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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 379 records · Page 21
All sourcesNASA NTRSDOE OSTI
NASA NTRS1996

An All Sky Cirrus Confusion Noise Map for WIRE

The Wide Field Infrared Explorer (WIRE) is an infrared space observatory being developed inder NASA's small explorer program for launch inlate 1998 (Schember, et al. 1996). WIRE's main function will be to produce a sky survey at wavelengths of 12 and 25(micro), covering several tens of square degrees at a sensitivity of 0.2mJy, 5(standard deviation)at 25(micro)m, and several hundred square degrees at a sensitivity of 0.7 mJy, 5(standard deviation) at 25(micro)m to study starburst galaxies and search for luminous protogalaxies.

WIRE wide field infrared explorer infrared space o↗
NASA NTRS2013

Hot-Film and Hot-Wire Anemometry for a Boundary Layer Active Flow Control Test

Unsteady active flow control (AFC) has been used experimentally for many years to minimize bluff-body drag. This technology could significantly improve performance of rotorcraft by cleaning up flow separation. It is important, then, that new actuator technologies be studied for application to future vehicles. A boundary layer wind tunnel was constructed with a 1ft-x-3ft test section and unsteady measurement instrumentation to study how AFC manipulates the boundary layer to overcome adverse pressure gradients and flow separation. This unsteady flow control research requires unsteady measurement methods. In order to measure the boundary layer characteristics, both hot-wire and hot-film Constant Temperature Anemometry is used. A hot-wire probe is mounted in the flow to measure velocity while a hot-film array lays on the test surface to measure skin friction. Hot-film sensors are connected to an anemometer, a Wheatstone bridge circuit with an output that corresponds to the dynamic flow response. From this output, the time varying flow field, turbulence, and flow reversal can be characterized. Tuning the anemometers requires a fan test on the hot-film sensors to adjust each output. This is a delicate process as several variables drastically affect the data, including control resistance, signal input, trim, and gain settings.

Control Test↗
NASA NTRS2019

Pot-ability Assessment of Litz Wires for High Power Density Electric Motor

An alternative process technique, namely vacuum-assisted axial injection potting (VaAIP), has been developed to pot the Litz wires in the stator winding of high power density electric motors for the future electrified aircrafts. Initial trials of the process showed significant improvement in potting quality with less voids, thus potential improvement in thermal management of the motors. As an initial effort of pot-ability assessment, microstructures, 2-D and 3-D, of the Litz wires including dimensions and distribution of conductor filament, coating, and open spaces; packing patterns; shape/configuration changes of each bundles or the overall cross-sections per degree of twist were determined and quantified successfully. The microstructure analyses were performed not only for effective potting process development but also for more realistic electro-thermal modeling solutions. This paper will present results of the microstructure analyses, potentials of the VaAIP process from the trials, and future plans for scale-up and implementation of the process into a full-scale prototype stator winding.

Electrified aircraft↗
NASA NTRS2019

Thermal Analysis of Potted Litz Wire for High-Power-Density Aerospace Electric Machines

Increasing the power density and efficiency of electric machines (motors and generators) is integral to bringing Electrified Aircraft (EA) to commercial realization. To that end an effort to create a High Efficiency Megawatt Motor (HEMM) with a goal of exceeding 98% efficiency and 1.46 MW of power has been undertaken at the NASA Glenn Research Center. Of the motor components the resistive losses in the stator windings are by far the largest contributor (34%) to total motor loss. The challenge is the linear relationship between resistivity and temperature, making machine operation sensitive to temperature increases. In order to accurately predict the thermal behavior of the stator the thermal conductivity of the Litz wire-potting-electrical insulation system must be known. Unfortunately, this multi material system has a wide range of thermal conductivities (0.1 W/m-K – 400 W/m-K) and a high anisotropy (axial vs transverse) making the prediction of the transverse thermal conductivity an in turn the hot spot temperatures in the windings is difficult. In order to do this a device that simulates the thermal environment found in the HEMM stator was designed. This device is not unlike the motorettes (little motors) that are described in IEEE standards for testing electrical insulation lifetimes or other electric motor testing. However, because the HEMM motor design includes significant rotor electrical and thermal considerations the term motorette was not deemed appropriate. Instead statorette (or little stator) was adopted as the term for this test device. This paper discussed the design, thermal heat conjugate analysis (thermal model), manufacturing and testing of HEMM's statorette. Analysis of the results is done by thermal resistance network model and micro thermal model and is compared to analytical predictions of thermal conductivity of the insulated and potted Litz wire system.

