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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

Vapor-Fed Cathode Microbial Electrolysis Cells with Closely Spaced Electrodes Enables Greatly Improved Performance

Hydrogen can be electrochemically produced in microbial electrolysis cells (MECs) by current generated from bacterial anodes with a small added voltage. MECs typically use a liquid catholyte containing a buffer or salts. However, anions in these catholytes result in charge being balanced predominantly by ions other than hydroxide or protons, leading to anode acidification. To enhance only hydroxide ion transport to the anode, we developed a novel vapor-fed MEC configuration lacking a catholyte with closely spaced electrodes and an anion exchange membrane to limit the acidification. This MEC design produced a record-high sustained current density of 43.1 ± 0.6 A/m 2 and a H 2 production rate of 72 ± 2 LH 2 /L-d (cell voltage of 0.79 ± 0.00 V). There was minimal impact on MEC performance of increased acetate concentrations, solution conductivity, or anolyte buffer capacity at applied voltages up to 1.1 V, as shown by a nearly constant internal resistance of only 6.8 ± 0.3 mΩ m 2 . At applied external voltages >1.1 V, the buffer capacity impacted performance, with current densities increasing from 28.5 ± 0.6 A/m 2 (20 mM phosphate buffer solution (PBS)) to 51 ± 1 A/m 2 (100 mM PBS). Furthermore, these results show that a vapor-fed MEC can produce higher and more stable performance than liquid-fed cathodes by enhancing transport of hydroxide ions to the anode.

anion exchange membrane↗

Reduced Recombination and Improved Performance of CdSe/CdTe Solar Cells due to Cu Migration Induced by Light Soaking

The performance of CdTe solar cells has advanced impressively in recent years with the incorporation of Se. Instabilities associated with light soaking and copper reorganization have been extensively examined for the previous generation of CdS/CdTe solar cells, but instabilities in Cu-doped Se-alloyed CdTe devices remain relatively unexplored. In this work, we fabricated a range of CdSe/CdTe solar cells by sputtering CdSe layers with thicknesses of 100, 120, 150, 180, and 200 nm on transparent oxide-coated glass and then depositing CdTe by close-spaced sublimation. After CdCl 2 annealing, Cu-doping, and back metal deposition, a variety of analyses were performed both before and after light soaking to understand the changes in device performance. The device efficiency was degraded with light soaking in most cases, but devices fabricated with a CdSe layer thickness of 120 nm showed reasonably good efficiency initially (13.5%) and a dramatic improvement with light soaking (16.5%). Here, the efficiency improvement is examined within the context of Cu ion reorganization that is well known for CdS/CdTe devices. Low-temperature photoluminescence data and V oc versus temperature measurements indicate a reduction in nonradiative recombination due to the passivation of defects and defect complexes in the graded CdSe x Te 1–x layer.

CdSexTe1−x↗

CF6 performance improvement

Potential CF6 engine performance improvements directed at reduced fuel consumption were identified and screened relative to airline acceptability and are reviewed. The screening process developed to provide evaluations of fuel savings and economic factors including return on investment and direct operating cost is described. In addition, assessments of development risk and production potential are made. Several promising concepts selected for full-scale development based on a ranking involving these factors are discussed.

Lennard, D. J.↗

Performance Improvements of the Griffin Solvers in FY24

The Griffin code is a MOOSE-based reactor physics application jointly developed by Idaho National Laboratory and Argonne National Laboratory under the Department of Energy Office of Nuclear Energy Nuclear Energy Advanced Modeling and Simulation Program. This fiscal year, we have made significant efforts to improve the performance of transport solver options and cross-section generation for the efficient use of Griffin in advanced reactor applications. For the HFEM-PN solver, the residual evaluations of HFEM kernels were optimized by utilizing the pre- computed averaged cross sections for individual elements. Numerical integration involving the evaluation of basis functions at quadrature points was bypassed by facilitating precomputed element mass matrices for response matrices. Red-black iterations were improved by introducing a new generalized minimum residual based solver. The memory usage of response matrix storage was significantly reduced by applying basis function rotations on interfaces and calculating volumetric odd-parity moments on the fly. Additionally, the adjoint flux and transient calculation capabilities of the HFEM-PN solver were successfully implemented and verified using the TWIGL benchmark problem. For the DFEM-SN solver, memory footprint and computation time were significantly reduced by not treating angular flux vectors as the MOOSE nonlinear system vectors. Specifically for IQS, scalar adjoint weighting was introduced to further eliminate angular adjoint flux storage in the MOOSE auxiliary system. It was demonstrated through the three-dimensional Advanced Burner Test Reactor core problem that the memory usage for transient calculations with the IQS method was reduced by over 7.5× compared to before the optimizations. For the self-shielding application programming interface, a new double-heterogeneity treatment method, named the Bell Function-Based Analytic Two-Region Slowing Down Method, was developed to efficiently flux-volume homogenize TRISO particles with the matrix. Additionally, optimizations were made to hyper- fine group (HFG) slowing down calculations by pretabulating collision probability coefficients and grouping isotopes, significantly reducing the computational time for calculating scattering sources per HFG. Lastly, the pin power reconstruction module was extended to account for temporal behavior in a microreactor analysis problem, specifically for a control drum transient. Verification tests for each of these improvements demonstrated significant performance enhancements and memory reduction.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

