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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS1995

Mathematical Model Of Curing Behavior Of A Polymer

Mathematical model predicts selected aspects of chemical, thermal and mechanical responses of polymeric liner and propellant materials during curing process. Predictions made both prior to processing and during process in quasi-real time. Developed specifically for use in designing and analyzing process in which bondline materials (including polymeric liners) and propellant cast and cured in rocket motor. With modifications, model applicable to curing of other polymeric materials. Further development may provide direct "in-line" program for calculations, including comparisons, in real time. This will constitute basis for more sophisticated control of process.

Loomis, Willard C.↗
NASA NTRSDate not supplied

Generative Design and Digital Manufacturing: Using AI and Robots to Build Lightweight Instruments

Digital Engineering technologies are transforming long-stagnant development processes by applying the tremendous advancements in Information Technology (IT) to classical engineering tasks such as design, analysis, and fabrication of space-flight instrument structures. Generative Design leverages developments in Artificial Intelligence (AI) and Cloud computing to enable a paradigm shift in the design process, allowing the engineer to focus on defining the requirements and objectives of the design while AI generates optimized designs which comply with the input requirements. Digital Manufacturing allows these complex lightweight designs to be efficiently manufactured by directly fabricating from the resulting 3D models. The development of these two Digital Engineering technologies realizes significant mass savings while simultaneously reducing structure development time from months to days. This paper describes the development of the Evolved Structures process applying these technologies to spaceflight optical instrument structures including an example demonstrating greater than 10x reduction in development time/cost and greater than 3x improvement in structural performance.

Ryan McClelland↗
NASA NTRS1991

Apparatus For Chemically Treating Graphite Fibers

New apparatus for chemical treatment of graphite-fiber tow developed. Applies chemical solutions to commercially purchased unsized fibers or in-house-made fibers, to improve following: handling of fibers, interface bonding of fiber to resin matrix during prepreg fabrication, and interface bonding in laminates during molding process. Designed for research and development, with predrying and post-drying in inert environments. Easily adaptable to different chemical solutions and well suited for small-scale, prototype, tailor-made fiber systems. Used to develop fiber/resin composites for aerospace, automotive, marine, and other applications.

Stanfield, Clarence E.↗
DOE OSTI2023

Combustion of petroleum-based transportation fuels and their blends with biofuels: a new approach for developing surrogates and understanding the effects of blending

Accurate and versatile reaction mechanisms are necessary to simulate combustion of transportation fuels blended with biofuels for improving fuel efficiency, reducing fuel consumption and mitigating the formation and emissions of combustion products harmful to the atmosphere. This project involved a combined effort of simulation and experimentation of liquid fuel burning using a combustion configuration amenable to numerical modeling with a level of detail not previously achieved for blends of biofuels with gasoline certification and surrogate fuels. The configuration of an isolated droplet burning under conditions where gas transport arises solely from fuel evaporation was selected as the platform for experiments and numerical modeling. The spherical symmetry and one-dimensional gas transport that results enabled simulating the droplet burning process with an precedented level of detail. Processes associated with unsteady gas and liquid transport, formation of particulate and gaseous products, radiation, multicomponent phase equilibrium at the droplet surface and moving boundary effects from droplet evaporation, were incorporated in a single numerical framework. The numerical model was based on the open source code OPENSmoke++ (OS) adapted to incorporate the effects noted above. In addition to simulation, an experimental design was developed for the isolated droplet configuration to acquire the data needed for validating the numerical model. Several broad accomplishments of the project were the following: demonstrating generally excellent agreement between measured and simulated combustion parameters for the fuel blends examined that included mixtures of heptane and isobutanol as a model system, and surrogates comprised of up to seven miscible components mixed with ethanol or isobutanol as representative biofuel additives; using a new approach to validate reaction mechanisms of biofuel blends which incorporated fuel evaporation into the process along with developing an experimental design for acquiring data to compare with simulations; and showing that a wealth of information could be obtained on the combustion physics of biofuels from experiments requiring volumes on the order of only nanoliters at a time thus opening the way to evaluating biofuels synthesized by new processes early in development.

