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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 NTRS1986

Design and experimental evaluation of a swept supercritical Laminar Flow Control (LFC) airfoil

A large chord swept supercritical laminar flow control (LFC) airfoil was designed, constructed, and tested in the NASA Langley 8-ft Transonic Pressure Tunnel (TPT). The LFC airfoil experiment was established to provide basic information concerning the design and compatibility of high-performance supercritical airfoils with suction boundary layer control achieved through discrete fine slots or porous surface concepts. It was aimed at validating prediction techniques and establishing a technology base for future transport designs and drag reduction. Good agreement was obtained between measured and theoretically designed shockless pressure distributions. Suction laminarization was maintained over an extensive supercritical zone up to high Reynolds numbers before transition gradually moved forward. Full-chord laminar flow was maintained on the upper and lower surfaces at M sub infinity = 0.82 up to R sub c is less than or equal to 12 x 10 to the 6th power. When accounting for both the suction and wake drag, the total drag could be reducted by at least one-half of that for an equivalent turbulent airfoil. Specific objectives for the LFC experiment are given.

Harvey, W. D.↗
NASA NTRS1943

Preliminary Investigation of the Effect of Compressibility on the Maximum Lift Coefficient, Special Report

Preliminary data are presented on the variation of the maximum lift coefficient with Mach number. The data were obtained from tests in the 8-foot high-speed tunnel of three NACA 16-series airfoils of 1-foot chord. Measurements consisted primarily of pressure-distribution measurements in order to illustrate the nature of the phenomena. It was found that the maximum lift coefficient of airfoils is markedly affected by compressibility even at Mach numbers as low as 0.2. At high Mach numbers pronounced decrease of the maximum lift coefficient was found. The magnitude of the effects of compressibility on the maximum lift coefficient and the low speeds at which these effects first appear indicate clearly that consideration of the take-off thrust for propellers will give results seriously in error if these considerations are based on the usual low-speed maximum-lift-coefficient data generally used.

Stack, John↗
NASA NTRS2003

Fuel Cells for Space Science Applications

Fuel cell technology has been receiving more attention recently as a possible alternative to the internal combustion engine for our automobile. Improvements in fuel cell designs as well as improvements in lightweight high-pressure gas storage tank technology make fuel cell technology worth a look to see if fuel cells can play a more expanded role in space missions. This study looks at the specific weight density and specific volume density of potential fuel cell systems as an alternative to primary and secondary batteries that have traditionally been used for space missions. This preliminary study indicates that fuel cell systems have the potential for energy densities of greater than 500 W-hr/kg, greater than 500W/kg and greater than 400 W-hr/liter, greater than 200 W/liter. This level of performance makes fuel cells attractive as high-power density, high-energy density sources for space science probes, planetary rovers and other payloads. The power requirements for these space missions are, in general, much lower than the power levels where fuel cells have been used in the past. Adaptation of fuel cells for space science missions will require down-sizing the fuel cell stack and making the fuel cell operate without significant amounts of ancillary equipment.

Burke, Kenneth A.↗
NASA NTRS1939

The Compressibility Burble and the Effect of Compressibility on Pressures and Forces Acting on a Airfoil

Simultaneous air-flow photographs and pressure-distribution measurements were made of the NACA 4412 airfoil at high speeds to determine the physical nature of the compressibility burble. The tests were conducted in the NACA 24-inch high-speed wind tunnel. The flow photographs were obtained by the Schlieren method and the pressures were simultaneously measured for 54 stations in the 5-inch-chord airfoil by means of a multiple-tube manometer. Following the general program, a few measurements of total-pressure loss in the wake of the airfoil at high speeds were made to illustrate the magnitude of the losses involved and the extent of the disturbed region; and, finally, in order to relate this work to earlier force-test data, a force test of a 5-inch-chord NACA 4412 airfoil was made. The results show the general nature of the phenomenon known as the compressibility burble. The source of the increased drag is shown to be a compression shock that occurs on the airfoil as its speed approaches the speed of sound. Finally, it is indicated that considerable experimentation is needed in order to understand the phenomenon completely.

