckley, J. D.↗

NASA NTRS1975

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

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

Lindena, S. J.↗

NASA NTRS2001

High Power Thruster Based on Inductive Magnetized Plasmoid Acceleration

Regardless of the power source, deep space missions will require both high specific impulse (greater than 500 s) and high thrust power (greater than 100kW). These high Isp thrusters will need to have high electrical efficiency (approx. 90%) and low specific mass (alpha approximately less than 10 kg/kW) as well. Additionally they should have high thrust to allow greater mission flexibility. All these requirements can potentially be achieved with the pulsed formation and acceleration of magnetically self-confined plasmoids commonly referred to as compact toroids (CTs). An electromagnetic plasma thruster based on CT acceleration makes an ideal candidate for a high power, high Isp thruster, since the CT is magnetically isolated from the accelerator so that there is no contact between the propellant and the accelerator. The transfer of momentum to the CT occurs through an electromagnetic interaction with the magnetic field. By maintaining an axial magnetic field gradient across it, the directed velocity of the CT can be increased indefinitely. In previous experiments carried out at the University of Washington, CT's of near milligram mass were accelerated to velocities of 250 km/s in a single pulse. The ejection of the plasmoid by an external axial field also avoids the serious problem of detachment, which would occur in thrusters that employ a magnetic mirror or magnetic nozzle. To employ the CT for propulsion, one must design, construct and test a plasma source that is capable of generating a self-confined plasma inductively, and to do it repeatedly at a sufficiently high rep rate. A repetitively pulsed 100 kW level FRC thruster was built and was operated for short bursts at a 10 kHz rep rate and will be described. Another regime for the FRC thruster however is to produce an FRC in a more conventional manner at high voltage and magnetic field. With the large energy transfer with each pulse, the rep rate for this approach is much lower (approximately 100 Hz). This is the approach that is being evaluated at MSFC in the FAST experiment. The purpose of this experiment is to build an FRC thruster, measure its performance characteristics e.g. specific impulse, thrust, and efficiency. This experiment will also be described as well as various mission scenarios that that are well matched for this type of propulsion.

Slough, John↗

NASA NTRS1990

High power density dc-to-dc converters for aerospace applications

Three dc-to-dc converter topologies aimed at high-power high-frequency applications are introduced. Major system parasitics, namely, the leakage inductance of the transformer and the device output capacitance are efficiently utilized. Of the three circuits, the single-phase and three-phase versions of the dual active bridge topology demonstrate minimal stresses, better utilization of the transformer, bidirectional, and buck-boost modes of operation. All circuits operate at a constant switching frequency, thus simplifying design of the reactive elements. The power transfer characteristics and soft-switching regions on the Vout-Iout plane are identified. Two coaxial transformers with different cross-sections were built for a rating of 50 kVA. Based on the single-phase dual active bridge topology, a 50 kW, 50 kHz converter operating at an input voltage of 200 Vdc and an output voltage of 1600 Vdc was fabricated. Characteristics of current-fed output make the dual active bridge topologies amenable to paralleling and hence extension to megawatt power levels. Projections to a 1 MW system operating from a 500 Vdc input, at an output voltage of 10 kVdc and a switching frequency of 50 kHz, using MOS-controlled thyristors, coaxially wound transformers operating at three times the present current density with cooling, and multilayer ceramic capacitors, suggests an overall power density of 0.075 to 0.08 kg/kW and an overall efficiency of 96 percent.

Divan, Deepakraj M.↗

NASA NTRS1998

Induction Bonding of Prepreg Tape and Titanium Foil

Hybrid structural laminates made of titanium foil and carbon fiber reinforced polymer composite offer a potential for improved performance in aircraft structural applications. To obtain information needed for the automated fabrication of hybrid laminates, a series of bench scale tests were conducted of the magnetic induction bonding of titanium foil and thermoplastic prepreg tape. Foil and prepreg specimens were placed in the gap of a toroid magnet mounted in a bench press. Several magnet power supplies were used to study power at levels from 0.5 to 1.75 kW and frequencies from 50 to 120 kHz. Sol-gel surface-treated titanium foil, 0.0125 cm thick, and PIXA/IM7 prepreg tape were used in several lay-up configurations. Data were obtained on wedge peel bond strength, heating rate, and temperature ramp over a range of magnet power levels and frequencies at different "power-on" times for several magnet gap dimensions. These data will be utilized in assessing the potential for automated processing. Peel strengths of foil-tape bonds depended on the maximum temperature reached during heating and on the applied pressure. Maximum peel strengths were achieved at 1.25kW and 8OkHz. Induction heating of the foil appears to be capable of good bonding up to 10 plies of tape. Heat transfer calculations indicate that a 20-40 C temperature difference exists across the tape thickness during heat-up.

