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Individual-pressure-vessel (IPV) nickel-hydrogen technology adanced with intention of improving cycle life and performance. One advancement to use 26 percent potassium hydroxide electrolyte to improve cycle life. Another to modify state-of-art cell design to eliminate identified failure modes.
The National Aeronautics and Space Administration has taken an active role in collaborative research with the U.S. aerospace industry to investigate technologies to minimize the impact of aviation on the environment. In December 2006, a new program, called the Fundamental Aeronautics Program, was established to enhance U.S. aeronautics technology and conduct research on energy, efficiency and the environment. A project within the overall program, the Subsonic Fixed Wing Project, was formed to focus on research related to subsonic aircraft with specific goals and time based milestones to reduce aircraft noise, emissions and fuel burn. This paper will present an overview of the Subsonic Fixed Wing Project environmental goals and describe a segment of the current research within NASA and also were worked collaboratively with partners from the U.S. aerospace industry related to the next generation of aircraft that will have lower noise, emissions and fuel burn.
High Energy Materials ( Cathodes, anodes and high voltage and safe electrolyte are required to meet the needs of the future space missions. A. Cathodes: The layered layered composites of of Li2MnO3 and LiMO2 are promising Power capability of the materials, however requires further improvement. Suitable morphology is critical for good performance and high tap (packing) density. Surface coatings help in the interfacial kinetics and stability. B. Electrolytes: Small additions of Flame Retardant Additives improves flammability without affecting performance (Rate and cycle life). 1.0 M in EC+EMC+TPP was shown to have good performance against the high voltage cathode; Performance demonstrated in large capacity prototype MCMB- LiNiCoO2 Cells. Formulations with higher proportions are looking promising. Still requires further validation through abuse tests (e.g., on 18650 cells).
We present a Brook streaming language implementation of the 3-D discontinuous Galerkin method for compressible fluid flow on tetrahedral meshes. Efficient implementation of the discontinuous Galerkin method using the streaming model of computation introduces several algorithmic design challenges. Using a cycle-accurate simulator, performance characteristics have been obtained for the Stanford Merrimac stream processor. The current Merrimac design achieves 128 Gflops per chip and the desktop board is populated with 16 chips yielding a peak performance of 2 Teraflops. Total parts cost for the desktop board is less than $20K. Current cycle-accurate simulations for discretizations of the 3-D compressible flow equations yield approximately 40-50% of the peak performance of the Merrimac streaming processor chip. Ongoing work includes the assessment of the performance of the same algorithm on the 2 Teraflop desktop board with a target goal of achieving 1 Teraflop performance.
Cycle life and performance tests for nickel- cadmium, silver-cadmium, and silver-zinc cells
Individual pressure vessel (IPV) nickel-hydrogen technology was advanced at NASA Lewis and under Lewis contracts with the intention of improving cycle life and performance. One advancement was to use 26 percent potassium hydroxide (KOH) electrolyte to improve cycle life. Another advancement was to modify the state-of-the-art cell design to eliminate identified failure modes. The modified design is referred to as the advanced design. A breakthrough in the low-earth-orbit (LEO) cycle life of IPV nickel-hydrogen cells has been previously reported. The cycle life of boiler plate cells containing 26 percent KOH electrolyte was about 40,000 LEO cycles compared to 3,500 cycles for cells containing 31 percent KOH. The boiler plate test results are in the process of being validated using flight hardware and real time LEO testing at the Naval Weapons Support Center (NWSC), Crane, Indiana under a NASA Lewis Contract. An advanced 125 Ah IPV nickel-hydrogen cell was designed. The primary function of the advanced cell is to store and deliver energy for long-term, LEO spacecraft missions. The new features of this design are: (1) use of 26 percent rather than 31 percent KOH electrolyte; (2) use of a patented catalyzed wall wick; (3) use of serrated-edge separators to facilitate gaseous oxygen and hydrogen flow within the cell, while still maintaining physical contact with the wall wick for electrolyte management; and (4) use of a floating rather than a fixed stack (state-of-the-art) to accommodate nickel electrode expansion due to charge/discharge cycling. The significant improvements resulting from these innovations are: extended cycle life; enhanced thermal, electrolyte, and oxygen management; and accommodation of nickel electrode expansion. The advanced cell design is in the process of being validated using real time LEO cycle life testing of NWSC, Crane, Indiana. An update of validation test results confirming this technology is presented.