Stack, John↗
NASA NTRS2000

TPS Materials and Costs for Future Reusable Launch Vehicles

There is considerable interest in developing new reusable launch vehicles (RLVs) for reducing the cost of transporting payload to and from orbit. This work reviews thirteen candidate thermal protection system (TPS) options currently available for RLVs. It is useful to begin with the current Shuttle TPS layout as a reference. The nose cap and wing leading edge , which reach the highest temperatures, are made of reinforced carbon-carbon (RCC) that is protected from oxidation by an external coating (about 0.020" thick) of silicon-carbide. Most of the windward surface is 9 lb/cubic ft ceramic tiles (LI-900) with a thin (about 0.012") coating of Reaction Cured Glass (RCG). The leeward side of the vehicle is covered largely by AFRSI, a quilted ceramic blanket, and FRSI, a polyamide felt. These four materials can be considered first generation reusable TPS. Since the time of the Shuttle design, considerable progress has been made advancing TPS technologies in terms of thermal performance, robustness, and cost. For each of the major systems, a second generation ceramic TPS has been developed, tested, and characterized. Metallic-based systems have also been developed. For applications requiring RCC in the past, advanced carbon-carbon (ACC) is now available. This material has better mechanical properties, somewhat higher temperature capability to 2900F and greatly increased oxidation resistance. New carbon fiber reinforced silicon-carbide matrix composites (C/SiCs) have shown additional improvement in properties over ACC with use temperatures to 3000F and above. For rigid tiles, NASA Ames has made two significant advancements. The first is a tile substrate called Alumina Enhanced Thermal Barrier, or AETB, that incorporates alumina fibers for improved dimensional stability at high temperatures, to 2600F and above. This material can be made to densities as low as 8 lb/cubic ft. The second is a coating preparation called Toughened Uni-piece Fibrous Insulation, or TUFT, that penetrates about 0.1 in. into the tile substrate. The resulting composite, with a functionally gradient density near the surface, provides orders of magnitude increased damage resistance compared with RCG coated LI-900, with only a small weight increase. The TPS that combines these two developments is called AETB-8/TUFI and has been adopted for high damage areas on the Shuttles. Two notable developments have occur-red in flexible ceramic blanket technology. The first is aluminoborosilicate-based fibers with use temperatures of 2200F and above," in comparison to quartz and silica fiber used in AFRSI which have multi-use temperature limits of 1200 to 1400F. Blankets incorporating these new high temperature fibers are referred to as AFRSI-HT. The second is an integral weaving techniques that produces a fluted core blanket with a smoother surface and greater resistance to aero-acoustic noise, to levels as high as 170 dB. This Ames innovation is called Tailorable Advanced Blanket Insulation, or TABI. Finally, for felt-based TPS, Boeing is developing Polybenzimidazole Blanket Insulation, or PBI, with a multi-use temperature limit of 1000F and above, in contrast to Shuttle FRSI which has a multi-use temperature limit of about 700F. 1.6 NASA Langley and BF Goodrich (formerly Rohr Corp.) have led the development of metallic-based TPS. This activity uses essentially three approaches: metallic tiles which encase a fibrous ceramic batting in a box fabricated largely from metallic honeycombs, typically Nickel based alloys; metallic honeycomb sheets, made of Nickel-based alloys, incorporating a fibrous back-side insulation encapsulated in a metallic foil bag, providing reduced weight; and metallic multi-wall, which is comprised of dimpled Titanium metal sheets, which are stacked and then diffusion bonded at contact points to form the TPS. The Nickel-based systems can be used up to temperatures of about 1800F, and the Titanium system to about 100F. These thirteen TPS materials have pros and cons to their usage in terms of temperature capability, weight, initial cost, and maintenance. Carbon-carbon and C/SiC systems have the highest temperature capability but are relatively expensive and heavy, requiring significant time, expertise, and costly facilities and tools for design and fabrication. Second generation ceramic tiles are relatively light, durable, simple to fabricate and easy to install; however, waterproofing is a concern. Blankets and felts are light, simple, inexpensive, and easy to install over curved vehicle surfaces, but durability and waterproofing are concerns. Metallics are robust and appear to have eliminated waterproofing, but they tend to be heavy and relatively expensive, requiring costly facilities and tools. If thin metal sheets are used to reduce weights, then issues arise from possible metal fatigue and corrosion caused by thermal cycling, pressure oscillations, and environmental exposure. For application to future RLVs, system analyses show that a significant component of the vehicle life cycle cost is from the TPS; however, it is difficult to quantify and to compare the potential savings of advanced systems without performing full vehicle designs using each of the different options. Because this entails a considerable effort and also tends to submerge TPS cost impacts under unrelated vehicle design assumptions, there is a clear need for a simpler quantitative method to evaluate the cost impact of different TPS options. To this end, this work introduces a TPS life-cycle cost parameter which is easily computed and applicable to generic RLVs.

