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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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DOE OSTI2024

Drop Analysis of a Department of Energy Standard Canister Containing Fort Saint Vrain SNF– 24138

DOE manages over 300 types of SNF, many of which are located at the INL site. Managing this large variety of SNF for storage, transportation, and disposal poses a challenge to DOE. The Idaho Cleanup Project and INL are collaborating on the DOE SNF Road-Ready Demonstration (“Road-Ready Demonstration”), which will develop and demonstrate the designs, technology, processes, and regulatory framework for packaging DOE-managed SNF for “road-ready dry storage.” Road-ready dry storage (RRDS) is an SNF management concept in which SNF is packaged into dry, sealed canisters that are then placed in on-site storage in anticipation of later transport and disposition. The forward-looking goal of the Road-Ready Demonstration is to establish the foundation for a large-scale RRDS program at the INL site. One critical aspect of RRDS is the ability to certify the DOE Standard Canister and its associated transportation package in accordance with 10 CFR 71 for offsite transportation. Depending on the SNF type and transportation strategy, DOE Standard Canisters may be required to maintain structural integrity under hypothetical accident scenarios (e.g., drop events). The DOE Standard Canisters have been tested and analyzed under various SNF loading configurations and accident drop events in support of the Idaho Spent Fuel Facility and other DOE programs; however, no analysis has yet been completed in support of the recently initiated Road-Ready Demonstration. This paper presents preliminary results from a finite element analysis of the Ø45.7 cm × 4.6 m (Ø18 in. × 15 ft) DOE Standard Canister under the 9 m drop at 80 degrees off-vertical drop scenario considered in previous INL tests and analyses. It considers the Fort St. Vrain spent nuclear fuel loading configuration proposed for the Road-Ready Demonstration, uses updated material properties, and applies the strain-based acceptance criteria established in ASME Boiler and Pressure Vessel Code’s Section III, Division 3 rules for storage and transportation spent nuclear fuel containments. This updated analysis is compared to previous DOE Standard Canister drop analyses. Preliminary results from the updated analysis show that certain regions of the containment exceed the allowable limits during the accidental drop event. However, these regions are limited to components performing a non-structural function. While further work on this analysis will be pursued, this analysis serves as the foundation for formal calculations used to support applicable certification efforts of the RRDS system at INL.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Drop Analysis of a Department of Energy Standard Canister Containing Fort Saint Vrain SNF

DOE manages over 300 types of SNF, many of which are located at the INL site. Managing this large variety of SNF for storage, transportation, and disposal poses a challenge to DOE. The Idaho Cleanup Project and INL are collaborating on the DOE SNF Road-Ready Demonstration (“Road-Ready Demonstration”), which will develop and demonstrate the designs, technology, processes, and regulatory framework for packaging DOE-managed SNF for “road-ready dry storage.” Road-ready dry storage (RRDS) is an SNF management concept in which SNF is packaged into dry, sealed canisters that are then placed in on-site storage in anticipation of later transport and disposition. The forward-looking goal of the Road-Ready Demonstration is to establish the foundation for a large-scale RRDS program at the INL site. One critical aspect of RRDS is the ability to certify the DOE Standard Canister and its associated transportation package in accordance with 10 CFR 71 for offsite transportation. Depending on the SNF type and transportation strategy, DOE Standard Canisters may be required to maintain structural integrity under hypothetical accident scenarios (e.g., drop events). The DOE Standard Canisters have been tested and analyzed under various SNF loading configurations and accident drop events in support of the Idaho Spent Fuel Facility and other DOE programs; however, no analysis has yet been completed in support of the recently initiated Road-Ready Demonstration. This paper presents preliminary results from a finite element analysis of the Ø45.7 cm × 4.6 m (Ø18 in. × 15 ft) DOE Standard Canister under the 9 m drop at 80 degrees off-vertical drop scenario considered in previous INL tests and analyses. It considers the Fort St. Vrain spent nuclear fuel loading configuration proposed for the Road-Ready Demonstration, uses updated material properties, and applies the strain-based acceptance criteria established in ASME Boiler and Pressure Vessel Code’s Section III, Division 3 rules for storage and transportation spent nuclear fuel containments. This updated analysis is compared to previous DOE Standard Canister drop analyses. Preliminary results from the updated analysis show that certain regions of the containment exceed the allowable limits during the accidental drop event. However, these regions are limited to components performing a non-structural function. While further work on this analysis will be pursued, this analysis serves as the foundation for formal calculations used to support applicable certification efforts of the RRDS system at INL.