Messier, Bernadette C.↗

NASA NTRS2007

A Method to have Multi-Layer Thermal Insulation Provide Damage Detection

Design and testing of a multi-layer thermal insulation system that also provides debris and micrometeorite damage detection is presented. One layer of the insulation is designed as an array of passive open-circuit electrically conductive spiral trace sensors. The sensors are a new class of sensors that are electrically open-circuits that have no electrical connections thereby eliminating one cause of failure to circuits. The sensors are powered using external oscillating magnetic fields. Once electrically active, they produce their own harmonic magnetic fields. The responding field frequency changes if any sensor is damaged. When the sensors are used together in close proximity, the inductive coupling between sensors provides a means of telemetry. The spiral trace design using reflective electrically conductive material provides sufficient area coverage for the sensor array to serves as a layer of thermal insulation. The other insulation layers are designed to allow the sensor s magnetic field to permeate the insulation layers while having total reflective surface area to reduce thermal energy transfer. Results of characterizing individual sensors and the sensor array s response to punctures are presented. Results of hypervelocity impact testing using projectiles of 1-3.6 millimeter diameter having speeds ranging from 6.7-7.1 kilometers per second are also presented.

Woodward, Stanley E.↗

NASA NTRS1994

Fluence-based relative biological effectiveness for charged particle carcinogenesis in mouse Harderian gland

Neoplasia in the rodent Harderian gland has been used to determine the carcinogenic potential of irradiation by HZE particles. Ions from protons to lanthanum at energies up to 670 MeV/a have been used to irradiate mice, and prevalence of Harderian gland tumors has been measured 16 months after irradiation. The Relative Biological Effectiveness (RBE) for tumor induction has been expressed as the RBE(sub max), which is the ratio of the initial slopes of the dose vs prevalence curve. The RBE(sub max) has been found to be approximately 30 for ions with Linear Energy Transfer (LET) values in excess of 100 keV/micrometer. Analysis on the basis of fluence as a substitute for dose has shown that on a per particle basis all of the ions with LET values in excess of 100 keV/micrometer have equal effectiveness. An analysis of the probabilities of ion traversals of the nucleus has shown that for these high stopping powers that a single hit is effective in producing neoplastic transformation.

Alpen, E. L.↗

NASA NTRS1992

The 10 kW power electronics for hydrogen arcjets

A combination of emerging mission considerations such as 'launch on schedule', resource limitations, and the development of higher power spacecraft busses has resulted in renewed interest in high power hydrogen arcjet systems with specific impulses greater than 1000 s for Earth-space orbit transfer and maneuver applications. Solar electric propulsion systems with about 10 kW of power appear to offer payload benefits at acceptable trip times. This work outlines the design and development of 10 kW hydrogen arcjet power electronics and results of arcjet integration testing. The power electronics incorporated a full bridge switching topology similar to that employed in state of the art 5 kW power electronics, and the output filter included an output current averaging inductor with an integral pulse generation winding for arcjet ignition. Phase shifted, pulse width modulation with current mode control was used to regulate the current delivered to arcjet, and a low inductance power stage minimized switching transients. Hybrid power Metal Oxide Semiconductor Field Effect Transistors were used to minimize conduction losses. Switching losses were minimized using a fast response, optically isolated, totem-pole gate drive circuit. The input bus voltage for the unit was 150 V, with a maximum output voltage of 225 V. The switching frequency of 20 kHz was a compromise between mass savings and higher efficiency. Power conversion efficiencies in excess of 0.94 were demonstrated, along with steady state load current regulation of 1 percent. The power electronics were successfully integrated with a 10 kW laboratory hydrogen arcjet, and reliable, nondestructive starts and transitions to steady state operation were demonstrated. The estimated specific mass for a flight packaged unit was 2 kg/kW.