Rasky, Dan J.↗
NASA NTRS1939

Tests of Airfoils Designed to Delay the Compressibility Burble

Development of airfoil sections suitable for high-speed applications has generally been difficult because little was known of the flow phenomenon that occurs at high speeds. A definite critical speed has been found at which serious detrimental flow changes occur that lead to serious losses in lift and large increases in drag. This flow phenomenon, called the compressibility burble, was originally a propeller problem, but with the development of higher speed aircraft serious consideration must be given to other parts of the airplane. Fundamental investigations of high-speed airflow phenomenon have provided new information. An important conclusion of this work has been the determination of the critical speed, that is, the speed at which the compressibility burble occurs. The critical speed was shown to be the translational velocity at which the sum of the translational velocity and the maximum local induced velocity at the surface of the airfoil or other body equals the local speed of sound. Obviously then higher critical speeds can be attained through the development of airfoils that have minimum induced velocity for any given value of the lift coefficient. Presumably, the highest critical speed will be attained by an airfoil that has uniform chordwise distribution of induced velocity or, in other words, a flat pressure distribution curve. The ideal airfoil for any given high-speed application is, then, that form which at its operating lift coefficient has uniform chordwise distribution of induced velocity. Accordingly, an analytical search for such airfoil forms has been conducted and these forms are now being investigated experimentally in the 23-inch high-speed wind tunnel. The first airfoils investigated showed marked improvement over those forms already available, not only as to critical speed buy also the drag at low speeds is decreased considerably. Because of the immediate marked improvement, it was considered desirable to extend the thickness and lift coefficient ranges for which the original forms had been designed before further extending the investigation.

Stack, John↗
NASA NTRS2006

Asian Summer Monsoon Anomalies Induced by Aerosol Direct Forcing: The Role of the Tibetan Plateau

In this paper we present results of a numerical study using the NASA finite-volume GCM to elucidate a plausible mechanism for aerosol impact on the Asian summer monsoon involving interaction with physical processes over the Tibetan Plateau (TP). During the premonsoon season of March April, dusts from the deserts of western China, Afghanistan/Pakistan, and the Middle East are transported into and stacked up against the northern and southern slopes of the TP. The absorption of solar radiation by dust heats up the elevated surface air over the slopes. On the southern slopes, the atmospheric heating is reinforced by black carbon from local emission. The heated air rises via dry convection, creating a positive temperature anomaly in the mid-to-upper troposphere over the TP relative to the region to the south. In May through early June in a manner akin to an elevated heat pump , the rising hot air forced by the increasing heating in the upper troposphere, draws in warm and moist air over the Indian subcontinent, setting the stage for the onset of the South Asia summer monsoon. Our results suggest that increased dust loading coupled with black carbon emission from local sources in northern India during late spring may lead to an advance of the rainy periods and subsequently an intensification of the Indian summer monsoon. The enhanced rainfall over India is associated with the development of an aerosol-induced large-scale sea level pressure anomaly pattern, which causes the East Asia (Mei-yu) rain belt to shift northwestward, suppressing rainfall over East Asia and the adjacent oceanic regions.