42 ENGINEERING↗
DOE OSTI2023

Fabrication and Testing of DOE Standard Canister Closure Leak Test Assembly – 24139

DOE manages over 300 types of spent nuclear fuel (SNF), many of which are located at the Idaho National Laboratory (INL) site. Managing this large variety of SNF for storage, transportation, and disposal poses a challenge to DOE. The Idaho Cleanup Project and INL are collaborating on the DOE SNF Road-Ready Demonstration (“Road-Ready Demonstration”), which will develop and demonstrate the designs, technology, processes, and regulatory framework for packaging DOE-managed SNF for “road-ready dry storage.” Road-ready dry storage is an SNF management concept in which SNF is packaged into dry, sealed canisters that are then placed in onsite storage in anticipation of later transport and disposition. The forward-looking goal of the Road-Ready Demonstration is to establish the foundation for a large-scale road-ready dry storage program at the INL site. In support of establishing a large-scale road-ready dry storage program at the INL site, the Road-Ready Demonstration will first package Fort St. Vrain SNF currently in dry storage at INL into several DOE Standard Canisters (DOESCs). These DOESCs will in turn be loaded into another containment similar to commercial multi-purpose canisters. This multi-purpose canister will then be compatible with a transportation or storage system, such as a storage cask for interim storage or transportation package for offsite transport. These DOESCs will remain sealed over the course of their storage, transportation, and applicable disposal functions. The closure process for the DOESC will include fuel and basket loading, welding, inspection, leak testing, and, if needed, repair. As a follow-up to previous discussions on the design of the DOE Closure Leak Test Assembly (LTA), this report describes recent fabrication and testing efforts performed at INL. DOESCs are sealed by two sequential gas tungsten arc welds, both of which are performed by remotely operated and semiautomatic welding systems. The first weld is a circumferential pipe weld that completes the assembly of the canister body and lid assembly. The second and final closure weld attaches the vent plug to the vent socket via a butt joint. After the second weld is performed, the welds are helium leak tested using an evacuated envelope technique. The LTA was designed for both remote and manual operation. This report describes the fabrication and performance testing associated with the evacuated envelope technique. INL staff designed, fabricated, and tested the LTA at INL facilities. This testing included establishing technique and system sensitivities in accordance with ASME and American National Standards Institute N14.5 requirements. Forthcoming work will cover such areas as design optimization, process and personnel qualification, and implementation in Road-Ready Demonstration operations.

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DOE OSTI2018

Commissioning and Startup of a New Category 2 Nuclear Facility for RH TRU Sludge Packaging - 18614

For many years the Department of Energy (DOE) has been executing a plan to eliminate all threats of Radiological release to the Columbia River from the Hanford site, in Richland, Washington. While the River Corridor Closure Project is nearing completion, one of the last remaining facilities along the Columbia River is the 100K reactor complex. Since the 1950's the 105KW fuel storage basin has contained varying levels of spent reactor fuel and products of the degradation of aging stored fuel. Having previously removed all of the distinguishable spent fuel components, CH2M HILL Plateau Remediation Company (CH2M) is now in the final stages of readiness review to commence removal of the residual sludge material that has accumulated in the basin throughout the years of operation. There is approximately 27 m3 of sludge in the 105KW basin currently. This sludge material exhibits a very high radiation dose rate with levels reaching 100 R/hr. It is also very difficult to mobilize and transfer due to its physical characteristics. CH2M engineers have developed a novel mechanical system for mobilization and transfer of the sludge to specially designed storage containers. Once transferred to these containers, the sludge will be moved away from the river and taken to T Plant, a decontamination and repair facility on site, for interim storage, while a project to treat and package the material for final disposition is established. The Sludge Removal Project (SRP) is a $309 M capital line item project that was established to achieve the goals of this mission. Part of the project is to develop and install the equipment needed to do the transfer, and part of the project is to construct a new Category 2 sludge packaging facility. Construction of the facility is now complete, all equipment is installed and the project is well into the commissioning phase. Over the final three months of 2017, the project progressed into the final stages of readiness to transition to operations. This will represent the first commissioning of a new Category 2 process and facility at Hanford in over 10 years. The SRP team has crossed over many hurdles in establishing a workable plan for the safety basis for installing, commissioning and transitioning to operations within the boundaries of an existing Facility Safety Analysis Report. The project team has also applied extensive use of a mockup facility in the development and execution of the path to readiness and commencement of operations. At the time of the conference, the project will have completed a DOE Operational Readiness Review and will be very near of just entering full operation. This paper will share the experiences of the project team through these final steps and lessons learned on making the project successful. (author)