Motor↗
NASA NTRS2023

Assessment of Electrical, Electronic, and Electromechanical (EEE) Parts Copper Wire Bonds for Space Programs

The NASA Electronic Parts and Packaging Program co-manager, requested the NASA Engineering and Safety Center (NESC) to compile a body of publicly available knowledge on copper (Cu) wire bonds and perform reliability testing and analysis on these bonds, including environment tests, sample destructive physical analysis, and bond pull/shear tests during environment test intervals. The goal was to understand the risks of using Cu wire bonds for space applications and develop guidelines on Cu bond pull/shear limits for NASA applications. This document contains the results of the NESC assessment.

Electrical, Electronic, and Electromechanical↗
DOE OSTI2025

Time-Dependent 600 °C Post-Weld Heat Treatment Response of Laser-Wire-Directed Energy Deposited Austenitic Stainless Steel Claddings on Carbon Steel

Austenitic stainless steel overlay claddings are often used to protect nuclear reactor pressure vessels from corrosion. Arc welding processes are traditionally employed, which require a high heat input to bond the dissimilar metals, creating a large heat-affected zone and high residual stress that demands a lengthy stress-relieving post-weld heat treatment, up to 48 hours. High energy beam (e.g., laser, electron beam) directed energy deposition-based overlay cladding processes show promise for fabricating claddings with superior performance compared to arc welded ones because of their localized heat input; however, their necessity and time of post-weld heat treatment are currently unclear. In this research, we investigate the time dependence of a 600 C stress-relieving post-weld heat treatment of austenitic stainless steel clad on low carbon steel by laser-wire-directed energy deposition, comparing the microstructure and mechanical properties of the as-fabricated condition to 2-, 10-, and 48-hour heat treatment times. Diffusion simulations and microscopy show a gradual carburization of the stainless steel cladding and decarburization of the heat-affected zone/base metal. Nanoindentation testing shows up to a 1.8–2.69 embrittlement in the cladding and a 0.33 to 0.69 softening in the heat-affected zone after the 48-hour post-weld heat treatment. Tensile testing of the cladding composites reveals that increasing post-weld heat treatment time raises clad cracking susceptibility due to intergranular carbide formation and shows that laser-wire-directed energy deposition claddings may not require post-weld heat treatment.

Coating↗
DOE OSTI2026

Supramolecular assembly of molecular wires alternating crown ethers and metal–halide complexes

Metal–halide complexes serve as key emissive centres in halide perovskites; however, precise control over their spatial organization through bottom-up assembly is challenging. Here we show that a crown-ether-assisted supramolecular assembly strategy can alternatingly connect metal–halide complexes and (crown ether@A) 2+ (where ‘A’ is an alkaline earth metal cation) complexes into a one-dimensional molecular wire, which can then be packed into a hexagonal crystal structure. This process resulted in the creation of an (18C6@Ba)MnBr 4 single crystal with green emission, achieving over 80% photoluminescence quantum yield and a narrow full width at half maximum. In addition, the non-centrosymmetric crystal structure gave rise to strong nonlinear optical responses, including second-harmonic generation. This versatile supramolecular assembly approach could be generalized to create various [M(I)X 2 ] − , [M(I)X 3 ] 2− , [M(II)X 4 ] 2− and [M(III)X 5 ] 2− molecular wires, broadening the potential for diverse emission colours and distinct optical properties. This strategy provides a general design principle for constructing supramolecular metal–halide building blocks with diverse optical functionalities.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Axial confinement of wire array Z-pinch precursor plasmas by a pulsed magnetic mirror field

A novel wire-array Z-pinch platform has been developed to study the effect of a pulsed magnetic mirror field on a collisional high energy density plasma. The mirror is driven in series with the Z-pinch target and, therefore, scales with driver current. Axial confinement is observed based on visible imaging and axial flow velocity measurements. The presence of axial compressing J xB force is determined indirectly based on Thomson scattering and interferometry measurements and corroborated by three-dimensional extended-MHD simulations. Compared to non-magnetized wire array Z-pinch, a modified pulsed mirror configuration is observed to increase precursor plasma thermal energy density by about 30%. If optimized, such a configuration could potentially improve magnetized liner inertial fusion performance by reducing axial plasma end loss.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Directional, joule per steradian THz pulses from multi-joule laser irradiation of wires