Individual pressure vessel (IPV) nickel-hydrogen technology was advanced at NASA Lewis and under Lewis contracts with the intention of improving cycle life and performance. One advancement was to use 26 percent potassium hydroxide (KOH) electrolyte to improve cycle life. Another advancement was to modify the state-of-the-art cell design to eliminate identified failure modes. The modified design is referred to as the advanced design. A breakthrough in the LEO cycle life of IPV nickel-hydrogen cells has been previously reported. The cycle life of boiler plate cells containing 26 percent KOH electrolyte was about 40,000 LEO cycles compared to 3,500 cycles for cells containing 31 percent KOH. The boiler plate test results are in the process of being validated using flight hardware and real time LEO testing. The primary function of the advanced cell is to store and deliver energy for long-term, LEO spacecraft missions. The new features of this design are: (1) use of 26 percent rather than 31 percent KOH electrolyte; (2) use of a patented catalyzed wall wick; (3) use of serrated-edge separators to facilitate gaseous oxygen and hydrogen flow within the cell, while still maintaining physical contact with the wall wick for electrolyte management; and (4) use of a floating rather than a fixed stack (state-of-the-art) to accommodate nickel electrode expansion due to charge/discharge cycling. The significant improvements resulting from these innovations are: extended cycle life; enhanced thermal, electrolyte, and oxygen management; and accommodation of nickel electrode expansion.
An analytical study was made of the performance of air, steam, and water-cooled gas-turbine/steam turbine combined-cycle systems with and without thermal-barrier coatings. For steam cooling, thermal barrier coatings permit an increase in the turbine inlet temperature from 1205 C (2200 F), resulting in an efficiency improvement of 1.9 percentage points. The maximum specific power improvement with thermal barriers is 32.4 percent, when the turbine inlet temperature is increased from 1425 C (2600 F) to 1675 C (3050 F) and the airfoil temperature is kept the same. For water cooling, the maximum efficiency improvement is 2.2 percentage points at a turbine inlet temperature of 1683 C (3062 F) and the maximum specific power improvement is 36.6 percent by increasing the turbine inlet temperature from 1425 C (2600 F) to 1730 C (3150 F) and keeping the airfoil temperatures the same. These improvements are greater than that obtained with combined cycles using air cooling at a turbine inlet temperature of 1205 C (2200 F). The large temperature differences across the thermal barriers at these high temperatures, however, indicate that thermal stresses may present obstacles to the use of coatings at high turbine inlet temperatures.
The paper presents the results of a concept development study of heat rejection systems for Space Station solar dynamic power systems. The thermal performance and weights of each of the heat rejection subsystems have been addressed in detail, and critical technologies which require development tests and evaluation for successful demonstration were assessed and identified. Baseline and several alternate heat rejection system configurations and optimum designs were developed for both Brayton and Rankine cycles. The thermal performance, mass properties, assembly requirements, reliability, maintenance requirements, and life cycle costs were determined for each of the system configurations. Trade studies were performed on each configuration with respect to the heat pipe wall thickness and the amount of redundancy to determine the effects on system reliability, maintenance requirements, and life cycle costs. An optimum design was then selected for each configuration.
Reductions in heat loss at appropriate points in the diesel engine which result in substantially increased exhaust enthalpy were shown. The concepts for this increased enthalpy are the turbocharged, turbocompounded diesel engine cycle. A computer simulation of the heavy duty turbocharged turbo-compounded diesel engine system was undertaken. This allows the definition of the tradeoffs which are associated with the introduction of ceramic materials in various parts of the total engine system, and the study of system optimization. The basic assumptions and the mathematical relationships used in the simulation of the model engine are described.
One hundred thin (120 microns to 260 microns) silicon-aluminum solar cells were fabricated and tested. Silicon slices were prepared, into which an aluminum alloy was evaporated over a range of temperatures and times. Antireflection coatings of tantalum oxide were applied to the cells. Reflectance of the silicon-aluminum interfaces was correlated to alloy temperature (graphs are shown). Optical measurements of the rear surface-internal reflectance of the cells were performed using a Beckman spectrophotometer. An improved gridline pattern was evaluated and stability tests (thermal cycling tests) were performed. Results show that: (1) a high-index, high-transmittance antireflection coating was obtained; (2) the improved metallization of the cells gave a 60 percent rear surface-internal reflectance, and the cells displayed excellent fill factors and blue response of the spectrum; (3) an improved gridline pattern (5 micron linewidths compared to 13 micron linewidths) resulted in a 1.3 percent improvement in short circuit currents; and (4) the stability tests showed no change in cell properties.
JPL is now teaming with Teledyne-Webb-Research to produce the first thermal glider that uses PCM for direct buoyancy control (not electronic pumps) and to produce all other required electricity. TWR has increased electrical production total efficiency from 0.45 to 0.61. JPL performed over 6000 cycles (2.4 years) of accelerated life testing of a piston accumulator. Design, fabrication, and testing will be performed in 2012, with deployment by Rutgers University in late 2012. The proposed goal of the ocean endurance tests was 3 months, but will be extended to at last 1 year. The piston accumulator was cycled over 6,000 times in a three-month period in order to simulate continuous glider life of about 2.4 years, The life test data suggests that we might accumulate roughly 0.5 cc of gas in the oil bladders for each cycle. PCM canisters will be fabricated with a compressed aluminum foam core, 7.5% foam selected (< 42 minutes to freeze anticipated) An Axi 5345/18 3-Phase AC alternator selected for power generation, 61% energy storage efficiency A 4-Cell A123 Energy Storage Systems battery selected for energy storage, buss voltage 14.4 to 12.5 V (13.2 V nominal) Glider deployment expected in late 2012
The present invention comprises an approach for calibrating the sensitivity to polarization, optics degradation, spectral and stray light response functions of instruments on orbit. The concept is based on using an accurate ground-based laser system, Ground-to-Space Laser Calibration (GSLC), transmitting laser light to instrument on orbit during nighttime substantially clear-sky conditions. To minimize atmospheric contribution to the calibration uncertainty the calibration cycles should be performed in short time intervals, and all required measurements are designed to be relative. The calibration cycles involve ground operations with laser beam polarization and wavelength changes.