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DOE OSTI2019

Light-Duty Fuel Cell Electric Vehicle Validation Data (Final Report)

Since 2005, Mercedes-Benz Research & Development North America (MBRDNA) participated in the DOE’s Technology Validation Programs to help accelerate the market introduction of fuel cell vehicles. Under the U.S. Department of Energy (DOE) contract DE-EE0005971, which ran from 2013 - 2019, MBRDNA collaborated with the DOE to evaluate overall vehicle degradation effects of fuel cell vehicles, as well as evaluate the generational improvements from one vehicle generation to another. The goal was to achieve a mileage target of 10,000-12,000 miles per vehicle per year and 750 to 1,000 operating hour accumulation per fuel cell stack. The MBRDNA Project Team (Project Team) leased a total of 69 fuel cell vehicles to regular Mercedes-Benz customers through select dealerships in Northern and Southern California. Of these 69 vehicles, a minimum of 20 active vehicles were chosen to participate in this project based on customer driving habits, average daily miles, and geographic conditions. These vehicles were equipped with a data acquisition system that automatically collected statistically relevant data for submission to the National Renewable Energy Laboratory, which monitors the progress of fuel cell vehicle technology for the DOE. As customer operation of GEN II vehicles ended in Q4 2017, a decision was made to focus GEN III vehicle operation in Europe and Japan only, and not to deploy the vehicle in the United States. Despite the intention to include three GEN III vehicles in durability runs in Southern California for purposes of data collection for this project, the plan could not be realized given the decision not to deploy GEN III vehicles in the U.S. market at this time. In total, over 1.3 million miles and 60,000 operational hours of fuel cell system and powertrain operation were submitted to DOE under this project. The data provided revealed insights into real-world customer operation and system durability of fuel cell vehicles, enabling the DOE to observe the technology maturity and readiness of fuel cell vehicles outside of the controlled corporate research and development environment. Mercedes-Benz Research and Development North America (MBRDNA) has been promoting fuel cell technology in the U.S. since 2000. Over this time, it has been a pleasure to work in conjunction with the Department of Energy (DOE) on two separate projects surrounding fuel cell vehicle and market readiness. MBRDNA looks forward to future opportunities to collaborate in the interest of helping to further a sustainable transportation future.

08 HYDROGEN↗
NASA NTRS2018

Overview of Heatshield for Extreme Entry Environment Technology (HEEET) Project

The objective of the Heatshield for Extreme Entry Environment Technology (HEEET) projects is to mature a 3-D Woven Thermal Protection System (TPS) to Technical Readiness Level (TRL) 6 to support future NASA missions to destinations such as Venus and Saturn. Destinations that have extreme entry environments with heat fluxes up to 5000 watts per square centimeter and pressures up to 5 atmospheres, entry environments that NASA has not flown since Pioneer-Venus and Galileo. The scope of the project is broad and can be split into roughly four areas, Manufacturing/Integration, Structural Testing and Analysis, Thermal Testing and Analysis and Documentation. Manufactruing/Integration covers from raw materials, piece part fabrication to final integration on a 1-meter base diameter 45-degree sphere cone Engineering Test Unit (ETU). A key aspect of the project was to transfer as much of the manufacturing technology to industry in preparation to support future mission infusion. The forming, infusion and machining approaches were transferred to Fiber Materials Inc. and FMI then fabricated the piece parts from which the ETU was manufactured. The base 3D-woven material consists of a dual layer weave with a high density outer layer to manage recession in the system and a lower density, lower thermal conductivity inner layer to manage the heat load. At the start of the project it was understood that due to weaving limitations the heat shield was going to be manufactured from a series of tiles. And it was recognized that the development of a seam solution that met the structural and thermal requirements of the system was going to be the most challenging aspect of the project. It was also recognized that the seam design would drive the final integration approach and therefore the integration of the ETU was kept in-house within NASA. A final seam concept has been successfully developed and implemented on the ETU and will be discussed. The structural testing and analysis covers from characterization of the different layers of the infused material as functions of weave direction and temperature, to sub-component level testing such as 4-pt bend testing at sub-ambient and elevated temperature. ETU test results are used to validate the structural models developed using the element and sub-component level tests. Given the seam has to perform both structurally and aerothermally during entry a novel 4-pt bend test fixture was developed allowing articles to be tested while the front surface is heated with a laser. These tests are intended to establish the system's structural capability during entry. A broad range of aerothermal tests (arcjet tests) are being performed to develop material response models for predicting the required TPS thickness to meet a mission's needs and to evaluate failure modes. These tests establish the capability of the system and assure robustness of the system during entry. The final aspect of the project is to develop a comprehensive Design and Data Book such that a future mission will have the information necessary to adopt the technology. This presentation will provide an overview and status of the project and describe the status of the tehnology maturation level for the inner and outer planet as well as earth entry sample return missions.