Lau, K. M.↗
DOE OSTI2024

Prediction of s ± -Wave Superconductivity Enhanced by Electronic Doping in Trilayer Nickelates La 4 Ni 3 O 10 under Pressure

Motivated by the recently reported signatures of superconductivity in trilayer La 4 ⁢Ni 3 ⁢O 10 under pressure, here we comprehensively study this system using ab initio and random-phase approximation techniques. Without electronic interactions, the Ni d 3z 2 –r 2 orbitals show a bonding-antibonding and nonbonding splitting behavior via the O p z orbitals inducing a “trimer” lattice in La 4⁢ Ni 3 ⁢O 10 , analogous to the dimers of La 3 ⁢Ni 2 ⁢O 7 . The Fermi surface consists of three electron sheets with mixed e g orbitals, and a hole and an electron pocket made up of the d 3⁢z 2 –r 2 orbital, suggesting a Ni two-orbital minimum model. In addition, we find that superconducting pairing is induced in the s ± -wave channel due to partial nesting between the M = (π,π) centered pockets and portions of the Fermi surface centered at the Γ = (0,0) point. With changing electronic density n, the s ± instability remains leading and its pairing strength shows a domelike behavior with a maximum around n = 4.2 ( ~6.7% electron doping). The superconducting instability disappears at the same electronic density as that in the new 1313 stacking La 3 ⁢Ni 2 ⁢O 7 , correlated with the vanishing of the hole pocket that arises from the trilayer sublattice, suggesting that the high-T c superconductivity of La 3⁢ Ni 2 ⁢O 7 does not originate from a trilayer and monolayer structure. Furthermore, we confirm the experimentally proposed spin state in La 4 ⁢Ni 3 ⁢O 10 with an in-plane (π, π) order and antiferromagnetic coupling between the top and bottom Ni layers, and spin zero in the middle layer.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
NASA NTRS2010

Spatio-Temporal Pattern of Saturn's Equatorial Oscillation

Recent ground-based and Cassini CIRS thermal-infrared data have characterized the spatial and temporal characteristics of an equatorial oscillation in the middle atmosphere of Saturn above the 100-mbar level. The CIRS data [I] indicated a pattern of warm and cold anomalies near the equator, stacked vertically in alternating fashion. The ground-based observations s2, although not having the altitude range or vertical resolution of the CIRS observations, covered several years and indicated an oscillation cycle of approx.15 years, roughly half of Saturn's year. In Earth's middle atmosphere, both the quasi-biennial (approx.26 months) and semi-annual equatorial oscillations have been extensively observed and studied (see e.g., [3]), These exhibit a pattern of alternating warmer and cooler zonal-mean temperatures with altitude, relative to those at subtropical latitudes. Consistent with the thermal wind equation, this is also associated with an alternating pattern of westerly and easterly zonal winds. Moreover, the pattern of winds and temperatures descends with time. Momentum deposition by damped vertically propagating waves is thought to play a key role m forcing both types of oscillation, and it can plausibly account for the descent. Here we report the direct observation of this descent in Saturn's equatorial atmosphere from Cassini radio occultation soundings in 2005 and 2009. The retrieved temperatures are consistent with a descent of 0.7 x the pressure scale height. The descent rate is related to the magnitude of the wave forcing, radiative damping, and induced meridional circulations. We discuss possible implications.

Flasar, F. M.↗
NASA NTRS1998

Ionospheric Signature of Surface Mine Blasts from Global Positioning System Measurements