02 PETROLEUM↗
NASA NTRS2020

Simulation of Hydrogen Flow in a Nuclear-Thermal Propulsion Reactor Subsystem: Conjugate Heat Transfer in Surrogate Fuel Elements and Flow Through the Dome Inlet to the Fuel Elements

NASA is performing research related to a Nuclear-Thermal Propulsion (NTP) engine as a step toward future manned missions to Mars. BWX Technologies (BWXT), in conjunction with NASA, is developing the reactor subsystem for that NTP engine design. As a subset of the reactor subsystem, the fuel elements have continued to evolve in design, as well. A set of experiments within the Nuclear Thermal Reactor Element Environmental Simulator at NASA Marshall has been developed to compliment that design process, including a series of surrogate fuel elements. Before the experiments of each surrogate can be completed, they must be deemed safe using structural analysis, which itself requires thermal and conjugate heat transfer analyses of the articles. Therefore, conjugate heat transfer simulations of the hydrogen flow through the test article fuel element surrogates were developed to provide estimates of heating, as well as to provide assessments of the fluid flow through the elements. The set of simulations involved not only the separate test conditions, but also a sensitivity study to estimate the effect of physical parameter uncertainty on the selected quantities of interest. Additionally, the fluid flow through the fore section inner plenum dome to the entrances of the fuel elements, another section of the reactor subsystem still under active development, was simulated and analyzed. The simulations show the extent of non-uniformity in the mass flow distribution across the dome outlets. Furthermore, additional analyses estimate the effects of required flow blockages on the potential development of flow dynamics. These analyses were used in the design cycle to make improvements to the reactor subsystem design.

Kalen E. Braman↗
NASA NTRS1983

Development and fabrication of an augmented power transistor

The development of device design and processing techniques for the fabrication of an augmented power transistor capable of fast switching and high voltage power conversion is discussed. The major device goals sustaining voltages in the range of 800 to 1000 V at 80 A and 50 A, respectively, at a gain of 14. The transistor switching rise and fall times were both to have been less than 0.5 microseconds. The development of a passivating glass technique to shield the device high voltage junction from moisture and ionic contaminants is discussed as well as the development of an isolated package that separates the thermal and electrical interfaces. A new method was found to alloy the transistors to the molybdenum disc at a relatively low temperature. The measured electrical performance compares well with the predicted optimum design specified in the original proposed design. A 40 mm diameter transistor was fabricated with seven times the emitter area of the earlier 23 mm diameter device.

Geisler, M. J.↗
NASA NTRS1989

Improved Transparent Furnace For Crystal-Growth Experiments

Novel design and fabrication process for transparent crystal-growing furnace developed. Design consists of one or more heater zones in which heating wire coiled around insides of quartz tubes. Ampoule of material supported inside furnace by guide wire. Crystal then grown by directional freezing of material in ampoule. Distinct feature of use of quartz is capability of direct visual observation of crystal-growth process during experiment. Study of transparent electronic materials conducted in new furnaces.

Rosenthal, Bruce N.↗
NASA NTRS1998

Optimization of Turbine Blade Design for Reusable Launch Vehicles

To facilitate design optimization of turbine blade shape for reusable launching vehicles, appropriate techniques need to be developed to process and estimate the characteristics of the design variables and the response of the output with respect to the variations of the design variables. The purpose of this report is to offer insight into developing appropriate techniques for supporting such design and optimization needs. Neural network and polynomial-based techniques are applied to process aerodynamic data obtained from computational simulations for flows around a two-dimensional airfoil and a generic three- dimensional wing/blade. For the two-dimensional airfoil, a two-layered radial-basis network is designed and trained. The performances of two different design functions for radial-basis networks, one based on the accuracy requirement, whereas the other one based on the limit on the network size. While the number of neurons needed to satisfactorily reproduce the information depends on the size of the data, the neural network technique is shown to be more accurate for large data set (up to 765 simulations have been used) than the polynomial-based response surface method. For the three-dimensional wing/blade case, smaller aerodynamic data sets (between 9 to 25 simulations) are considered, and both the neural network and the polynomial-based response surface techniques improve their performance as the data size increases. It is found while the relative performance of two different network types, a radial-basis network and a back-propagation network, depends on the number of input data, the number of iterations required for radial-basis network is less than that for the back-propagation network.