Ellerby, Don↗
NASA NTRS2021

Planetary and Lunar Environment Thermal Toolbox Elements (PALETTE) Project Year One Results

This paper summarizes the technology development progress made during year one of the three-year JPL PALETTE project, which is funded by the NASA STMD Game Changing Development (GCD) Program. The project goal is to ensure that a full “palette” of flight-ready (high TRL) thermal “toolbox” elements is available so that engineers can create passive, ultra-isolative thermal designs for science instruments on a variety of carriers in lunar/planetary extreme environments. PALETTE is structured to meet the need via four design/build/test tasks and four analysis/study tasks. This paper focuses on Tasks 1-4, the four design/build/test tasks. Task 1 involves the development of nested thermally-switched enclosures featuring a reverse-operation DTE thermal switch (ROD-TSW) in series with a propylene miniaturized loop heat pipe (mini-LHP). Task 2 involves the development of a parabolic reflector radiator (PRR) for low latitude lunar sites. Task 3 involves the development of a low effective emissivity (e*) multilayer insulation (MLI) known as “spacerless” MLI. Finally, Task 4 involves the development of low conductance (G) thermal isolators. Available test results for all four tasks will be summarized in the paper, as will the plans for the remainder of the PALETTE project.

Britton, Shawn R↗
NASA NTRS2008

NASA's Plans for Materials Science on ISS: Cooperative Utilization of the MSRR-MSL

The ISS Research Project draws Life (non-human) and Physical Sciences investigations on the ISS, free flyer and ground-based into one coordinated project. The project has two categories: I. Exploration Research Program: a) Utilizes the ISS as a low Technology Readiness Level (TRL) test bed for technology development, demonstration and problem resolution in the areas of life support, fire safety, power, propulsion, thermal management, materials technology, habitat design, etc.; b) Will include endorsement letters from other ETDP projects to show relevancy. II. Non-Exploration Research Program; a) Not directly related to supporting the human exploration program. Research conducted in the life (non-human) and physical sciences; b) The program will sustain, to the maximum extent practicable, the United States scientific expertise and research capability in fundamental microgravity research. Physical Sciences has about 44 grants, and Life Sciences has approximately 32 grants, mostly with universities, to conduct low TRL research; this includes grants to be awarded from the 2008 Fluid Physics and Life Science NRA's.

Chiaramonte, Francis↗
NASA NTRS1997

IITA Cooperative Agreement Projects for Classroom Usability

Based on this review, the following conclusions are drawn regarding the 'school readiness' of the sites. All six of the sites had great appeal to the reviewers and therefore we can conclude that each has tremendous potential for use in the classroom. None, however, were given a completely 'school-ready' assessment. With recommended revisions, each site will be a valuable asset to the classroom teacher. For each as well, teachers particularly had problems with access or finding them, but once there, felt they all had some relevance. Many of the weaknesses noted related to lack of guidance for teachers with links to their curriculum or provision of activities. Other weaknesses related to the lack of educational purpose, however, this may be addressed in the development of strong teacher resources and guides linked to the sites. For those sites with a weak or without a teacher's guide, adding this component would be worth the expenditure of time and money needed.