Sources such as atmospheric or buried explosions and shallow earthquakes are known to produce infrasonic pressure waves in the atmosphere. Because of the coupling between neutral particles and electrons at ionospheric altitudes, these acoustic and gravity waves induce variations of the ionospheric electron density. The Global Positioning System (GPS) provides a way of directly measuring the total electron content in the ionosphere and, therefore, of detecting such perturbations in the upper atmosphere. In July and August 1996, three large surface mine blasts (1.5 Kt each) were detonated at the Black Thunder coal mine in eastern Wyoming. As part of a seismic and acoustic monitoring- experiment, we deployed five dual-frequency GPS receivers at distances ranging from 50 to 200 km from the mine and were able to detect the ionospheric perturbation caused by the blasts. The perturbation starts 10 to 15 min after the blast, lasts for about 30 min, and propagates with an apparent horizontal velocity of 1200 meters per second. Its amplitude reaches 3 x 10 (exp 14) el per square meters in the 7-3 min period band, a value close to the ionospheric perturbation caused by the M = 6.7 Northridge earthquake. The small signal-to-noise ratio of the perturbation can be improved by slant-stacking the electron content time-series recorded by the different GPS receivers taking into account the horizontal propagation of the perturbation. The energy of the perturbation is concentrated in the 200 to 300 second period band, a result consistent with previous observations and numerical model predictions. The 300 second band probably corresponds to gravity modes and shorter periods to acoustic modes, respectively. Using a 1-D stratified velocity model of the atmosphere we show that linear acoustic ray tracing fits arrival times at all GPS receivers. We interpret the perturbation as a direct acoustic wave caused by the explosion itself. This study shows that even relatively small subsurface events can produce ionospheric perturbations that are above the detection threshold of the GPS technique. By sensing derivative signals, which can be detected over a relatively broad region, it appears that GPS might be particularly useful for source characterization within the first acoustic quiet zone where infrasound would probably be ineffective. This suggests that dual-frequency GPS monitoring could contribute to Comprehensive Nuclear Test Ban Treaty verification.

Calais, Eric↗
DOE OSTI2024

Kinetics of HCP-BCC Phase Transition Boundary in Magnesium at High Pressure

Under high pressures, many crystalline metals undergo solid–solid phase transformations. In order to accurately model the behavior of materials under extreme loading conditions, it is essential to understand the kinetics of phase transition. Using molecular dynamics simulations, this work demonstrates the feasibility of characterizing the speeds of a moving phase boundary using atomistic simulations employing a suitable empirical potential for single-crystal magnesium. The model can provide temperature- and tensorial stress-dependent velocity of a moving phase boundary as a rate-limiting contribution to the kinetics of phase transformation in continuum codes. Results demonstrate that a nonlinear interaction exists between plasticity and phase transition, facilitating a jump in the velocity of a moving phase boundary, facilitated by activated plastic deformation mechanisms.

36 MATERIALS SCIENCE↗
NASA NTRS2018

Magnetized Disk Winds in NGC 3783

We analyze a 900 kilosecond stacked Chandra/HETG (High-Energy Transmission Grating) spectrum of NGC 3783 in the context of magnetically driven accretion-disk wind models in an effort to provide tight constraints on the global conditions of the underlying absorbers. Motivated by the earlier measurements of its absorption measure distribution (AMD) indicating X-ray-absorbing ionic columns that decrease slowly with decreasing ionization parameter, we employ 2-dimension (2-D) magnetohydrodynamic (MHD) disk wind models to describe the global outflow. We compute its photoionization structure along with the wind kinematic properties, allowing us to further calculate in a self-consistent fashion the shapes of the major X-ray absorption lines. With the wind radial density profile determined by the AMD, the profiles of the ensemble of the observed absorption features are determined by the two global parameters of the MHD wind; i.e., disk inclination theta (sub obs) and wind density normalization n (sub o). Considering the most significant absorption features in the approximately 1.8-20 angstrom range, we show that the MHD wind is best described by n(r) approximately equal to 6.9 times 10 (sup 11) (r/r (sub o)) (sup - 1.15) cubic centimeters and theta (sub obs). We argue that winds launched by X-ray heating or radiation pressure, or even MHD winds but with steeper radial density profiles, are strongly disfavored by data. Considering the properties of Fe K-band absorption features (i.e., Fe XXV and Fe XXVI), while typically prominent in the active galactic nucleus X-ray spectra, they appear to be weak in NGC 3783. For the specific parameters of our model obtained by fitting the AMD and the rest of the absorption features, these features are found to be weak, in agreement with observations.

