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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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NASA NTRS2012

A Compendium of Brazed Microstructures For Fission Power Systems Applications

NASA has been supporting design studies and technology development for fission-based power systems that could provide power to an outpost on the Moon, Mars, or an asteroid. Technology development efforts have included fabrication and evaluation of components used in a Stirling engine power conversion system. This investigation is part of the development of several braze joints crucial for the heat exchanger transfer path from a hot-side heat exchanger to a Stirling engine heat acceptor. Dissimilar metal joints are required to impart both mechanical strength and thermal path integrity for a heater head of interest. Preliminary design work for the heat exchanger involved joints between low carbon stainless steel to Inconel 718, where the 316L stainless steel would contain flowing liquid metal NaK while Inconel 718, a stronger alloy, would be used as structural reinforcement. This paper addressed the long-term microstructural stability of various braze alloys used to join 316L stainless steel heater head to the high conductivity oxygen-free copper acceptor to ensure the endurance of the critical metallic components of this sophisticated heat exchanger. The bonding of the 316L stainless steel heater head material to a copper heat acceptor is required to increase the heat-transfer surface area in contact with flowing He, which is the Stirling engine working fluid.

Locci, Ivan E.↗

NASA NTRS2018

Why Space Technology Needs More Non-Traditional Chemical Engineers – From the Perspective of a NASA Chemical Engineering Student

Final document is attached. With planetary missions and deep space gateway on the horizon, humankind is entering a new era of space exploration. Manned mission durations will be longer than any previous flight, resupply capabilities are limited, and system robustness is more imperative than ever. Traditional space systems, especially in the realm of carbon dioxide removal and water remediation, are large in size, mass, energy consumption, and number of mechanical moving parts prone to failure. Non-traditional space exploration needs non-traditional technology solutions. Organizational psychologist Adam Grant is well-known for his studies on originality and how non-conformists can move the world. In the words of Adam Grant, "to become original, you have to try something new, which means accepting some measure of risk." As chemical engineers, we shouldn't let that measure of risk stop us from considering ingenious technology. As a part of the new generation of engineers at NASA, I believe we need a paradigm shift in space technology for this new era of exploration.

Rogers, Tanya↗

NASA NTRS2000

Development of Ceramic Matrix Composite Turbine Blisks for Rocket Engines

Ceramic matrix composite (CMC) integrally bladed turbine disks (blisks) are being considered for use in various advanced propulsion systems for space vehicles. The successful development of this technology can significantly impact National Aeronautics and Space Administration (NASA) space transportation missions, by enabling new efficient systems that can operate at higher temperatures, while reducing costs. Composite blisks comprised of carbon (C) fibers and a silicon carbide (SiC) ceramic matrix were designed, fabricated, characterized, and tested by a multidisciplinary team involving materials, design, structural analysis, turbomachinery, and nondestructive evaluation representatives from government, academia, and industry during a 4.5 year effort led by the NASA Marshall Space Flight Center (MSFC). The testing of several of these blisks, which were developed in the Simplex Turbopump CMC Blisk ]Program for use in rocket engine turbopumps, was recently completed. CMC blisks offer potential advantages in rocket engine turbopumps including increased safety resulting from increased operating temperature margins and greater pump reliability, and decreased costs resulting from improved turbopump performance. The progress that was achieved in that development effort is reviewed, and some of the technology that could be applied to other advanced space transportation propulsion systems is discussed.

Effinger, Mike↗

NASA NTRS1974

Measurement of gaseous emissions from a turbofan engine at simulated altitude conditions

Gaseous emission from a TFE 731-2 turbofan engine were measured over a range of fuel-air ratios from idle to full power at simulated from near sea level to 13,200 m. Carbon monoxide and unburned hydrocarbon emissions were highest at idle and lowest at high power settings; oxides of nitrogen exhibited the reverse trend. Carbon monoxide and unburned hydrocarbon levels decreased with increasing altitude. Oxides of nitrogen emissions were successfully correlated by a parametric group of combustor operating variables.

Diehl, L. A.↗

NASA NTRS1978

The effect of ambient conditions on the emissions of an idling gas turbine

Changes in ambient conditions - pressure, temperature, and humidity - affect the exhaust emissions of a gas turbine engine. Such variations must be compensated for during engine certification. The results of a test program employing a JT8D-17 combustor are presented which quantize the effect of carefully controlled changes on unburned hydrocarbons, carbon monoxide, and oxides of nitrogen at simulated idle operating conditions. Analytical results are given to explain the observed hydrocarbon and carbon monoxide behavior. It is shown that for a complete range of possible ambient variations, significant changes do occur in the amount of pollutants emitted by an idling gas turbine.