We report on THz pulses with energy flux exceeding 2.5 J/sr and high directionality, generated from picosecond, joule laser irradiation of microwires. The impact of wire diameter, length, and laser irradiation orientation is explored with the irradiation of 160 μm diameter, 750 μm, sharpened wires at the dull base found to produce the highest energy and shortest wavelength THz pulses among the targets tested. A traveling wave antenna combined with coherent transition radiation model is developed to explain the emission pattern, pulse energy, and spectrum seen.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2026

Fabrication of 8-Strand Rutherford Cables Using Roped Strands Made from Ultrafine Wires

Conventional Rutherford cables are typically made from solid round wire. While multi-stage cables have been made elsewhere, the purpose was usually to achieve a higher strand count and therefore a higher current carrying capability. In this work, we attempt to use two-stage roped strands made from ultrafine wires to fabricate Rutherford cables. The ultimate goal of this work is to obtain a very flexible cable that can wind accelerator magnet coils with a very tight bend radius in both the “easy way” (along the broad face of the cable) and the “hard way” (along the edge of the cable) in the wind-and-react manner, or wind coils with a radius typically used today but in the react and-wind manner with a much reduced degradation in critical current. We report our experience fabricating such Rutherford cables at the Lawrence Berkeley National Laboratory, and the initial findings from the analysis of the experimental cables made. We will discuss how the conventional wisdom and some rules of thumb for making Rutherford cables are no longer applicable or relevant, and the new thinking required in designing these cables.

Pong, Ian↗
DOE OSTI2025

Calorimetric wire detector for measurement of atomic hydrogen beams

A calorimetric detector for minimally disruptive measurements of atomic hydrogen beams is described. The calorimeter measures heat released by the recombination of hydrogen atoms into molecules on a thin wire. As a demonstration, the angular distribution of a beam with a peak intensity of ≈ 10 16 atoms/(cm 2 s) is measured by translating the wire across the beam. The data agree well with an analytic model of the beam from the thermal hydrogen atom source. Using the beam shape model, the relative intensity of the beam can be determined to 5% precision or better at any angle.

Astaschov, M. [Johannes Gutenberg Univ., Mainz (Ge↗
DOE OSTI2024

A Co-Registered In-Situ and Ex-Situ Dataset of Electrical, Acoustic, and CT Characteristics from Wire Arc Additive Manufacturing Process

Recent progress in sensing techniques and data analytics tools have significantly accelerated the development of Wire Arc Additive Manufacturing (WAAM) systems. This data centric approach emphasizes leveraging available data throughout the production process to optimize performance. Integration of extensive data analysis provides the opportunity to improve precision, reduce waste, and enhance the quality of produced parts. This method relies on AI/ML models and optimization techniques, which are developed using the data collected from various sources, including in-situ sensors, ex-situ imaging, and manufacturing process parameters. The quality and diversity of this data, along with the alignment between different data streams (achieved through spatiotemporal registration) are critical for the successful development of AI/ML and optimization models. In this work, we present a spatiotemporally registered dataset generated during the WAAM process of deposition of a rectangular block. The dataset includes the comprehensive description of deposition process, process parameters, in-situ collected welding characteristics, acoustic data, and X-Ray Computed Tomography analysis data for the build. Dataset A Co-Registered In-Situ and Ex-Situ Dataset of Electrical, Acoustic, and CT Characteristics from Wire Arc Additive Manufacturing Process has arisen under UT-Battelle, LLC’s Prime Contract No. DE-AC05-00OR22725 with the U.S. Department of Energy (DOE) to manage and operate the Oak Ridge National Laboratory. UT-Battelle, LLC will not assert any rights under United States law or under the Prime Contract it has in the dataset against any user of the dataset, including any copyrights or patent rights. UT-Battelle, LLC requests that attribution to the dataset is provided as academically appropriate.