Fukumura, Keigo↗
DOE OSTI2026

Simulations of a hypersonic turbulent boundary layer over wavy surfaces

Here, we conduct large-eddy simulations of a Mach 5.84 cold wall turbulent boundary layer over one-dimensional wavy walls with varying amplitudes and wavelengths. Across all wall topologies, a series of alternating shock and expansion waves is shown to influence the entire boundary layer, and generate repeating wave patterns in the turbulent stresses, dispersive stresses, and turbulent kinetic energy budget. The series of alternating shocks and expansions imposes repeating adverse and favourable pressure gradients across the wavy wall, and at sufficient wall amplitude, triggers flow separation in the trough of the wave. Flow separation is demonstrated to influence the behaviour of wall pressure fluctuations over the wavy wall. In attached flows, the prominent frequencies are consistent with integral-scale boundary layer turbulence, whereas in separated flows, a two-decade frequency range is present, akin to two-dimensional shock–boundary layer interactions. Counter-rotating streamwise-oriented structures are observed on the windward side of the wave, which diminish over the wave crest. A conditional analysis demonstrates that these structures are present in the upstream boundary layer, and are amplified with increasing wall amplitude. An examination of the Görtler number and probability density function (PDF) of the fluctuating lateral wall shear stress demonstrates the strong correlation between a large Görtler number and growth of the PDF tail density, suggesting that the amplification of the counter-rotating streamwise-oriented structures are linked to centrifugal instabilities in regions of streamline concavity.

boundary layers↗
DOE OSTI2025

Development and Validation of MALAMUTE model for Electric Field Assisted Sintering of Structural Materials

Fusion power plant designs feature extreme material performance requirements for structural material candidates. In addition to conventional alloys, more advanced composites and oxide dispersion strengthened (ODS) alloys are being explored, however, achieving the desired microstructures to maximize performance using traditional manufacturing methods can be challenging. The advanced manufacturing (AM) electric field-assisted sintering (EFAS) technique offers improved control over the final microstructure through higher heating and cooling rates and moderate pressures. Modeling and simulation tools show promise in elucidating the process-structure-property-performance (PSPP) correlation for AM-produced parts, including the EFAS process. An inherently multiscale process, the EFAS technique aligns well with the multiscale modeling capability of the open-source Multiphysics Object-Oriented Simulation Environment (MOOSE)[cite]. We present here an electro-thermo-mechanical approach to modeling the EFAS process using the MOOSE Application Library for Advanced Manufacturing UTilitiEs (MALAMUTE) code. Prediction of the field and gradient distributions across the EFAS tooling is required to accurately describe the conditions for the lower-scale microstructural evolution models. In this work we present the MALAMUTE model developed to predict the electrical potential, temperature, and mechanical stress distribution across the EFAS graphite tooling and part at the larger engineering-scale. Validation of the MALAMUTE engineering-scale model is completed using data from experimental densification and pre-densified runs of iron powder via EFAS at 1000oC. These runs were conducted using a Thermal Technology DCS-5 EFAS system. Data collected during the experiment runs include the direct current (DC) supplied to the graphite tooling, the temperature of the graphite tooling as measured with a pyrometer, and the force applied to the top of the graphite tooling stack, and the data were recorded every 10 seconds. Our validation approach used the current and force data from the EFAS run as boundary condition inputs to the MAMALUTE simulation; the temperature data were used to evaluate the MALAMUTE EFAS model prediction. Results of the MALAMUTE simulations are employed to connect the external pyrometer temperature measurement to the temperature profile across the part undergoing consolidation. We investigate the impact of material property variation and mesh deformation on the temperature profile as predicted by MALAMUTE. We conclude by highlighting projects where the MALAMUTE EFAS modeling and simulation capabilities will be used to assist experimental design.

36 - MATERIALS SCIENCE↗
NASA NTRS1992

Validation test of advanced technology for IPV nickel-hydrogen flight cells - Update

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.