Shyy, Wei↗
NASA NTRS2018

In Situ Thermal Inspection of Automated Fiber Placement Operations for Tow and Ply Defect Detection

The advent of Automated Fiber Placement (AFP) systems have aided the rapid manufacturing of composite aerospace structures. One of the challenges that AFP systems pose is the uniformity of the deposited prepreg tape layers, which complicates detection of laps, gaps, overlaps and twists. The current detection method used in industry involves halting fabrication and performing a time consuming, visual inspection of each tape layer. Typical AFP systems use a quartz lamp to heat the base layer to make the surface tacky as it deposits another tape layer. The innovation proposed in this paper is to use the preheated base layer as a through-transmission heat source for inspecting the newly added tape layer in situ using a thermographic camera mounted on to the AFP hardware. Such a system would not only increase manufacturing throughput by reducing inspection times, but it would also aid in process development for new structural designs or material systems by providing data on as-built parts. To this end, a small thermal camera was mounted onto an AFP robotic research platform at NASA, and thermal data was collected during typical and experimental layup operations. The data was post processed to reveal defects such as tow overlap/gap, wrinkling, and peel-up. Defects that would have been impossible to detect visually were also discovered in the data, such as poor/loss of adhesion between plies and the effects of vacuum debulking. This paper will cover the results of our experiments, and the plans for future versions of this inspection system.

Juarez, Peter D.↗
NASA NTRS2012

Maturing Pump Technology for EVA Applications in a Collaborative Environment

The transition from low earth orbit Extravehicular Activity (EVA) for construction and maintenance activities to planetary surface EVA on asteroids, moons, and, ultimately, Mars demands a new spacesuit system. NASA's development of that system has resulted in dramatically different pumping requirements from those in the current spacesuit system. Hamilton Sundstrand, Cascon, and NASA are collaborating to develop and mature a pump that will reliably meet those new requirements in space environments and within the design constraints imposed by spacesuit system integration. That collaboration, which began in the NASA purchase of a pump prototype for test evaluation, is now entering a new phase of development. A second generation pump reflecting the lessons learned in NASA's testing of the original prototype will be developed under Hamilton Sundstrand internal research funding and ultimately tested in an integrated Advanced Portable Life Support System (APLSS) in NASA laboratories at the Johnson Space Center. This partnership is providing benefit to both industry and NASA by supplying a custom component for EVA integrated testing at no cost to the government while providing test data for industry that would otherwise be difficult or impossible to duplicate in industry laboratories. This paper discusses the evolving collaborative process, component requirements and design development based on early NASA test experience, component stand alone test results, and near term plans for integrated testing at JSCs.