42 ENGINEERING↗
DOE OSTI2024

Geant4 Simulations on Faraday Cup Design for PIP-II Laser Wire Scanner System

The Proton Improvement Plan-II (PIP-II) accelerator upgrade at Fermilab represents a groundbreaking leap forward in high-energy physics research. This ambitious initiative involves enhancing Fermilab's accelerator complexby replacing the current linear accelerator (linac) with awarm front end (WFE) capable of accelerating H- beamsup to 2.1 MeV. Subsequently, a superconducting linac further accelerates these beams up to 800 MeV. To preciselymeasure the transverse beam profile, a combination of traditional wire scanners at the WFE section and Laser wirescanners along the superconducting linac are planned forimplementation. This investigation is centered on refiningthe Faraday cup design for the PIP-II Laser wire scannersby utilizing GEANT4, a Monte Carlo simulation toolkit.Leveraging this method enables a comprehensive analysisof particle trajectories, energy deposition, secondary particle emission, backscattering, etc., facilitating optimizationthrough adjustments to cup geometries, materials, andplacement to maximize its efficacy in beam diagnostics.

43 PARTICLE ACCELERATORS↗
DOE OSTI2024

A hybrid-kinetic simulation tool for non-thermal warm x-ray z-pinch sources, with gas-puff and wire array exemplars

Increasing the fluence of z-pinch x-ray radiation sources above ∼ 10 keV has been a long-standing goal for scientists at Sandia National Laboratories’ Z Machine. Optimizing sources for non-thermal “cold Kα” emission in higher atomic-number materials appears to be a promising path to increase warm x-ray yield. However, this emission is generated by supra-thermal electrons, which are not treated in the magnetohydrodynamic (MHD) codes that are typically used in z-pinch source development. MHD codes do not allow for charge separation or space-charge-generated electric fields, and constrain particle kinematics to Maxwellian distributions. The kinetic codes which do accommodate discrete, non-thermal energy distributions are computationally prohibitive when modeling plasmas near solid density and when modeling/tracking higher ionization states. Thus, modeling non-thermal z-pinch sources requires a new simulation tool. In this report, we present a new hybrid modeling capability that uses the fast features of MHD-type particles to the greatest extent possible, then transitions to the slower but more complete kinetic particle treatment to correctly capture the particle energy spectra that generate non-thermal emission. This capability is founded on the fully-relativistic particle-in-cell code Chicago, which already includes fluid particle treatments. The governing equations and hybrid methodology presented here are applied in simulations of an argon gas-puff and a molybdenum wire-array to provide preliminary code validation. The argon simulation is compared to measured implosion times and yields from Jones et al., Phys. Plasmas 22, 020706 (2015). The simulated x-ray yield is within 25% of measurements and the implosion times agree within a few percent. The molybdenum wire array simulation captures the implosion timing reported in Hansen et al., Phys. Plasmas 21, 031202 (2014), but work is needed to verify the available EOS table. These exemplar simulations represents the type of non-thermal sources that will be developed using the hybrid code capability going forward.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Setup and Testing of the RS105 Wire Array Pulser

The report covers the RS105 Wire Array Pulser testbed. The setup of the wire array at Reapplication, building 996, is laid out. Setup instructions are provided. Details of the commissioning test are given. Measurement data from the commissioning test shows the field output of the array exceeds 50 kV/m and that tuning the pulser output with a peaking switch can provide a rise time of ~2.3 ns and a pulse width of ~23 ns. The field levels and timeframes shown are within the tolerance conditions of

42 ENGINEERING↗
DOE OSTI2024

Validation of Exploding Wire Tests Using Alegra-NG

Exploding wire tests are used to characterize materials undergoing high voltage loading and to validate computational models in a simple configuration. In this report, the materials emphasized are gold, aluminum, copper and nickel wires. Model validation is presented using the nominal model (no uncertainty) in the form of heat maps (per material) that show model bias across scalar quantities and initial voltage. Mesh convergence and uncertainty quantification is also presented.

36 MATERIALS SCIENCE↗
DOE OSTI2023

ER4047 Filler Wire Development - Initial Studies

This report describes the results of bead on pipe welding trials for the purpose of evaluating commercial off the shelf (COTS) 0.047” ER4047 filler material vendors for down selection of the of best candidate filler material for future Gas-metal Arc Welding (GMAW) development efforts. Four candidate COTS ER4047 filler wires were evaluated during this work - Astrolite, Alcotec, Hobart, and Lincoln. The storage condition of each of these filler wires was documented and visual inspection was performed.

36 MATERIALS SCIENCE↗
NASA NTRS1964

Cooling method prolongs life of hot-wire transducer

To cool a hot-wire transducer, the two ends of the wire are supported on thermally and electrically conductive rods, surrounded by a fluid cooling medium. By keeping the supporting rods at a substantially constant temperature, the probe is prevented from overheating.

Baldwin, L. V.↗