Smithrick, John J.↗
NASA NTRS2014

Current Ground Test Options for Nuclear Thermal Propulsion (NTP)

About 20 different NTP engines/ reactors were tested from 1959 to 1972 as part of the Rover and Nuclear Engine for Rocket Vehicle Application (NERVA) program. Most were tested in open air at test cell A or test cell C, at the Nevada Test Site (NTS). Even after serious engine breakdowns of the reactor (e.g., Phoebus 1A), the test cells were cleaned up for other engine tests. The engine test stand (ETS) was made for high altitude (approximately 1 psia) testing of an NTP engine with a flight configuration, but still had the exhaust released to open air. The Rover/NERVA program became aware of new environmental regulations which would prohibit the release of any significant quantity of radioactive particulates and noble gases into the open air. The nuclear furnace (NF-1) was the last reactor tested before the program was cancelled in 1973, but successfully demonstrated a scrubber concept on how to filter the NTP exhaust. The NF-1 was demonstrated in the summer of 1972. The NF-1 used a 44MW reactor and operated each run for approximately 90 minutes. The system cooled the hot hydrogen exhaust from the engine with a water spray before entering a particle filter. The exhaust then passed through a series of heat exchangers and water separators to help remove water from the exhaust and further reduce the exhaust temperatures. The exhaust was next prepared for the charcoal trap by passing through a dryer and effluent cooler to bring exhaust temperatures close to liquid nitrogen. At those low temperatures, most of the noble gases (e.g., Xe and Kr made from fission products) get captured in the charcoal trap. The filtered hydrogen is finally passed through a flare stack and released to the air. The concept was overall successful but did show a La plating on some surfaces and had multiple recommendations for improvement. The most recent detailed study on the NTP scrubber concept was performed by the ARES Corporation in 2006. The concept is based on a 50,000 lbf thrust engine (approximately 1 GW) with a maximum burn time of 1 hour. The concept utilized lessons learned from NF-1. The strategy breaks down the exhaust into parallel paths to allow flexibility with engine size and mass flow of exhaust. Similar to NF-1, the exhaust is slowed down, cooled, filtered of particulates, filtered of noble gases, and then the clean hydrogen is flared to open air. Another concept proposed by Steve Howe (currently Director of the Center for Space Nuclear Research) to simplify the NTP exhaust filtering is to run the hydrogen exhaust into boreholes underground to filter the exhaust. The two borehole site locations proposed are at the NTS and at the Idaho National Laboratory (INL). At NTS, the boreholes are 8' diameter and 1200' deep. The permeability of hydrogen through the soil and its buoyancy will allow it to rise up through the soil and allow the filtering of noble gases and radioactive particulates. The exhaust needs to be cooled to 600C before entering the borehole to avoid soil glazing. Preliminary analysis shows a small buildup of back pressure with time which depends on permeability. Noble gases entering the borehole walls deep can take a long time before reaching the surface. Other factors affecting permeability include borehole pressure, water saturation, and turbulence. Also, a possible need to pump out contaminated water collected at the bottom of the borehole. At INL, the borehole concept is slightly different. The underground borehole has openings to the soil at special depths which have impermeable interbeds above the water table and below the surface to allow the exhaust to travel horizontal between the impermeable layers. Preliminary results indicate better permeability than at NTS. The last option is total containment of the exhaust during the test run. The concept involves slowing down the flow to subsonic in a water cooled diffuser. The hydrogen is burned off in an oxygen rich afterburner with the only products being steam, oxygen, and some noble gases. A heat exchanger and water spray pulls heat from the steam and lowers the temperature for condensation. The optimum ratio between the two is being investigated, with a goal to minimize the total volume of the water hold tanks. A water tank farm collects the contaminated water. The amount of water produced from burning the hydrogen is approximately 100,000 gallons (not including cooling water) for a 25k lbf engine operating for 50 minutes. Residual gases (e.g., oxygen and some noble gases) can be captured at cryogenic levels with a liquid nitrogen cooled dewar. After a few weeks post-test, the radiation levels can drop to more favorable levels before slowly draining each capture tank and using existing filters. With today's environmental regulations, the NTP exhaust is filtered to meet 10 mrem/year exposure to the general public (at a DOE site) or 100 mrem/year (via NRC when tested elsewhere), when natural background radiation exposure to the general public is 300- 600 mrem per year. The current society feels more comfortable with filtering even lower to as low as reasonably achievable (ALARA).

