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At least 379 records · Page 21
All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Total Cost of Ownership Reduction Using Passive Pre-Chamber Ignition in Natural Gas Engines

Spark plug durability is a factor affecting the total cost of ownership (TCO) of spark-ignited natural gas engines, with some heavy-duty platforms requiring plug replacement after only 750 hours of operation. The high ignition energy demand under lean or diluted conditions accelerates electrode wear, shortening plug life and increasing maintenance frequency. This work evaluates passive pre-chamber (PC) ignition operating at lowered spark energies as a strategy to reduce spark energy requirements and extend plug durability, thereby lowering TCO. Experiments were conducted on a medium-duty Cummins 6.7L ISB engine at 1600 RPM and 50% load under varying exhaust gas recirculation (EGR) dilution levels (0–40%). Two passive pre-chambers with 1.1 mm and 1.6 mm nozzle diameters were compared with conventional spark ignition (SI). SI was operated with a fixed coil dwell of 4 ms (~90 mJ), while the PC configuration was tested across 2–4 ms dwell times (~30–90 mJ). Cylinder pressure analysis revealed that PC ignition sustained stable combustion at significantly lower spark energies than SI, with improved combustion stability at ~30 mJ compared with SI at ~90 mJ. The PC system also extended the dilution tolerance beyond that achievable with SI, while delivering up to ~2% higher indicated thermal efficiency and reducing the COV by nearly 90% at 30% EGR. A TCO analysis was conducted to assess the economic benefit of adopting a passive PC system operating at reduced spark energies compared to SI. It was found that adopting a passive PC system could reduce TCO by approximately $11,000 per engine over a five-year operational period, primarily due to fuel savings, extended spark plug life, and reduced maintenance frequency. These projections were weighed against the additional hardware cost of the pre-chamber, yielding a rapid estimated return on investment of ~300 operating hours. Therefore, this work motivates continued research and development of passive PC technology and its commercial adoption in natural gas engines used in transportation applications.

Dhotre, Akash [University of Minnesota]↗
NASA NTRS1972

Protection Against Hearing Loss in General Aviation Operations, Phase II

An inflight evaluation of four aural protectors is presented. The hearing protection devices studied were ear muffs, plastic ear plugs, rubber ear plugs, and wax ear plugs. It is concluded that ear plugs are satisfactory for providing adequate sound attenuation in general aviation aircraft. However, two problems were found in the use of ear plugs; comfort and interference with cabin communications.

Parker, J. F., Jr.↗
NASA NTRS1979

Unconventional nozzle tradeoff study

Plug cluster engine design, performance, weight, envelope, operational characteristics, development cost, and payload capability, were evaluated and comparisons were made with other space tug engine candidates using oxygen/hydrogen propellants. Parametric performance data were generated for existing developed or high technology thrust chambers clustered around a plug nozzle of very large diameter. The uncertainties in the performance prediction of plug cluster engines with large gaps between the modules (thrust chambers) were evaluated. The major uncertainty involves, the aerodynamics of the flow from discrete nozzles, and the lack of this flow to achieve the pressure ratio corresponding to the defined area ratio for a plug cluster. This uncertainty was reduced through a cluster design that consists of a plug contour that is formed from the cluster of high area ratio bell nozzles that have been scarfed. Light-weight, high area ratio, bell nozzles were achieved through the use of AGCarb (carbon-carbon cloth) nozzle extensions.

Obrien, C. J.↗
NASA NTRS1983

Electrical self-aligning connector

A self-aligning electrical connector device includes a receptacle component having a conically contoured interior and a plug component having a correspondingly contoured conical body receivable in the receptacle component. The plug component has a number of spaced conductive ring elements with a mating face and the receptacle component includes corresponding spaced conductive ring elements providing mating interface with the mating face of the ring elements of the plug component when connected to it. Each ring element of the receptacle component has several segmented portions which defect downwardly when the plug component is inserted. A biasing force is asserted against the face of the ring elements of the plug component providing positive electrical contact and connection between the ring elements of the components.

Clark, K. H.↗
NASA NTRS1988

Integrated fountain effect pump device for fluid management at low gravity

A new device for fluid management at low gravity is described. The system is basically the same as the enclosed capillary device using screens, in which the screens along the gallery channels are replaced by porous plugs which are responsible for both the fluid retention and pumping of He II; in this device, no downstream pump is needed. The plugs in contact with liquid He on both sides act as a fountain-effect pumps (FEPs), while plugs exposed to vapor on one side behave as vapor-liquid phase separators (VLPSs). The total net rate of He II transfer into the receiving tank equals the mass flow rate through the FEP plugs minus the liquid loss from the VLPS plugs. The results of the performance analysis of this integrated FEP device are presented together with its schematic diagram.