Hamley, John A.↗

NASA NTRS2011

Comparison Between MAD-IPA Thrust Stand Measurements and Performance Modeling

The high specific impulse values associated with electric propulsion (EP) that allow for higher payload fractions than conventional, chemical propulsion are achieved by the acceleration of ionized propellant (plasma) by electromagnetic body forces. The lifetime of many EP devices is limited by electrode erosion caused by direct plasma-electrode interaction, while the efficiency is often limited by, among other thruster-specific factors, the available power in space. The efficiency can be increased during higher power operation since the amount of power required to ionize the propellant is fixed and decreases as a percentage of the increased input power. Pulsed inductive plasma accelerators [1-3] are a potentially elegant solution to the problems of high power demands and electrode erosion. The former is addressed in the pulsed nature of these devices, which allows for instantaneous operation on the order of megawatts while requiring a continuous supply on the order of only kilowatts, while the latter is addressed by inductive coupling of the thruster to ionized propellant. These devices operate by rapidly (on the order of microseconds) discharging stored energy at a given pulse repetition rate through a coil creating time-varying magnetic and electric fields that cause ionization, current formation and acceleration of propellant away from the coil. While the inductive (contact-less) nature of the energy transfer from the thruster to the propellant alleviates the problem of erosion and enables the use of in-situ and storable propellants incompatible with metallic electrodes, it places high voltage demands (on the order of tens of kilovolts) on the energy storage system to achieve propellant ionization.

Hallock, Ashley K.↗

NASA NTRS2007

Development of a Tunable Electromechanical Acoustic Liner for Engine Nacelles

This report describes the development of a tunable electromechanical Helmholtz resonator (EMHR) for engine nacelles using smart materials technology. This effort addresses both near-term and long-term goals for tunable electromechanical acoustic liner technology for the Quiet Aircraft Technology (QAT) Program. Analytical models, i.e. lumped element model (LEM) and transfer matrix (TM) representation of the EMHR, have been developed to predict the acoustic behavior of the EMHR. The models have been implemented in a MATLAB program and used to compare with measurement results. Moreover, the prediction performance of models is further improved with the aid of parameter extraction of the piezoelectric backplate. The EMHR has been experimentally investigated using standard two-microphone method (TMM). The measurement results validated both the LEM and TM models of the EMHR. Good agreement between predicted and measured impedance is obtained. Short- and open circuit loads define the limits of the tuning range using resistive and capacitive loads. There is approximately a 9% tuning limit under these conditions for the non-optimized resonator configuration studied. Inductive shunt loads result in a 3 degree-of-freedom DOF) system and an enhanced tuning range of over 20% that is not restricted by the short- and open-circuit limits. Damping coefficient ' measurements for piezoelectric backplates in a vacuum chamber are also performed and indicate that the damping is dominated by the structural damping losses, such as compliant boundaries, and other intrinsic loss mechanisms. Based on models of the EMHR, a Pareto optimization design of the EMHR has been performed for the EMHR with non-inductive loads. The EMHR with non-inductive loads is a 2DOF system with two resonant fiequencies. The tuning ranges of the two resonant frequencies of the EMHR with non-inductive loads cannot be optimized simultaneously; a trade-off (i.e., a Pareto solution) must be reached. The Pareto solution provides the information for a designer that shows how design trade-offs can be used to satisfy specific design requirements. The optimization design of the EMHR with inductive loads aims at optimal tuning of these three resonant fiequencies. The results indicate that it is possible to keep the acoustic reactance of the resonator close to a constant over a given frequency range. An effort to mimic the second layer of the NASA 2DOF liner using a piezoelectric composite diaphragm has been made. The optimal acoustic reactance of the second layer of the NASA 2DOF liner is achieved using a thin PVDF composite diaphragm, but matching the acoustic resistance requires further investigation. Acoustic energy harvesting is achieved by connecting the EMHR to an energy reclamation circuit that converts the ac voltage signal across the piezoceramic to a conditioned dc signal. Energy harvesting experiment yields 16 m W continuous power for an incident SPL of 153 dB. Such a level is sufficient to power a variety of low power electronic devices. Finally, technology transfer has been achieved by converting the original NASA ZKTL FORTRAN code to a MATLAB code while incorporating the models of the EMHR. Initial studies indicate that the EMHR is a promising technology that may enable lowpower, light weight, tunable engine nacelle liners. This technology, however, is very immature, and additional developments are required. Recommendations for future work include testing of sample EMHR liner designs in NASA Langley s normal incidence dual-waveguide and the grazing-incidence flow facility to evaluating both the impedance characteristics as well as the energy reclamation abilities. Additional design work is required for more complex tuning circuits with greater performance. Poor electromechanical coupling limited the electromechanical tuning capabilities of the proof of concept EMHR. Different materials than those studies and perhaps novel composite material systems may dramatically improvehe electromechanical coupling. Such improvements are essential to improved mimicking of existing double layer liners.