The present invention comprises an approach for calibrating the sensitivity to polarization, optics degradation, spectral and stray light response functions of instruments on orbit. The concept is based on using an accurate ground-based laser system, Ground-to-Space Laser Calibration (GSLC), transmitting laser light to instrument on orbit during nighttime substantially clear-sky conditions. To minimize atmospheric contribution to the calibration uncertainty the calibration cycles should be performed in short time intervals, and all required measurements are designed to be relative. The calibration cycles involve ground operations with laser beam polarization and wavelength changes.
HFAST is a general-purpose third-order harmonic analysis and design program for predicting the cyclic-steady state thermodynamic performance of Stirling cycles. It represents the state-of-the-art results of years of research efforts at Mechanical Technology Inc. (MTI) in the development of Stirling cycle machines. The code has been extensively used at MTI to support the development of both free-piston and kinematic Stirling cycle machines. Lately, HFAST has undergone many major improvements, both in the analysis method and in the user's interface. This paper presents a brief description of the current analysis method used in HFAST.
As focus shifts towards long-duration space exploration missions, an increased interest in active thermal control of cryogenic propellants to achieve zero boil-off of cryogens has emerged. An active thermal control concept of considerable merit is the integration of a broad area cooling system for a cryogenic propellant tank with a combined cryocooler and circulator system that can be used to reduce or even eliminate liquid cryogen boil-off. One prospective cryocooler and circulator combination is the reverse turbo-Brayton cycle cryocooler. This system is unique in that it has the ability to both cool and circulate the coolant gas efficiently in the same loop as the broad area cooling lines, allowing for a single cooling gas loop, with the primary heat rejection occurring by way of a radiator and/or aftercooler. Currently few modeling tools exist that can size and characterize an integrated reverse turbo-Brayton cycle cryocooler in combination with a broad area cooling design. This paper addresses efforts to create such a tool to assist in gaining a broader understanding of these systems, and investigate their performance in potential space missions. The model uses conventional engineering and thermodynamic relationships to predict the preliminary design parameters, including input power requirements, pressure drops, flow rate, cycle performance, cooling lift, broad area cooler line sizing, and component operating temperatures and pressures given the cooling load operating temperature, heat rejection temperature, compressor inlet pressure, compressor rotational speed, and cryogenic tank geometry. In addition, the model allows for the preliminary design analysis of the broad area cooling tubing, to determine the effect of tube sizing on the reverse turbo-Brayton cycle system performance. At the time this paper was written, the model was verified to match existing theoretical documentation within a reasonable margin. While further experimental data is needed for full validation, this tool has already made significant steps towards giving a clearer understanding of the performance of a reverse turbo-Brayton cycle cryocooler integrated with broad area cooling technology for zero boil-off active thermal control.
Requirements for the orbit transfer vehicle engine were examined. Engine performance/weight sensitivities, the effect of a service life of 300 start/shutdown cycles between overalls on the maximum engine operating pressure, and the sensitivity of the engine design point (i.e., thrust chamber pressure and nozzle area ratio) to the performance requirements specified are among the factors studied. Preliminary engine systems analyses were conducted on the stage combustion, expander, and gas generator engine cycles. Hydrogen and oxygen pump discharge pressure requirements are shown for various engine cycles. Performance of the engine cycles is compared.
The low-cycle fatigue characteristics of smooth bar and notched bar specimens (hourglass shape) of zirconium-copper, 1/2 Hard, material (R-2 Series) were evaluated at room temperature in axial strain control. Over the fatigue life range from about 300 to 3000 cycles the ratio of fatigue life for smooth bar to fatigue life for notched bar remained constant at a value of about 6.0. Some additional hold-time data for the R-2 alloy tested in argon at 538 C are reported. An analysis of the relaxation data obtained in these hold-time tests is also reported and it is shown that these data yield a fairly consistent correlation in terms of instantaneous stress rate divided by instantaneous stress. Two thermal-mechanical strain cycling tests were also performed using a cyclic frequency of 4.5 cycles per hour and a temperature cycling interval from 260 to 538 C. The fatigue life values in these tests were noticeably lower than that observed in isothermal tests at 538 C.