Grabowski, Barbara↗
NASA NTRS2009

Overview of NASA's Thermal Control System Development for Exploration Project

NASA's Constellation Program includes the Orion, Altair, and Lunar Surface Systems (LSS) project offices. The first two elements, Orion and Altair, are manned space vehicles while the third element is broader and includes several subelements including Rovers and a Lunar Habitat. The upcoming planned missions involving these systems and vehicles include several risks and design challenges. Due to the unique thermal environment, many of these risks and challenges are associated with the vehicles thermal control system. NASA s Exploration Systems Mission Directorate (ESMD) includes the Exploration Technology Development Program (ETDP). ETDP consists of several technology development projects. The project chartered with mitigating the aforementioned risks and design challenges is the Thermal Control System Development for Exploration Project. The risks and design challenges are addressed through a rigorous technology development process that culminates with an integrated thermal control system test. The resulting hardware typically has a Technology Readiness Level (TRL) of approximately six. This paper summarizes the development efforts being performed by the technology development project. The development efforts involve heat acquisition and heat rejection hardware including radiators, heat exchangers, and evaporators. The project has also been developing advanced phase change material heat sinks and performing assessments for thermal control system fluids.

Stephan, Ryan A.↗
DOE OSTI2017

Transitioning from Construction to Startup for the Waste Treatment and Immobilization Plant's Low-Activity Waste Facility - 17284

The original design of the Waste Treatment and Immobilization Plant (WTP) required all waste be processed through the Pretreatment (PT) Facility in order to separate the low-activity waste and high-level waste streams. The U.S. Department of Energy (DOE), Office of River Protection (ORP) has developed a sequenced approach to completing the WTP Project, beginning with delivering some liquid waste directly to the Low-Activity Waste (LAW) Facility, bypassing the PT Facility. This operating configuration is referred to as direct-feed LAW (DFLAW). The primary driver for the DFLAW approach is to enable startup and commissioning of the LAW Facility for low-activity waste processing prior to the completion and availability of the PT and High-Level Waste facilities. In March 2016, a federal judge amended the Consent Decree between DOE and the State of Washington to require completion of hot commissioning for the LAW Facility no later than December 31, 2023. During the next few years ORP and the WTP contractor will transition the project from completion of construction to the startup and commissioning phase for the LAW Facility and the associated support facilities. The WTP contractor has developed an integrated management process to successfully conduct facility startup testing for the WTP facilities required to support DFLAW. The WTP contractor will also develop a commissioning plan and facility transition plan. These plans will describe the strategy; schedule; and requirements for safe, efficient, and sequential startup, commissioning, and transfer of the WTP facilities to an operations contractor. The WTP contractor has also established a strategy to achieve operational readiness for the facilities required to support DFLAW consistent with DOE O 425.1D, Verification of Readiness to Start Up or Restart Nuclear Facilities and DOE O 413.3B, Program and Project Management for the Acquisition of Capital Assets. ORP has established a strategy for oversight of the WTP contractor's startup, commissioning, and readiness activities. The strategy also encompasses ORP's own activities to achieve readiness. (authors)

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DOE OSTI2022

Improving tide-estuary representation in MPAS-Ocean (Final Report)

The overarching goal of this research is to produce a skill-assessed tide-estuary representation, including BGC (biogeochemistry) components of the ecosystem, into the MPAS-O global climate modeling system. Specifically, in the original proposal we proposed one-way nesting, into global MPAS-O, of a high-resolution model for TES (tidal and estuary systems) including the coupling of the BGC components. We have completed the proposed tasks during the past 4 years. Specifically, after extensive consultation with the MPAS-O group during the first year, we have decided to go beyond the original proposal and to two-way nest SCHISM into MPAS-O. As a result, SCHISM-CoSiNE (with CoSiNE being the BGC model) is now fully integrated into MPAS-O as a subroutine (more precisely, an analysis member) and can be invoked as MPAS-O is running with two-way exchange of information between the TES and global models (with proper spatial interpolation done on the fly). As originally proposed, we have also developed the new finite-volume (FV) model MPAS-OI (aka ELCIRC-sub) for TES. We have conducted several tests using the coupled MPAS-SCHISM- CoSiNE model and also MPAS-OI for Columbia River, San Francisco Bay and Chesapeake Bay. Four journal publications have been produced so far as the result of the project and 1 is under review (cf. Publication section). With these achievements, we will be ready to conduct fully coupled simulations of TES and global ocean anywhere, as soon as some missing capabilities in MPAS-O (e.g. tides, improved ability to handle the boundary conditions, and streamlining of the global BGC model) are worked out. The significance of the outcome of this project cannot be overstated. It marks the first time, as far as we know, that a global climate model is tightly coupled to a bona fide nearshore and terrestrial model (SCHISM system); in fact SCHISM is the first bona fide compound flooding model that seamlessly covers the coastal ocean, estuaries, rivers and watersheds (Ye et al. 2020; Zhang et al. 2020). The coupled model will reduce the errors and uncertainties of the MPAS-O global climate model system. It also complements and extends on-going E3SM project, as the latter seeks in the long-term to include components required to simulate impacts of sea-level change and storm surge on coastal regions, including wave models and focusing resolution in coastal and storm-track regions, as an important component of the Cryosphere-ocean system. Note that a spectral wave model (the unstructured-grid version of Wave Watch III, aka Wind Wave Model) is already incorporated inside the SCHISM system and is therefore directly accessible in the coupled system.