Yuan, S. W. K.↗
NASA NTRS1949

Comparison of Performance of AN-F-58 Fuel and Gasoline in J34-WE-22 Turbojet Engine

As part of an investigation of the performance of AN-F-58 fuel in various types of turbojet engine, the performance of this fuel in a 3000-pound-thrust turbojet engine has been investigated in an altitude test chamber together with the comparative performance of 62-octane gasoline. The investigation of normal engine performance, which covered a range of engine speeds at altitudes from 5000 to 50,000 feet and flight Mach numbers up to 1.00, showed that both the net thrust and average turbine-outlet temperatures were approximately the same for both fuels. The specific fuel consumption and the combustion efficiency at the maximum engine speeds investigated were approximately the same for both fuels at altitudes up to 35,000 feet, but at an altitude of 50,000 feet the specific fuel consumption was about 9 percent higher and the combustion efficiency was correspondingly lower with the AN-F-58 fuel than with gasoline. The low-engine-speed blow-out limits were about the same for both fuels. Ignition of AN-F-58 fuel with the standard spark plug was possible only with the spark plug in a clean condition; ignition was impossible at all flight conditions investigated when the plug was fouled by an accumulation of liquid fuel from a preceding false start. Use of an extended-electrode spark plug provided satisfactory ignition over a slightly smaller range of altitudes and flight Mach numbers than for gasoline with the standard spark plug.

Dowman, Harry W↗
NASA NTRS2001

Metal Flow During Friction Stir Welding

The flow of metal during Friction Stir Welding is clarified using a faying surface tracer and a nib frozen in place during welding. It is shown that material is transported by two processes. The first is a wiping of material from the advancing front side of the nib onto a plug of material that rotates and advances with the nib. The material undergoes a helical motion within the plug that both rotates and advances with the plug and descends in the wash of the threads on the nib and rises on the outer part of the plug. After one or more rotations, this material is sloughed off the plug in its wake, primarily on the advancing side. The second process is an entrainment of material from the front retreating side of the nib that fills in between the sloughed off pieces from the advancing side. These two processes produce material with different mechanical properties and the strength of a weld should depend on the relative importance of the processes.

Guerra, M.↗
NASA NTRS2001

Material Flow During Friction Stir Welds

The flow of metal during Friction Stir Welding is clarified using a faying surface tracer and a nib frozen in place during welding. It is shown that material is transported in two distinct streams or currents. One stream is a wiping of material from the advancing front side of the nib onto a plug of material that rotates and advances with the nib. The material undergoes a helical motion within the plug that both rotates and advances with the plug and descends in the wash of the threads on the nib and rises on the outer part of the plug. After one or more rotations, this material is sloughed off the plug in the wake of the tool primarily on the advancing side. The second stream of material is an entrainment of material from the retreating side of the nib that fills in between the sloughed off pieces from the advancing side. These two processes produce material with different mechanical properties and the strength of a weld should depend on the relative importance of the processes.

Guerra, M.↗
NASA NTRS1996

Adaptation of primate vestibuloocular reflex to altered peripheral vestibular inputs. I. Frequency-specific recovery of horizontal VOR after inactivation of the lateral semicircular canals