Space shuttle external tank performance improvements: The challenge

The external tank (ET) has been actively involved in performance improvements since the inception of the space shuttle program, primarily by weight savings. Weight savings were realized on the first block of flight articles (standard weight tank). With a need for further performance improvements, the ET Program Office was requested to develop a program to reduce tank weight an additional 6000 lb and schedule delivery of the first lightweight ET (LWT) for June 1982. The weight savings program was accomplished by: (1) a unique approach to use of factors of safety; (2) design optimization; and (3) redesign of structures with large margins of safety which resulted in an actual weight savings of 7294 lb. Additional studies have identified further weight savings which are to be implemented at appropriate times in production flow. Examples are an improved thermal protection system for the LH2 tank aft dome and reduction of slosh baffles in the LO2 tank based on flight data. All performance improvements were compared and selected based on non-recurring and recurring cost and technical risk.

Coldwater, H. R.↗

Performance Improvement Through Indexing of Turbine Airfoils: Numerical Simulation - Part 2

An experimental/analytical study has been conducted to determine the performance improvements achievable by circumferentially indexing succeeding rows of turbine stator airfoils. A series of tests was conducted to experimentally investigate stator wake clocking effects on the performance of the space shuttle main engine (SSME) alternate turbopump development (ATD) fuel turbine test article (TTA). The results from this study indicate that significant increases in stage efficiency can be attained through application of this airfoil clocking concept. Details of the experiment and its results are documented in part 1 of this paper. In order to gain insight into the mechanisms of the performance improvement, extensive computational fluid dynamics (CFD) simulations were executed. The subject of the present paper is the initial results from the CFD investigation of the configurations and conditions detailed in part 1 of the paper. To characterize the aerodynamic environments in the experimental test series, two-dimensional (2D), time accurate, multistage, viscous analyses were performed at the TTA midspan. Computational analyses for five different circumferential positions of the first stage stator have been completed. Details of the computational procedure and the results are presented. The analytical results verify the experimentally demonstrated performance improvement and are compared with data whenever possible. Predictions of time-averaged turbine efficiencies as well as gas conditions throughout the flow field are presented. An initial understanding of the turbine performance improvement mechanism based on the results from this investigation is described.

Griffin, Lisa W.↗

CF6 fan performance improvement

A significant portion of the NASA-sponsored Performance Improvement Program for the CF6 engine was the development of an improved fan concept. This involved aerodynamic redesign of the CF6 fan blade to increase fan efficiency while retaining the mechanical integrity, operability, and acoustic characteristics of the existing blade. A further improvement in performance was obtained by adding a fan case stiffener ring to decouple blade-case vibrational characteristics, permitting a significant reduction in running tip clearance. Engine testing was performed to establish the performance, mechanical and acoustic properties of the new design relative to the current fan, and to establish power management characteristics for the CF6-50C2/E2 engine. A significant improvement in cruise power SFC of 1.8 percent was demonstrated in Sea Level testing projected to altitude flight conditions.

Patt, R. F.↗

JT8D-15/17 High Pressure Turbine Root Discharged Blade Performance Improvement

The JT8D high pressure turbine blade and seal were modified, using a more efficient blade cooling system, improved airfoil aerodynamics, more effective control of secondary flows, and improved blade tip sealing. Engine testing was conducted to determine the effect of these improvements on performance. The modified turbine package demonstrated significant thrust specific fuel consumption and exhaust gas temperature improvements in sea level and altitude engine tests. Inspection of the improved blade and seal hardware after testing revealed no unusual wear or degradation.