Hodgson, Edward↗
NASA NTRS2010

Toward Right-Fidelity Rotorcraft Conceptual Design

The aviation Advanced Design Office (ADO) of the US Army Aeroflightdynamics Directorate (AMRDEC) performs conceptual design of advanced Vertical Takeoff and Landing (VTOL) concepts in support of the Army's development and acquisition of new aviation systems. In particular, ADO engages in system synthesis to assess the impact of new technologies and their application to satisfy emerging warfighter needs and requirements. Fundamental to ADO being successful in accomplishing its role; is the ability to evaluate a wide array of proposed air vehicle concepts, and independently synthesize new concepts to inform Army and DoD decision makers about the tradespace in which decisions will be made (Figure 1). ADO utilizes a conceptual design (CD) process in the execution of its role. Benefiting from colocation with NASA rotorcraft researchers at the Ames Research Center, ADO and NASA have engaged in a survey of the current rotorcraft PD practices and begun the process of improving those capabilities to enable effective design and development of the next generation of VTOL systems. A unique aspect of CD in ADO is the fact that actual designs developed in-house are not intended to move forward in the development process. Rather, they are used as reference points in discussions about requirements development and technology impact. The ultimate products of ADO CD efforts are technology impact assessments and specifications which guide industry design activity. The fact that both the requirement and design are variables in the tradespace adds to the complexity of the CD process. A frequent need is ability to assess the relative "cost" of variations in requirement for a diverse set of VTOL configurations. Each of these configurations may have fundamentally different response characteristics to this requirement variation, and such insight into how different requirements drive different designs is a critical insight ADO attempts to provide decision makers. The processes and tools utilized are driven by the timeline in which questions must be answered. This can range from quick "back-of-the-envelope" assessments of a configuration made in an afternoon, to more detailed tradespace explorations that can take upwards of a year to complete. A variety of spreadsheet based tools and conceptual design codes are currently in use. The in-house developed conceptual sizing code RC (Rotorcraft) has been the preferred tool of choice for CD activity for a number of years. Figure 2 illustrates the long standing coupling between RC and solid modeling tools for layout, as well as a number of ad-hoc interfaces with external analyses. RC contains a sizing routine that is built around the use of momentum theory for rotors, classic finite wing theory, a referred parameter engine model, and semi-emperical weight estimation techniques. These methods lend themselves to rapid solutions, measured in seconds and minutes. The successful use of RC, however requires careful consideration of model input parameters and judicious comparison with existing aircraft to avoid unjustified extrapolation of results. RC is in fact a legacy of a series of codes whose development started in the early 1970s, and is best suited to the study of conventional helicopters and XV-15 style tiltrotors. Other concepts have been analyzed with RC, but typically it became necessary to modify the source code and methods for each unique configuration. Recent activity has lead to the development of a new code, NASA Design and Analysis of Rotorcraft (NDARC). NDARC uses a similar level of analytical fidelity as RC, but is built on a new framework intended to improve modularity and ability to rapidly model a wider array of concepts. Critical to achieving this capability is the decomposition of the aircraft system into a series of fundamental components which can then be assembled to form a wide-array of configurations. The paper will provide an overview of NDARC and its capabilities.

Sinsay, Jeffrey D.↗
NASA NTRS1990

Documenting the decision structure in software development

Current software development paradigms focus on the products of the development process. Much of the decision making process which produces these products is outside the scope of these paradigms. The Decision-Based Software Development (DBSD) paradigm views the design process as a series of interrelated decisions which involve the identification and articulation of problems, alternates, solutions and justifications. Decisions made by programmers and analysts are recorded in a project data base. Unresolved problems are also recorded and resources for their resolution are allocated by management according to the overall development strategy. This decision structure is linked to the products affected by the relevant decision and provides a process oriented view of the resulted system. Software maintenance uses this decision view of the system to understand the rationale behind the decisions affecting the part of the system to be modified. D-HyperCase, a prototype Decision-Based Hypermedia System is described and results of applying the DBSD approach during its development are presented.

Wild, J. Christian↗
NASA NTRS1984

Characterization of physiochemical properties of polymeric and electrochemical materials for aerospace flight

Nickel-cadmium rechargeable batteries are a vital and reliable energy storage source for aerospace applications. As the demand for longer life and more reliable space batteries increases, the understanding and solving of cell aging factors and mechanisms become essential. Over the years, many cell designs and manufacturing process changes have been developed and implemented. Cells fabricated with various design features were life cycled in a simulated low-Earth orbit regime. Following the test program, a comprehensive electrochemical analysis of cell components was undertaken to study cell degradation mechanisms. Discharge voltage degradation or voltage plateau has been observed during orbit cycling, but, its cause and explanation have been the subject of much discussion. A Hg/HgO reference electrode was used to monitor the reference versus each electrode potential during the discharge of a cycled cell. The results indicate that the negative electrode was responsible for the voltage plateau. Cell analysis revealed large crystals of cadmium hydroxide on the surface of the negative electrode and throughout the separator.