1. The adaptive plasticity of the vestibuloocular reflex (VOR) following a selective lesion of the peripheral vestibular organs was investigated in rhesus monkeys whose lateral semicircular canals were inactivated by plugging of the canal lumen in both ears. Gain and phase of horizontal, vertical, and torsional slow-phase eye velocity were determined from three-dimensional eye movement recordings obtained acutely after the plugging operation, as well as in regular intervals up to 10 mo later. 2. Acutely after plugging, horizontal VOR was minimal during yaw rotation with gains of < 0.1 at all frequencies. Horizontal VOR gain gradually increased over time, reaching gains of 0.4-0.5 for yaw oscillations at 1.1 Hz approximately 5 mo after lateral canal inactivation. This response recovery was strongly frequency dependent: horizontal VOR gains were largest at the highest frequency tested and progressively decreased for lower frequencies. Below approximately 0.1 Hz, no consistent horizontal VOR could be elicited even 10 mo after plugging. 3. The frequency-dependent changes in gain paralleled changes in horizontal VOR phase. Below approximately 0.1-0.05 Hz large phase leads were present, similarly as in semicircular canal primary afferents. Smaller phase leads were also present at higher frequencies, particularly at 1.1 Hz (the highest frequency tested). 4. Consistent with the afferent-like dynamics of the adapted horizontal VOR, per- and postrotatory horizontal responses to constant-velocity yaw rotations were short lasting. Time constants of the slow-phase eye velocity envelope of the horizontal postrotatory nystagmus were approximately 2 s. Nonetheless, a consistent horizontal optokinetic afternystagmus was evoked in plugged animals. 5. A torsional component that was absent in intact animals was consistently present during yaw rotation acutely after lateral canal inactivation and remained approximately constant thereafter. The frequency response characteristics of this torsional component resembled those of the adapted horizontal slow-phase responses: gain decreased and large phase leads were introduced at frequencies below approximately 0.05-0.1 Hz. Torsional responses elicited by roll oscillations in supine position, on the other hand, were indistinguishable in their dynamics from intact animals. No consistent vertical nystagmus was elicited during yaw rotation. 6. Our results show that there is a slow, frequency-specific recovery of horizontal VOR after selective inactivation of the lateral semicircular canals. Both the spatial organization and the dynamic properties of the adapted VOR responses are distinctly different from responses in intact animals, suggesting complex changes in the underlying vestibuloocular circuitry.

NASA Program Space Physiology and Countermeasures↗
NASA NTRS1989

Quick actuating closure

A quick actuating closure for a pressure vessel 80 in which a wedge ring 30 with a conical outer surface 31 is moved forward to force shear blocks 40, with conical inner surfaces 41, radially outward to lock an end closure plug 70 within an opening 81 in the pressure vessel 80. A seal ring 60 and a preload ramp 50 sit between the shear blocks 40 and the end closure plug 70 to provide a backup sealing capability. Conical surfaces 44 and 55 of the preload ramp 50 and the shear blocks 40 interact to force the seal ring 60 into shoulders 73 and 85 in the end closure plug 70 and opening 81 to form a tight seal. The end closure plug 70 is unlocked by moving the wedge ring 30 rearward, which causes T-bars 32 of the wedge ring 30 riding within T -slots 42 of the shear blocks 40 to force them radially inward. The end closure plug 70 is then removed, allowing access to the interior of the pressure vessel 80.

White, III, Dorsey E.↗
NASA NTRS2003

Device for Automated Cutting and Transfer of Plant Shoots

A device that enables the automated cutting and transfer of plant shoots is undergoing development for use in the propagation of plants in a nursery or laboratory. At present, it is standard practice for a human technician to use a knife and forceps to cut, separate, and grasp a plant shoot. The great advantage offered by the present device is that its design and operation are simpler than would be those of a device based on the manual cutting/separation/grasping procedure. [The present device should not be confused with a prior device developed for partly the same purpose and described in Compliant Gripper for a Robotic Manipulator (NPO-21104), NASA Tech Briefs, Vol. 27, No. 3 (March 2003), page 59.]. The device (see figure) includes a circular tube sharpened at its open (lower) end and mounted on a robotic manipulator at its closed (upper) end. The robotic manipulator simply pushes the sharpened open end of the tube down onto a bed of plants and rotates a few degrees clockwise then counterclockwise about the vertical axis, causing the tube to cut a cylindrical plug of plant material. Exploiting the natural friction between the tube and plug, the tube retains the plug, without need for a gripping mechanism and control. The robotic manipulator then retracts the tube, translates it to a new location over a plant-growth tray, and inserts the tube part way into the growth medium at this location in the tray. A short burst of compressed air is admitted to the upper end of the tube to eject the plug of plant material and drive it into the growth medium. A prototype has been tested and verified to function substantially as intended. It is projected that in the fully developed robotic plant-propagation system, the robot control system would include a machine- vision subsystem that would automatically guide the robotic manipulator in choosing the positions from which to cut plugs of plant material. Planned further development efforts also include more testing and refinement of the design and operation described above.