Liu, Fei↗

NASA NTRS1990

Factors shaping the evolution of electronic documentation systems

The main goal is to prepare the space station technical and managerial structure for likely changes in the creation, capture, transfer, and utilization of knowledge. By anticipating advances, the design of Space Station Project (SSP) information systems can be tailored to facilitate a progression of increasingly sophisticated strategies as the space station evolves. Future generations of advanced information systems will use increases in power to deliver environmentally meaningful, contextually targeted, interconnected data (knowledge). The concept of a Knowledge Base Management System is emerging when the problem is focused on how information systems can perform such a conversion of raw data. Such a system would include traditional management functions for large space databases. Added artificial intelligence features might encompass co-existing knowledge representation schemes; effective control structures for deductive, plausible, and inductive reasoning; means for knowledge acquisition, refinement, and validation; explanation facilities; and dynamic human intervention. The major areas covered include: alternative knowledge representation approaches; advanced user interface capabilities; computer-supported cooperative work; the evolution of information system hardware; standardization, compatibility, and connectivity; and organizational impacts of information intensive environments.

Dede, Christopher J.↗

NASA NTRS1977

Design of single-winding energy-storage reactors for dc-to-dc converters using air-gapped magnetic-core structures

A procedure is presented for designing air-gapped energy-storage reactors for nine different dc-to-dc converters resulting from combinations of three single-winding power stages for voltage stepup, current stepup and voltage stepup/current stepup and three controllers with control laws that impose constant-frequency, constant transistor on-time and constant transistor off-time operation. The analysis, based on the energy-transfer requirement of the reactor, leads to a simple relationship for the required minimum volume of the air gap. Determination of this minimum air gap volume then permits the selection of either an air gap or a cross-sectional core area. Having picked one parameter, the minimum value of the other immediately leads to selection of the physical magnetic structure. Other analytically derived equations are used to obtain values for the required turns, the inductance, and the maximum rms winding current. The design procedure is applicable to a wide range of magnetic material characteristics and physical configurations for the air-gapped magnetic structure.

Ohri, A. K.↗

NASA NTRS1983

Development of a rotary power transformer and inverter drive for spacecraft

Many future satellites and spacecraft with spun and despun configurations will require the transfer of power across rotating interfaces in lieu of slip-rings and/or flexures. This is particularly true of spacecraft that have to demonstrate a long life expectancy. The rotary transformer has the desirable characteristics of high reliability and low noise, which qualify it as a potential replacement for slip rings. Development of a rotary power transformer follows the successful completion of a task to develop rotary signal-level transformers for the Galileo Spacecraft Project. The physical configuration of a rotary power transformer has a significant effect on its magnetic and electrical characteristics and therefore impacts the design of the dc/ac inverter driver. Important characteristics addressed during this development effort include: operating frequency, efficiency, transformer gap size, leakage inductance, and leakage flux. A breadboard inverter and rotary transformer were designed, fabricated and tested.