Rock, M.↗
NASA NTRSDate not supplied

Having a Come-Apart: Lessons Learned from Additively Manufactured Hardware Failures

NASA has been engaged with additively manufactured (AM) process and component development since the 2000’s. AM offers various technical advantages, such as enhanced hardware design complexity, part consolidation, and processing of novel alloys in addition to programmatic advantages for reduction in processing time and cost. The focus of much of the AM development at NASA has been to mature the various processes, characterize material properties, develop standards, produce demonstrator parts, and integrate AM hardware in liquid rocket engines. These aspects have been demonstrated through process and design iterations using a methodical characterization, test-fail-fix cycles, as well as application and dissemination of lessons learned. In addition to these fundamental demonstrations of the AM process and hardware development, alloys that provide performance advantages in the high temperature and high-pressure environments have been matured for use in rocket engines. These environments are challenging for any alloy and any design, and the AM process is required to fully meet the intended design requirements. The importance of proper AM process was made evident in the failure of a Laser Powder Bed Fusion (L-PBF) copper-alloy combustion chamber during a hot-fire test due to a degraded material quality resulted from an AM process issue. The hot-fire test aimed to demonstrate high duty cycle under a risk-tolerant development project, where consequences of component failure would be minimal. However, the unintentional component failure emphasized the necessity of robust material characterization and rigorous process control procedures for the safe use of AM components in critical applications. In part, such concerns motivate the AM certification approach that NASA has recently adopted in NASA-STD-6030 “Additive Manufacturing Requirements for Spaceflight Systems”. This presentation provides an overview of the previously mentioned failure, a discussion on the evaluation of the failed chamber and supplemental chambers produced at the same time, a representative material samples that included intentional build witness lines, and a summary of the key results and recommendations from the evaluations. NASA continues to approach AM processes and designs with a level of risk and acceptance of failures that is appropriate for the project objectives, with the overall goal of safe implementation of AM technology and transferring AM technology into commercial space applications. The objective of this presentation is to provide awareness to the community working critical and non-critical AM components and the lessons learned on proper implementation of AM.

Additive Manufacturing↗
NASA NTRS2019

Additive Manufacturing Development and Hot-Fire Testing of Liquid Rocket Channel Wall Nozzles Using Blown Powder Directed Energy Deposition Inconel 625 and JBK-75 Alloys

Additive manufacturing (AM) is being investigated at NASA and across much of the rocket propulsion industry as an alternate fabrication technique to create complex geometries for liquid engine components that offers schedule and cost saving opportunities. The geometries that can be created using AM offer a significant advantage over traditional techniques. Internal complexities, such as internal coolant channels for combustion chambers and nozzles that would typically require several operations to manufacture traditionally can be fabricated in one process. Additionally, the coolant channels are closed out as a part of the AM build process, eliminating the complexities of a traditional process like brazing or plating. The primary additive manufacturing technique that has been evaluated is powder bed fusion (PBF), or selective laser melting (SLM), but there is a scale limitation for this technique. There are several alternate additive manufacturing techniques that are being investigated for large-scale nozzles and chambers including directed energy deposition (DED) processes. A significant advantage of the DED processes is the ability to adapt to a robotic or gantry CNC system with a localized purge or purge chamber, allowing unlimited build volume. This paper will discuss the development and hot-fire testing of channel-cooled nozzles fabricated utilizing one form of DED called blown powder deposition. This initial development work using blown powder DED is being explored to form the entire channel wall nozzle with integral coolant channels within a single AM build. Much of this development is focused on the design and DED-fabrication of complex and thin-walled features and on characterization of the materials properties produced with this techniques in order to evolve this process. Subscale nozzles were fabricated using this DED technique and hot-fire tested in Liquid Oxygen/Hydrogen (LOX/GH2) and LOX/Kerosene (LOX/RP-1) environments accumulating significant development time and cycles. The initial materials that were evaluated during this testing were high-strength nickel-based Inconel 625 and JBK-75. Further process development is being completed to increase the scale of this technology for large-scale nozzles. This paper will summarize the general design considerations for DED, specific channel-cooled nozzle design, manufacturing process development, property development, initial hot-fire testing and future developments to mature this technology for regeneratively-cooled nozzles. An overview of future development at NASA will also be discussed.