58 GEOSCIENCES↗
NASA NTRS2016

Heatshield for Extreme Entry Environment Technology (HEEET) Development Status

The Heat shield for Extreme Entry Environment Technology (HEEET) Project is a NASA STMD and SMD co-funded effort. The goal is to develop and mission infuse a new ablative Thermal Protection System that can withstand extreme entry. It is targeted to support NASAs high priority missions, as defined in the latest decadal survey, to destinations such as Venus and Saturn in-situ robotic science missions. Entry into these planetary atmospheres results in extreme heating. The entry peak heat-flux and associated pressure are estimated to be between one and two orders of magnitude higher than those experienced by Mars Science Laboratory or Lunar return missions. In the recent New Frontiers community announcement NASA has indicated that it is considering providing an increase to the PI managed mission cost (PIMMC) for investigations utilizing the Heat Shield for Extreme Entry Environment Technology (HEEET) and in addition, NASA is considering limiting the risk assessment to only their accommodation on the spacecraft and the mission environment. The HEEET ablative TPS utilizes 3D weaving technology to manufacture a dual layer material architecture. The 3-D weaving allows for flat panels to be woven. The dual layer consists of a top layer designed to withstand the extreme external environment while the inner or insulating layer by design, is designed to achieve low thermal conductivity, and it keeps the heat from conducting towards the structure underneath. Both arc jet testing combined with material properties have been used to develop thermal response models that allows for comparison of performance with heritage carbon phenolic. A 50 mass efficiency is achieved by the dual layer construct compared to carbon phenolic for a broad range of missions both to Saturn and Venus. The 3-D woven flat preforms are molded to achieve the shape as they are compliant and then resin infusion with curing forms a rigid panels. These panels are then bonded on to the aeroshell structure. Gaps exist between the panels and these gaps have to be filled with seams. The seam material then has to be bonded on to adjacent panels and also to the structure. The heat-shield assembly is shown in Figure 1. One of the significant challenges we have overcome recently is the design, development and testing of the seam. HEEET material development and the seam concept development have utilized some of the unique test capabilities available in the US. The various test facilities utilized in thermal testing along with the entry environment for Saturn and Venus missions are shown in Figure 2. The HEEET project is currently in its 3rd year of a four-year development. Figure 3 illustrates the key accomplishments to date and the challenges yet to be overcome before the technology is ready for mission infusion. This proposed presentation will cover both progress that has been made in the HEEET project and also the challenges to be overcome that is highlighted in Figure 3. Objective of the HEEET project is to mature the system in time to support the next New Frontiers opportunity and we believe we are well along the way to mission infuse HEEET.

Thermal Protection System↗
NASA NTRS2011

Shuttle Propulsion System Major Events and the Final 22 Flights

Numerous lessons have been documented from the Space Shuttle Propulsion elements. Major events include loss of the Solid Rocket Boosters (SRB's) on STS-4 and shutdown of a Space Shuttle Main Engine (SSME) during ascent on STS-51F. On STS-112 only half the pyrotechnics fired during release of the vehicle from the launch pad, a testament for redundancy. STS-91 exhibited freezing of a main combustion chamber pressure measurement and on STS-93 nozzle tube ruptures necessitated a low liquid level oxygen cut off of the main engines. A number of on pad aborts were experienced during the early program resulting in delays. And the two accidents, STS-51L and STS-107, had unique heritage in history from early program decisions and vehicle configuration. Following STS-51L significant resources were invested in developing fundamental physical understanding of solid rocket motor environments and material system behavior. And following STS-107, the risk of ascent debris was better characterized and controlled. Situational awareness during all mission phases improved, and the management team instituted effective risk assessment practices. The last 22 flights of the Space Shuttle, following the Columbia accident, were characterized by remarkable improvement in safety and reliability. Numerous problems were solved in addition to reduction of the ascent debris hazard. The Shuttle system, though not as operable as envisioned in the 1970's, successfully assembled the International Space Station (ISS). By the end of the program, the remarkable Space Shuttle Propulsion system achieved very high performance, was largely reusable, exhibited high reliability, and was a heavy lift earth to orbit propulsion system. During the program a number of project management and engineering processes were implemented and improved. Technical performance, schedule accountability, cost control, and risk management were effectively managed and implemented. Award fee contracting was implemented to provide performance incentives. The Certification of Flight Readiness and Mission Management processes became very effective. A key to the success of the propulsion element projects was related to relationships between the MSFC project office and support organizations with their counterpart contractor organizations. The teams worked diligently to understand and satisfy requirements and achieve mission success.