Cipra, Raymond↗
DOE OSTI2025

Particle-based modelling of axisymmetric tandem mirror devices

In this work, we describe the use of a 1D-2V quasi-neutral hybrid electrostatic PIC with Monte-Carlo Coulomb collisions and non-uniform magnetic field to model the parallel transport and confinement in an axisymmetric tandem mirror device. End-plugs, based on simple-mirrors, are positioned at each end of the device and fueled with neutral beams (25 and 100 keV) to produce a sloshing ion population and increase the density of the end-plugs relative to the central cell. Results show the formation of a potential difference barrier between the central cell and the end-plugs. This potential confines a large fraction of the low energy thermal ions in the central cell which would otherwise be lost in a simple mirror, demonstrating the advantage of the beam-driven tandem mirror configuration relative to simple mirrors. In addition, we explore the effect of end-plug electron temperature on the confinement time of the device and compare it with theoretical estimates. Finally, we discuss the limitations of the code in its present form and describe the next logical steps to improve its predictive capability such as a fully nonlinear Fokker–Planck collision operator, multiply nested flux surface solutions and modeling the exhaust region up to the wall.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Optimizing the Heisenberg Vortex Tube for Hydrogen Cooling (Final Technical Report)

Hydrogen utilization at Plug Power sites ranges between 70-93% with the remainder vented and lost to the atmosphere. The goal of this project was to improve hydrogen utilization at Plug Power fulfillment centers via the patented Heisenberg vortex tube (HVT). The HVT combines conventional counterflow vortex tubes with para-orthohydrogen conversion catalyst to allow the cooling of hydrogen flows with no moving parts or external energy inputs. In year 1 of this project the HVT was evaluated to improve hydrogen utilization via the following concepts: 1) increasing liquid hydrogen pump volumetric efficiency by 20% through vapor separation and subcooling of the liquid, 2) reducing liquid hydrogen storage tank boil-off losses by 20% through thermal vapor shielding (TVS), and 3) increase isentropic efficiency of supercritical hydrogen expansion at 40-50 K, from 31% to over 40%. The TVS concept was selected as the most favorable application for further development. While the conceptual analysis was underway, the cryocatalysis hydrogen experiment facility (CHEF) was retrofitted with a new cryocooler, higher pressure condenser tanks, and in-situ fiber-optic Raman probes for ortho-parahydrogen composition analysis at the inlets and outlets of the HVT. To our knowledge this is the first in-situ implementation of cryogenic Raman probes for ortho-parahydrogen analysis. Subsequent testing of catalyzed and non-catalyzed HVT identified a low flow rate, high-conversion efficacy regime well suited for TVS development. Computational fluid dynamics (CFD), Reduced order modeling (ROM), and quantum Monte Carlo atomistic simulations were applied to optimize the design of the HVT implemented for TVS. The simulations and analysis identified a ruthenium-based catalyst as the most optimal for high conversion with little pressure losses and was matched to experimental measurements. These results indicated the design could achieve the 20% boil-off reduction target. An HVT field-trial was designed and constructed by Plug Power and implemented at a customer site. However, budget limitations reduced the amount of catalyst that could be applied to the HVT. With the reduced amount of catalyst, CFD analysis estimated about 3% reduction in boil-off. A similar amount of boil-off reduction was observed during preliminary measurements during tank commissioning. However, the results have a large margin for error and were operated at relatively low tank temperatures when the HVT has the lowest potential for improvement. This project demonstrated the use of para-orthohydrogen catalysis for reducing liquid hydrogen tank boil-off losses. The field trial system is anticipated to provide long-term experimental measurements on tank operational performance that will allow Plug Power to instrument additional tanks in the future. Recommendations for future work include the development of higher activity, lower cost para-orthohydrogen conversion catalyst for use in the HVT. Tank process optimizations could maximize the efficacy of the HVT and further improve hydrogen utilization.

08 HYDROGEN↗
DOE OSTI2025

WHA Sphere Impacting RHA Plate: Modeling Brittle Behavior in Metal Alloys

Brittle behavior of metal alloys is often critical to modeling ballistic impact and penetration. The ALEGRA multiphysics finite element software incorporates calibrated models for the equation of state, elasticity, yield stress, plasticity and fracture, but simulations do not always capture expected metal fracture. Here we report concerted efforts to do so for one important case where experiments clearly show shear fractures: a tungsten sphere impacting a steel plate at various angles. Our best simulations show fractures that are qualitatively similar to experiments, but there are significant differences in quantitative metrics. Specifically, velocities of tracers used to quantify simulated plug parameters consistently fall short of measured plug velocities. Also, simulated plugs break apart more than expected from experimental evidence. We attribute these shortfalls to the lack of an explicit shear fracture mechanism in the material models, leading to over-estimated resistance to plug formation and movement.