Janus, A. S.↗

The CF6 engine performance improvement

As part of the NASA-sponsored Engine Component Improvement (ECI) Program, a feasibility analysis of performance improvement and retention concepts for the CF6-6 and CF6-50 engines was conducted and seven concepts were identified for development and ground testing: new fan, new front mount, high pressure turbine aerodynamic performance improvement, high pressure turbine roundness, high pressure turbine active clearance control, low pressure turbine active clearance control, and short core exhaust nozzle. The development work and ground testing are summarized, and the major test results and an enomic analysis for each concept are presented.

Fasching, W. A.↗

JT8D and JT9D jet engine performance improvement program. Task 1: Feasibility analysis

JT8D and JT9D component performance improvement concepts which have a high probability of incorporation into production engines were identified and ranked. An evaluation method based on airline payback period was developed for the purpose of identifying the most promising concepts. The method used available test data and analytical models along with conceptual/preliminary designs to predict the performance improvements, weight, installation characteristics, cost for new production and retrofit, maintenance cost, and qualitative characteristics of candidate concepts. These results were used to arrive at the concept payback period, which is the time required for an airline to recover the investment cost of concept implementation.

Gaffin, W. O.↗

Performance improvements of an F-15 airplane with an integrated engine-flight control system

An integrated flight and propulsion control system has been developed and flight demonstrated on the NASA Ames-Dryden F-15 research aircraft. The highly integrated digital control (HIDEC) system provides additional engine thrust by increasing engine pressure ratio (EPR) at intermediate and afterburning power. The amount of EPR uptrim is modulated based on airplane maneuver requirements, flight conditions, and engine information. Engine thrust was increased as much as 10.5 percent at subsonic flight conditions by uptrimming EPR. The additional thrust significantly improved aircraft performance. Rate of climb was increased 14 percent at 40,000 ft and the time to climb from 10,000 to 40,000 ft was reduced 13 percent. A 14 and 24 percent increase in acceleration was obtained at intermediate and maximum power, respectively. The HIDEC logic performed fault free. No engine anomalies were encountered for EPR increases up to 12 percent and for angles of attack and sideslip of 32 and 11 degrees, respectively.

Myers, Lawrence P.↗

Performance improvements of an F-15 airplane with an integrated engine-flight control system

An integrated flight and propulsion control system has been developed and flight demonstrated on the NASA Ames-Dryden F-15 research aircraft. The highly integrated digital control (HIDEC) system provides additional engine thrust by increasing engine pressure ratio (EPR) at intermediate and afterburning power. The amount of EPR uptrim is modulated based on airplane maneuver requirements, flight conditions, and engine information. Engine thrust was increased as much as 10.5 percent at subsonic flight conditions by uptrimming EPR. The additional thrust significantly improved aircraft performance. Rate of climb was increased 14 percent at 40,000 ft and the time to climb from 10,000 to 40,000 ft was reduced 13 percent. A 14 and 24 percent increase in acceleration was obtained at intermediate and maximum power, respectively. The HIDEC logic performed fault free. No engine anomalies were encountered for EPR increases up to 12 percent and for angles of attack and sideslip of 32 and 11 deg, respectively.

Myers, Lawrence P.↗

INL Human Performance Improvement Guide, GDE-863

Guidance on Integrating Human Performance Improvement including guidance on Developing Area Specific Implementation Plans, Tool Usage, and Building the Capacity for Resiliency aka Failing Safely.

99 GENERAL AND MISCELLANEOUS↗

Electrolysis Performance Improvement and Validation Experiment

Viewgraphs on electrolysis performance improvement and validation experiment are presented. Topics covered include: water electrolysis: an ever increasing need/role for space missions; static feed electrolysis (SFE) technology: a concept developed for space applications; experiment objectives: why test in microgravity environment; and experiment description: approach, hardware description, test sequence and schedule.

Schubert, Franz H.↗

Improved Performance of Cu(InGa)(SeS) 2 PV Modules Using the Reaction of Metal Precursors. Final Report