Mclyman, W. T.↗

NASA NTRS1982

Effect of Fluid Flow on Zinc Electrodeposits from Acid Chloride Electrolytes

Zinc was deposited potentiostatically from acid chloride baths. Once bath chemistry and electrochemistry were controlled, the study was focused on convective mass transfer at horizontal electrodes and its effect on cell performance. A laser schlieren imaging technique allowed in situ observations of flow patterns and their correlation with current transients. Convection was turbulent and mass transfer as a function of Rayleigh number was well correlated by: Sh = 0.14 R to the 1/3 power. Similarly, convection initiation time was correlated by DT/d squared = 38 Ra to the -2/3 power. Time scale of fluctuations was about half the initiation time. Taking the boundary layer thickness as a characteristic length, a critical Rayleigh number for the onset of convection was deduced: Ra sub CR = 5000. Placing the anode on the top of the cathode completely changed the flow pattern but kept the I-t curves identical whereas the use of a cathode grid doubled the limiting current. A well defined plateau in the current voltage curves suggested that hydrogen evolution has been successfully inhibited. Finally, long time deposition showed that convection at horizontal electrodes increased the induction time for dentrite growth by at least a factor of 2 with respect to a vertical wire.

Abdelmassir, A. A.↗

NASA NTRS2016

Single-Event Latchup Testing of the Micrel MIC4424 Dual Power MOSFET Driver

We conducted 47 exposures of four different MIC4424 devices and did not observe any SEL or high-current events. This included worst-case conditions with a LET of 81 MeV-sq cm/mg, applied voltage of 18.5 V, a case temperature greater than 120 C, and a final fluence of 1x10(exp 7)/sq cm. We also monitored both the outputs for the presence of SETs. While the period of the 1 MHz square wave was slightly altered in some cases, no pulses were added or deleted. 1. Purpose: The purpose of this testing is to characterize the BiCMOS/DMOS Micrel MIC4424 dual, non-inverting MOSFET driver for single-event latchup (SEL) susceptibility. These data will be used for flight lot evaluation purposes. 2. Devices Tested: The MIC4423/4424/4425 family are highly reliable BiCMOS/DMOS buffer/driver MOSFET drivers. They are higher output current versions of the MIC4426/4427/4428. They can survive up to 5V of noise spiking, of either polarity, on the ground pin. They can accept, without either damage or logic upset, up to half an amp of reverse current (either polarity) forced back into their outputs. Primarily intended for driving power MOSFETs, the MIC4423/4424/4425 drivers are suitable for driving other loads (capacitive, resistive, or inductive) which require low-impedance, high peak currents, and fast switching times. Heavily loaded clock lines, coaxial cables, or piezoelectric transducers are some examples. The only known limitation on loading is that total power dissipated in the driver must be kept within the maximum power dissipation limits of the package. Five (5) parts were provided for SEL testing. We prepared four parts for irradiation and reserved one piece as an un-irradiated control. More information about the devices can be found in Table 1. The parts were prepared for testing by removing the lid from the CDIP package to expose the target die. The parts were then soldered to small copper circuit adapter boards for easy handling. These parts are fabricated in a bulk BiCMOS/DMOS technology. Since we do not know the number of overlayers used in the fabrication processes, linear energy transfer calculations are determined based on the top-surface incident ion species and kinetic energy.

Power MOSFET↗

NASA NTRS2014

Analytic Couple Modeling Introducing Device Design Factor, Fin Factor, Thermal Diffusivity Factor, and Inductance Factor

A set of convenient thermoelectric device solutions have been derived in order to capture a number of factors which are previously only resolved with numerical techniques. The concise conversion efficiency equations derived from governing equations provide intuitive and straight-forward design guidelines. These guidelines allow for better device design without requiring detailed numerical modeling. The analytical modeling accounts for factors such as i) variable temperature boundary conditions, ii) lateral heat transfer, iii) temperature variable material properties, and iv) transient operation. New dimensionless parameters, similar to the figure of merit, are introduced including the device design factor, fin factor, thermal diffusivity factor, and inductance factor. These new device factors allow for the straight-forward description of phenomenon generally only captured with numerical work otherwise. As an example a device design factor of 0.38, which accounts for thermal resistance of the hot and cold shoes, can be used to calculate a conversion efficiency of 2.28 while the ideal conversion efficiency based on figure of merit alone would be 6.15. Likewise an ideal couple with efficiency of 6.15 will be reduced to 5.33 when lateral heat is accounted for with a fin factor of 1.0.

Seebeck effect↗