Kauffman, C. W.↗

NASA NTRS1995

SSME Main Combustion Chamber (MCC) hot oil dewaxing

In an attempt to comply with the changing environmental regulations, a process was developed for the replacement of perchloroethylene in the dewaxing of the Space Shuttle Main Engine (SSME) Main Combustion Chamber (MCC) and other associated hardware filled with the Rigidax (R) casting compound. Rigidax (R) is a hard blue-dyed, calcium carbonate filled thermoplastic casting compound (melting point 77 C) that is melted and poured into hardware cavities to prevent contamination during material removal processes, i.e. machining, grinding, drilling, and deburring. Additionally, it serves as a maskant for designated areas during electroforming processes. Laboratory testing was conducted to evaluate seven alternate fluids for the replacement of perchloroethylene in the dewaxing process. Based upon successful laboratory results, a mineral oil was selected for testing on actual hardware. The final process developed involves simultaneous immersion and flushing of the MCC channels using a distinct eight stage process. A nonvolatile hydrocarbon analysis of a solvent flush sample is performed to determine the hardware cleanliness for comparison to the previous perchloroethylene dewaxing process.

Akpati, Anthony U.↗

NASA NTRS2002

Structural Health Monitoring of Composite Wound Pressure Vessels

The increasing use of advanced composite materials in the wide range of applications including Space Structures is a great impetus to the development of smart materials. Incorporating these FBG sensors for monitoring the integrity of structures during their life cycle will provide valuable information about viability of the usage of such material. The use of these sensors by surface bonding or embedding in this composite will measure internal strain and temperature, and hence the integrity of the assembled engineering structures. This paper focuses on such a structure, called a composite wound pressure vessel. This vessel was fabricated from the composite material: TRH50 (a Mitsubishi carbon fiber with a 710-ksi tensile strength and a 37 Msi modulus) impregnated with an epoxy resin from NEWPORT composites (WDE-3D-1). This epoxy resin in water dispersed system without any solvents and it cures in the 240-310 degrees F range. This is a toughened resin system specifically designed for pressure applications. These materials are a natural fit for fiber sensors since the polyimide outer buffer coating of fiber can be integrated into the polymer matrix of the composite material with negligible residual stress. The tank was wound with two helical patterns and 4 hoop wraps. The order of winding is: two hoops, two helical and two hoops. The wall thickness of the composite should be about 80 mil or less. The tank should burst near 3,000 psi or less. We can measure the actual wall thickness by ultrasonic or we can burst the tank and measure the pieces. Figure 1 shows a cylinder fabricated out of carbon-epoxy composite material. The strain in different directions is measured with a surface bonded fiber Bragg gratings and with embedded fiber Bragg gratings as the cylinder is pressurized to burst pressures. Figure 2 shows the strain as a function of pressure of carbon-epoxy cylinder as it is pressurized with water. Strain is measured in different directions by multiple gratings oriented in both axial and hoops directions.

Joseph Grant↗

NASA NTRS2005

National Combustion Code Used To Study the Hydrogen Injector Design for Gas Turbines

Hydrogen, in the gas state, has been proposed to replace Jet-A (the fuel used for commercial jet engines) as a fuel for gas turbine combustion. For the combustion of hydrogen and oxygen only, water is the only product and the main greenhouse gas, carbon dioxide, is not produced. This is an obvious benefit of using hydrogen as a fuel. The situation is not as simple when air replaces oxygen in the combustion process. (Air is mainly a mixture of oxygen, nitrogen, and argon. Other components comprise a very small part of air and will not be mentioned.) At the high temperatures found in the combustion process, oxygen reacts with nitrogen, and this produces nitrogen oxide compounds, or NOx--the main component of atmospheric smog. The production of NOx depends mainly on two variables: the temperature at which combustion occurs, and the length of time that the products of combustion stay, or reside, in the combustor. Starting from a lean (excess air) air-to-fuel ratio, the goal of this research was to minimize hot zones caused by incomplete premixing and to keep the residence time short while producing a stable flame. The minimization of these two parameters will result in low- NOx hydrogen combustion.