Gradl, Paul R.↗
DOE OSTI2020

Quarterly Technical Progress Report Piperazine Advanced Stripper (PZAS™) Front End Engineering Design

EXECUTIVE SUMMARY This document summarizes the status of Cooperative Agreement DE-FE0031844, “Piperazine Advanced Stripper (PZAS™) Front-End Engineering Design,” during the reporting period of January 1 through March 31, 2020. The objective of this project is to develop accurate installed costs by conducting a Front-End Engineering Design (FEED) of PZAS™ at Golden Spread Electric Cooperative’s (GSEC) Mustang Station located in Denver City, TX. Complementary benefits include positioning the technology for a commercial project with the 45Q tax credits, qualifying PZAS™ for use on a Natural Gas Combined Cycle (NGCC) Cogen facility, and to provide cost detail to optimize PZAS™ and help guide R&D of second-generation solvent CO2 capture technologies. Results from the FEED will be used to evaluate the economic feasibility of the process at Mustang Station. This project is funded by the U.S. DOE National Energy Technology Laboratory under the aforementioned Cooperative Agreement. Exxon, Total, Chevron, UOP-Honeywell, and the University of Texas (UT) are project co-funders. AECOM and Trimeric are project team members; UT is the prime contractor. Summary of Progress Cooperative Agreement DE-FE0031844 was established in October 2019. The current reporting period, January 1 through March 31, 2020, is the second technical progress reporting period for the project. Several milestones were accomplished during this reporting period, including: • Kickoff Meeting with DOE on February 3, 2020. • Kickoff Meeting with GSEC on March 30, 2020. (Note: Due to Covid-19 travel restrictions and shelter-in-place guidelines, the kickoff meeting was conducted remotely via videoconferencing. See attached notes from that telecon.) • Updated Project Management Plan March 2020, submitted with this quarterly report Other activities during the quarter included progress on contracting and other legal agreements (e.g., non-disclosure agreements), internal kickoff meetings at both AECOM and Trimeric, and development of a Technical Implementation Plan (TIP). The TIP will help the team to make critical, early process decisions and, ultimately, to develop a project and process design basis. Note that all agreements between project team participants are complete as of this submittal, except the vendor agreement with Kiewit (steam cycle modeling). Plans for Next Reporting Period Activities during the next reporting period (April 1, 2020 through June 30, 2020) include: the completion of the Project Design Basis and progress towards the Process Design Basis/Process Design Package (PDP). The Project Design Basis is due as a deliverable and milestone during the next reporting period.

Rochelle, Gary T.↗
NASA NTRS1993

Object oriented Simulation of Maintenance and Operations for Space Systems (OSMOSSYS)

This paper describes the NASA/JSC Research Technology Opportunity Program (RTOP) activity to assess the supportability of space systems throughout their life cycles. Supportability analyses for space systems present unique attributes and problems. The OSMOSSYS (Object oriented Simulation of Maintenance and Operations for Space Systems) was developed using object-oriented design concepts to provide NASA an analysis tool which addresses the question `Will a proposed space facility be able to successfully perform the missions for which it is designed?' This model integrates the complete configuration of the system including the reliability and maintainability characteristics of each component, the logistics support, and the mission operations of the facility to assess the success rate of the planned mission(s). Two parallel design processes are being utilized; developing core modules utilizing C++, and incorporating as much code and ideas as possible from existing NASA models. The space station was used as a test case to demonstrate the applicability of the model.

Doran, Linda↗
DOE OSTI2023

Operation and Process Control Development for a Pilot-Scale Leaching and Solvent Extraction Circuit Recovering Rare Earth Elements From Coal-Based Sources

The US Department of Energy in 2010 has identified several rare earth elements as critical materials to enable clean technologies. As part of ongoing research in REEs (rare earth elements) recovery from coal sources, the University of Kentucky has designed, developed and is demonstrating a ¼ ton/hour pilot-scale processing plant to produce high-grade REEs from coal sources. Due to the need to control critical variables (e.g. pH, tank level, etc.), process control is required. To ensure adequate process control, a study was conducted on leaching and solvent extraction control to evaluate the potential of achieving low-cost REE recovery in addition to developing a process control PLC system. The overall operational design and utilization of Six Sigma methodologies is discussed. Further, the application of the controls design, both procedural and electronic for the control of process variables such as pH is discussed. Variations in output parameters were quantified as a function of time. Data trends show that the mean process variable was maintained within prescribed limits. Future work for the utilization of data analysis and integration for data-based decision-making will be discussed.

coal, rare earth elements, pilot plant, automation↗