36 MATERIALS SCIENCE↗
DOE OSTI2025

ELECTRIFICATION OF A HEAVY-DUTY OFF-ROAD MATERIAL HANDLER: ENERGY SAVINGS AND EMISSION REDUCTIONS

Federal regulations are driving the adoption of electrification technologies to reduce carbon dioxide equivalent (CO2e) emissions, a metric that quantifies the global warming potential of various greenhouse gases in terms of carbon dioxide (CO2). Although no specific CO2 regulations exist for heavy-duty off-road machines, future reductions are likely, given stricter emissions standards for on-road vehicles. The heavy-duty off-road sector offers significant fuel-saving potential, as its focus has traditionally been on reliability and performance rather than fuel efficiency. This dissertation examines fuel and CO2e savings opportunities on a heavy-duty off-road material handler, the Pettibone Cary-Lift 204i, from stock configuration to simple modifications to a complete teardown and reconfiguration of the machine with a plug-in series hybrid architecture using electrified hydraulics. The study begins by modeling the baseline machine’s fuel and energy consumption, calibrating with experimental data from custom operating cycles. An energy analysis identifies key areas for fuel savings. Two simple powertrain modifications result in a combined 16.2% fuel savings. Next, a Pugh-style analysis narrows a list of electrified architectures, leading to high-fidelity models that evaluate total lifetime CO2e and costs. Higher electrification levels reduce CO2e emissions but increase costs, and electricity grid emissions significantly impact CO2e for plug-in architectures. A plug-in series hybrid is chosen for the project. In its base control form, 49% fuel and 29% CO2e savings are expected from the plug-in series hybrid compared to the baseline machine. Further savings are pursued through regenerative braking (6.3%) and load-following hydraulic control (17.8%), totaling 24.1% fuel savings, and leading to a total of 61% fuel and 41% CO2e savings compared to the baseline. Battery chemistries and charging strategies are also analyzed for cost and CO2e impacts, finding LFP batteries as superior due to longevity, and overnight level 2 charging usually at a lower cost but resulting in higher emissions than opportunity DC fast-charging (DCFC). DCFC emissions are highly dependent on grid emissions, and DCFC cost is highly dependent on grid demand charges. Finally, artificial intelligence is applied to operating cycle recognition. Neural network accuracy ranges from 81% to 99%, with applications to worksite efficiency and safety improvements.

24 POWER TRANSMISSION AND DISTRIBUTION↗
NASA NTRS1975

Flight investigation of installation effects on a wedge nozzle installed on an underwing nacelle

A flight research program was conducted using a modified F-106B aircraft with an underwing-nacelle - engine installation to investigate installation effects on a wedge nozzle with retracted shrouds from Mach 0.70 to 1.10. These configurations simulated the subsonic flight geometries of a variable-geometry wedge nozzle design for Mach 2.70 operation. The nozzle was tested with a J85-GE-13 turbojet engine, and data were compared with that of 0.34-scale isolated wind tunnel model. Data are also compared with the flight results of a boattail plug nozzle and a cylindrical nacelle plug nozzle. A favorable installation effect occurred from Mach 0.82 to 0.96 with a nominal 4-percent corrected secondary weight-flow ratio. This favorable effect resulted from changes in pressure forces on the nozzle surfaces. The wedge nozzle gross thrust coefficient was about the same as the boattail nacelle plug nozzle and 2.50 to 1.30 percent higher than the cylindrical nacelle plug nozzle over the subsonic Mach number range.

Johns, A. L.↗
NASA NTRS1975

Working model of the London moment readout system

The operating characteristics of a porous plug which has liquid helium on one side and which is pumped on under vacuum on the other side are discussed. The system investigated consists of a container of liquid helium which is well isolated, and the only means for mass flow out of the container is through a plug mode of porous material. The plug was assumed to have liquid helium on the container side while the other side of the plug is evacuated. Three cases were considered: (1) perfect evacuation with zero pressure, (2) evacuation through a chocked orifice, and (3) evacuation through a long, small diameter pipe with heating. Mass flow rates were determined along with mass flow at temperature above the lambda point temperature. Solutions were obtained for normal and superfluid velocity.

Hendricks, J. B.↗
NASA NTRS1981

Development of a window protection assembly for a shuttle experiment

A window environmental protection assembly developed for the shuttle infrared leeside temperature experiment is described. The assembly consists of a carbon phenolic composite window mount which contains two silicon windows, a fibrous environmental protection plug to protect the windows during launch operations and ascent heating, a release mechanism used to jettison the plug just prior to atmospheric entry, and two pin puller mechanisms which retain the plug. The plug is released from the window mount assemblies using pneumatic pin pullers and separation springs in the release mechanism. The assembly was designed and tested to withstand the severe mechanical and thermal environments which could be experienced at the top of the shuttle orbiter vertical stabilizer during the ascent, on-orbit, and entry periods of the shuttle trajectory.

Bradley, O. H., Jr.↗