Owen, James W.↗
NASA NTRS2015

Microelectrospray Thrusters

Propulsion technology is often a critical enabling technology for space missions. NASA is investing in technologies to enable high value missions with very small spacecraft, even CubeSats. However, these nanosatellites currently lack any appreciable propulsion capability. CubeSats are typically deployed and tumble or drift without any ability to transfer to higher value orbits, perform orbit maintenance, or perform de-orbit. Larger spacecraft can also benefit from high precision attitude control systems. Existing practices include reaction wheels with lifetime concerns and system level complexity. Microelectrospray thrusters will provide new propulsion capabilities to address these mission needs. Electric propulsion is an approach to accelerate propellant to very high exhaust velocities through the use of electrical power. Typical propulsion systems are limited to the combustion energy available in the chemical bonds of the fuel and then acceleration through a converging diverging nozzle. However, electric propulsion can accelerate propellant to ten times higher velocities and therefore increase momentum transfer efficiency, or essentially, increase the fuel economy. Fuel efficiency of thrusters is proportional to the exhaust velocity and referred to as specific impulse (Isp). The state-of-the-art (SOA) for CubeSats is cold gas propulsion with an Isp of 50-80 s. The Space Shuttle main engine demonstrated a specific impulse of 450 s. The target Isp for the Mars Exploration Program (MEP) systems is >1,500 s. This propellant efficiency can enable a 1-kg, 10-cm cube to transfer from low-Earth orbit to interplanetary space with only 200 g of propellant. In September 2013, NASA's Game Changing Development program competitively awarded three teams with contracts to develop MEP systems from Technology Readiness Level-3 (TRL-3), experimental concept, to TRL-5, system validation in a relevant environment. The project is planned for 18 months of system development. Due to the ambitious project goals, NASA has awarded contracts to mature three unique methods to achieve the desired goals. Some of the MEP concepts have been developed for more than a decade at the component level, but are now ready for system maturation. The three concepts include the high aspect ratio porous surface (HARPS) microthruster system, the scalable ion electrospray propulsion system (S-iEPS), and an indium microfluidic electrospray propulsion system. The HARPS system is under development by Busek Co. The HARPS thruster is an electrospray thruster that relies on surface emission of a porous metal with a passive capillary wicking system for propellant management. The HARPS thruster is expected to provide a simple, high ΔV and low-cost solution. The HARPS thruster concept is shown in figure 1. Figure 1 includes the thruster, integrated power processing unit, and propellant reservoir.

Dankanich, John↗
DOE OSTI2024

Enabling the broader adoption of fusion simulation on complex geometry

This project addressed a key barrier to advanced fusion and nuclear simulation: the difficulty of performing high-fidelity Monte Carlo neutronics directly on complex, real-world CAD geometry. Traditional workflows require engineers to rebuild CAD models as simplified constructive solid geometry, a time-consuming and error-prone process that limits design iteration and broader adoption of simulation tools. The goal of this Phase I SBIR was to make CAD-based neutronics practical, accessible, and robust for industrial and research users. During the project, Coreform significantly enhanced the Direct Accelerated Geometry Monte Carlo (DAGMC) workflow and fully integrated it into Coreform Cubit as a first-class capability. Major achievements include optimized material assignment and surface meshing workflows, substantial performance improvements to geometry imprinting and preparation, native export of DAGMC models, and new visualization tools to support OpenMC source definition and lost-particle debugging. Coreform also expanded Cubit’s capabilities as a full OpenMC preprocessor, including the ability to convert OpenMC constructive solid geometry models back into CAD for visualization, multiphysics coupling, and debugging. In collaboration with Argonne National Laboratory, the project delivered comprehensive new DAGMC documentation and training materials, transforming DAGMC from a research-oriented tool into a production-ready workflow. Results were disseminated through tutorials, conference training, and multiple well-attended webinars demonstrating integrated CAD-based neutronics and multiphysics workflows. Overall, this project demonstrated that high-fidelity Monte Carlo simulations can be performed directly on complex CAD geometry, reducing setup time, improving usability, and enabling faster, more informed design decisions for fusion and nuclear energy systems.