This project “Improved Performance of Cu(InGa)(SeS) 2 PV Modules using the Reaction of Metal Precursors” was a partnership led by the Institute of Energy Conversion (IEC) at the University of Delaware with Columbia University and the Molecular Foundry at the Lawrence Berkeley National Laboratory. The aim was to develop pathways to improve Cu(InGa)(SeS) 2 (CIGSS) thin film photovoltaic modules using processes compatible with low manufacturing cost. The CIGSS approach investigated was a two-step process including deposition of metal precursor films following by reaction in hydride gases utilizing IEC’s novel reactor. The process was similar to that under commercial development by the project’s industry partner Stion. When Stion went out of business mid-project the focus changed to a rapid thermal process considered more commercially viable. Approaches to improve the performance of solar cells using the reacted films focused on two material innovations. First, the overall Ga content was increased to increase the operating voltage, which is desirable for scale-up to commercial modules. Second, the processing and performance advantages arising from Ag alloying were investigated. Advanced characterization guided process and material development including control of relative composition gradients. Research on the formation of Cu-Ga-In metal precursors utilized sputtering deposition which is normally used in commercial applications. The work resulted in processes for deposition of precursor stacks with increased relative Ga content and effects of deposition parameters on morphology and phase composition were established. It was shown that the metal precursor films have comparable phase composition and morphology so subsequent reaction follows from the same starting point. The addition of Ag to the metal precursors gave more uniform morphology and improved adhesion of reacted films which enable higher reaction temperature for faster processing. A novel outcome was the discovery of a previously undocumented material phase in sputter-deposited and evaporated Ag-Cu-In-Ga thin films. Hydride gas reaction processes including time-temperature-concentration profiles were developed for different precursor compositions. This enables control of composition profiles to engineer through-film gradients for solar cell optimization with characterization and simulations used to correlate measured film composition profiles to measurements of devices. In particular, the gradient of sulfur at the front of the CIGSS film was found to be critical. The simulations guided process development leading to improved reproducibility of devices improved performance with higher Ga content and higher voltage. With Ag-alloyed precursors, the reaction pathways leading were determined. A significant finding was that Ag-alloying increases the reaction rate to completely convert precursor films to the final chalcopyrite which could enable reduced reaction time to benefit manufacturability. To maintain potential commercial viability, the process under investigation was refocused to a rapid thermal process that could potentially be incorporated into an in-line process for manufacturing. Precursors with different composition were capped with an extra selenium layer and reacted in hydrogen sulfide 5-15 minutes, compared to typically 2 hours in the previous multi-step batch process. Critical RTP parameters were identified to control the reaction. Further optimization would be needed for high efficiency solar cells but pathways to high quality devices with further optimization and improved heating uniformity were developed. The project also developed new optoelectronic characterization approaches with a focus on development and application of spatial- and time-resolved photoluminescence and a custom mapping photoluminescence microscope built. It was shown how critical electronic transport properties strongly depend on the chemical composition of the material and that a wide range of samples show inhomogeneity on a length scale larger than the grains in the films. Additionally, two-photon excitation capability was developed to distinguish bulk vs surface losses. The project advances the state-of-the -art for precursor reaction processes in several ways that could impact manufacturing. This includes validation of approaches to increase voltage and establishment of model-guided control to form optimal composition profiles. The application of process control approaches with knowledge of phase formation and reaction pathways can be critically valuable in designing a large-scale process.

14 SOLAR ENERGY↗

Human Performance Improvement Task Group Task 21-1 Best Practice: Using virtual capabilities or options for HPI application (to reduce errors, strengthening defenses, strengthening the organization, and/or increasing capacity)

In 2020 the world was impacted by COVID-19. How work is done was dramatically changed for a large portion of the workforce. Many have made the abrupt shift to working from their home while others have adapted to COVID protocols (such as social distancing and wearing facemasks). Fundamentally, Human and Organizational Performance Improvement concepts and science did not change – only the delivery method changed (in some cases). The primary effect has been to accelerate dynamics already present in society – from e-commerce to online education to remote healthcare. Change is never easy for humans. However, remote work should be viewed as an opportunity; not a fix to a problem. In this Best Practice paper, you’ll get practical suggestions to help you reduce errors and improve Human Performance in remote, socially-distanced “work-from-home” environments.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Space Shuttle SRM performance improvement

A number of options for Solid Rocket Motor (SRM) performance improvement were studied and evaluated by NASA with respect to payload improvement potential, technical risk, schedule, cost, and impact on Shuttle system performance. It was found that the SRM delivered specific impulse could be improved by increasing the nozzle expansion ratio from 7.16 to 7.72. This was achieved by decreasing the throat diameter of the nozzle exit cone, while staying within tooling, facility, and ICD limitations. A simple modification of the grain inhibiting pattern was made to reshape the thrust-time history and thereby obtain more delivered impulse during the early portion of motor operation. These performance options, initiated in October 1980, provide a 3,000 lb payload increase. Longer range options are the use of a filament wound composite case, a HTPB propellant, and further increases in the nozzle expansion ratio. These improvements have a potential of 10,000 to 11,000 lb payload increase.

Speak, C. A.↗