Gerrish, Harold P., Jr.↗
NASA NTRS1992

Validation test of advanced technology for IPV nickel-hydrogen flight cells: Update

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.

Smithrick, John J.↗
DOE OSTI2026

Public Reference Data for Megawatt-Scale Hydrogen Electrolysis - NLR Historical Wind

The U.S. Department of Energy and the National Laboratory of the Rockies (NLR) demonstrate hydrogen electrolysis from variable sources, hydrogen compression and storage, and hydrogen fuel cell power production using megawatt-scale equipment at NLR’s Flatirons Campus as part of the Advanced Research on Integrated Energy Systems (ARIES) initiative. This dataset represents part of that effort and is intended for academic, national laboratory, industrial, and other stakeholders to plan, design, and validate models of megawatt-scale hydrogen technologies and diverse energy infrastructure nationwide. These data provide a baseline for how existing hydrogen electrolysis technologies perform when coupled with various energy technologies. Future datasets will demonstrate how existing hydrogen fuel cell technologies can provide controllable, dispatchable, and variable power output for artificial intelligence (AI) data centers and other variable loads. This dataset entry describes hydrogen production by conducting a statistical analysis of historical wind data over a five-year period (2020-2025) from a single 1.5MW turbine manufactured by General Electric (GE) located at NLR’s Flatirons Campus, to generate an experimental test profile that was deployed on a 1.25-MW proton exchange membrane type MC250 electrolyzer system manufactured by Nel Hydrogen . [1] While the electrolyzer balance-of-plant supports up to 2.5 MW of electrolysis, NLR only has a single 1.25-MW electrolysis stack. The historical wind data provided several metrics, however, the analysis particularly focused on the measured power output by the wind turbine. The power output time series of data for each day was categorized by total energy generation and standard deviation, and the day that represented the highest combination of these two metrics was chosen – December 25th, 2022. This process was then repeated for a moving four-hour window within this day to identify the most statistically variable period. Finally, this four-hour period was scaled by 65% to match the 1.25 MW electrolyzer. The electrolysis system controls hydrogen production by varying DC current applied to the stack, from a maximum of 3000 A to a minimum safe operation of 300 A, or 10%. Because the current – voltage characteristic changes as the stack ages and efficiency degrades, the actual minimum safe operating power changes over time. The historical wind profiles were translated from power (kilowatts) to current (amperes) using a curve fit with calibration data and sent to the electrolyzer power supply at 1 Hz frequency. For more details on the statistical analysis process, see the presentation labeled “ Public Reference Data for Megawatt-Scale Hydrogen Electrolysis” provided with each data entry. These datasets report relevant hydrogen balance-of-plant and system data, all captured at 1 Hz, including hydrogen mass production measured with an Emerson Coriolis flow meter. Each .zip file represents a single wind turbine electrolysis experiment and is formatted as follows: {technology}_{scaling factor}-{electrolyzer ramp rate in amperes/second} For instance, “wind-GE1.5MW_0.65-400.zip” represents the hour-long experiment using historical data from the wind-GE1.5MW turbine, scaled to 65%, with the electrolyzer power supply set to a maximum ramp rate (gain and slew) of 400 A/s. Each .zip folder contains the following files: A .csv file containing raw data An .xlsx file explaining all the fields in the raw data. A .png plot showing the time series of hydrogen production, electrolysis power consumption, and wind power input. A PDF file detailing the historical wind data statistical analysis used to generate the wind profile. An experiment labeled “characterization_200.zip” demonstrates the MC250 electrolyzer steady-state response with 30-minute load steps for a total duration of 5 hours. Finally, a .csv file is provided with all simulated wind experiments combined into one dataset labeled "combined_historical_wind_experiments.csv". NLR also built an AI/machine-learning predictive model based on these datasets. The model ingests the electrolyzer current command in amperes, as well as various pressures and temperatures across the system, and predicts hydrogen output in kilograms per hour. The complete model can be found at https://huggingface.co/NatLabRockies/ptmelt-hydrogen-electrolysis [1] nelhydrogen.com/product/mc-series-electrolyser .

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