42 ENGINEERING↗
DOE OSTI2024

Circular Economy for Photovoltaics in Service of Energy Transition

The challenge of energy transition is immediate and immense; current projections target 75 TW of photovoltaics (PV) capacity by 2050. While any transition to renewable energy technology is preferable to the current fossil-based system, it is ideal to improve the sustainability of PV to minimize negative environmental and social impacts. Circular economy (CE) has been proposed as a method to improve the sustainability of PV, especially for emerging materials like perovskites. CE is a set of actions, principles, and systems which aim to design out waste and keep products and materials in use, to reduce environmental impacts and enable sustainable development. At the most basic level, CE is "reduce, reuse, recycle", the R-actions, in ranked order. CE of a PV technology can be metricized in a variety of ways, such as the Material Circularity Indicator (Smith and Jones, Ellen MacArthur Foundation, 2019) or recycling rates. Unfortunately, standard CE metrics have several shortcomings for measuring renewable energy technologies in the context of deployment for energy transition (Figge 2018, Saidani 2019): 1) Only measure mass flows; 2) De-prioritization of the use phase in favor of mass circularity when scoring; and 3) Tight focus on a single product scale The use phase and energy flows of PV are key to energy transition, and therefore need to be quantified. Additionally, correlating product-scale to system-scale is necessary for quantifying the environmental impacts of energy transition. Life Cycle Assessment (LCA) can address some of these concerns, but also focuses on a single product scale and has trouble capturing the dynamics of system-scale energy transition, such as the interaction of module lifetime with manufacturing demands for energy transition deployment schedules. Therefore, we developed an open-source Python-based system dynamics model to quantify the mass, energy and carbon impacts of CE R-actions for PV technologies in the energy transition; PV in the CE (PV ICE) (Ovaitt & Mirletz 2021). The tool captures supply chains from material extraction through end of life, incorporating 5 circular end of life pathways. PV ICE takes in any evolving bill of materials, module properties and deployment schedule to support researchers and decision makers with data-backed insights. In this work, we quantify and compare proposed CE sustainable PV module designs and lifecycle management strategies, spanning currently commercialized technologies, government and industry technology targets, and several low Technology Readiness Level (TRL) emerging PV technologies, including perovskites. Our analyses capture the projected evolutions of lifetime, efficiency and material circularity of these PV technologies, as well as their material supply chains. Our analyses emphasize the importance of examining a suite of metrics to identify priorities and tradeoffs, and inform design or lifecycle management decisions holistically. Previous analyses have demonstrated the central importance of PV module lifetime to support energy transition while minimizing impacts. High levels of material circularity (>90%) enable minimizing lifecycle wastes, can reduce virgin material demands if paired with improving efficiency, but demonstrate tradeoffs in energy return on investment. In the fervor of new material and technology development, it is important to remember that CE is not the end goal; decarbonization and energy transition are the end goal. CE should be used in service to improve the sustainability of PV, and R-actions evaluated for their usefulness and efficacy to this end.

carbon↗
DOE OSTI2024

Scaling Up to Zero Energy Ready - and Down to 530 ft2

There is a demonstrated need for affordable housing and smaller homes. Reduced square footage new construction projects present a solution for this growing need. Completion of these types of projects is not without challenges however, as high efficiency building measures present problems with proper equipment sizing and indoor environmental quality. This case study describes the support provided by FSEC to the Manatee County Habitat for Humanity to create a small footprint home design that qualifies for Zero Energy Ready Home (ZERH) certification in Florida. Specific measures to address equipment sizing challenges, and interior air quality targets are identified among other construction elements that contribute to qualifying for ZERH certification. Discussion of the approach to meeting these challenges is informative to other efforts to build to above code standards in hot humid climates, and other regions.

ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION↗