Iannetti, Anthony C.↗

NASA NTRS2005

NASA Tech Briefs, February 2005

Topics discussed include: Instrumentation for Sensitive Gas Measurements; Apparatus for Testing Flat Specimens of Thermal Insulation; Quadrupole Ion Mass Spectrometer for Masses of 2 to 50 Da; Miniature Laser Doppler Velocimeter for Measuring Wall Shear; Coherent Laser Instrument Would Measure Range and Velocity; Printed Microinductors for Flexible Substrates; Digital Receiver for Microwave Radiometry; Printed Antennas Made Reconfigurable by Use of MEMS Switches; Traffic-Light-Preemption Vehicle-Transponder Software Module; Intersection-Controller Software Module; Central-Monitor Software Module; Estimating Effects of Multipath Propagation on GPS Signals; Parallel Adaptive Mesh Refinement Library; Predicting Noise From Aircraft Turbine-Engine Combustors; Generating Animated Displays of Spacecraft Orbits; Diagnosis and Prognosis of Weapon Systems; Training Software in Artificial-Intelligence Computing Techniques; APGEN Version 5.0; Single-Command Approach and Instrument Placement by a Robot on a Target; Three-Dimensional Audio Client Library; Isogrid Membranes for Precise, Singly Curved Reflectors; Nickel-Tin Electrode Materials for Nonaqueous Li-Ion Cells; Photocatalytic Coats in Glass Drinking-Water Bottles; Fast Laser Shutters With Low Vibratory Disturbances; Series-Connected Buck Boost Regulators; Space Physics Data Facility Web Services; Split-Resonator, Integrated-Post Vibratory Microgyroscope; Blended Buffet-Load-Alleviation System for Fighter Airplane; Gifford-McMahon/Joule-Thomson Refrigerator Cools to 2.5 K; High-Temperature, High-Load-Capacity Radial Magnetic Bearing; Fabrication of Spherical Reflectors in Outer Space; Automated Rapid Prototyping of 3D Ceramic Parts; Tissue Engineering Using Transfected Growth-Factor Genes; Automation of Vapor-Diffusion Growth of Protein Crystals; Atom Skimmers and Atom Lasers Utilizing Them; Gears Based on Carbon Nanotubes; Patched Off-Axis Bending/Twisting Actuators for Thin Mirrors; and Improving Control in a Joule-Thomson Refrigerator.

Source record↗

NASA NTRS2005

NASA Tech Briefs, March 2005

Topics covered include: Scheme for Entering Binary Data Into a Quantum Computer; Encryption for Remote Control via Internet or Intranet; Coupled Receiver/Decoders for Low-Rate Turbo Codes; Processing GPS Occultation Data To Characterize Atmosphere; Displacing Unpredictable Nulls in Antenna Radiation Patterns; Integrated Pointing and Signal Detector for Optical Receiver; Adaptive Thresholding and Parameter Estimation for PPM; Data-Driven Software Framework for Web-Based ISS Telescience; Software for Secondary-School Learning About Robotics; Fuzzy Logic Engine; Telephone-Directory Program; Simulating a Direction-Finder Search for an ELT; Formulating Precursors for Coating Metals and Ceramics; Making Macroscopic Assemblies of Aligned Carbon Nanotubes; Ball Bearings Equipped for In Situ Lubrication on Demand; Synthetic Bursae for Robots; Robot Forearm and Dexterous Hand; Making a Metal-Lined Composite-Overwrapped Pressure Vessel; Ex Vivo Growth of Bioengineered Ligaments and Other Tissues; Stroboscopic Goggles for Reduction of Motion Sickness; Articulating Support for Horizontal Resistive Exercise; Modified Penning-Malmberg Trap for Storing Antiprotons; Tumbleweed Rovers; Two-Photon Fluorescence Microscope for Microgravity Research; Biased Randomized Algorithm for Fast Model-Based Diagnosis; Fast Algorithms for Model-Based Diagnosis; Simulations of Evaporating Multicomponent Fuel Drops; Formation Flying of Tethered and Nontethered Spacecraft; and Two Methods for Efficient Solution of the Hitting- Set Problem.

Source record↗

NASA NTRS2014

A Fully Non-metallic Gas Turbine Engine Enabled by Additive Manufacturing

The Non-Metallic Gas Turbine Engine project, funded by NASA Aeronautics Research Institute (NARI), represents the first comprehensive evaluation of emerging materials and manufacturing technologies that will enable fully nonmetallic gas turbine engines. This will be achieved by assessing the feasibility of using additive manufacturing technologies for fabricating polymer matrix composite (PMC) and ceramic matrix composite (CMC) gas turbine engine components. The benefits of the proposed effort include: 50 weight reduction compared to metallic parts, reduced manufacturing costs due to less machining and no tooling requirements, reduced part count due to net shape single component fabrication, and rapid design change and production iterations. Two high payoff metallic components have been identified for replacement with PMCs and will be fabricated using fused deposition modeling (FDM) with high temperature capable polymer filaments. The first component is an acoustic panel treatment with a honeycomb structure with an integrated back sheet and perforated front sheet. The second component is a compressor inlet guide vane. The CMC effort, which is starting at a lower technology readiness level, will use a binder jet process to fabricate silicon carbide test coupons and demonstration articles. The polymer and ceramic additive manufacturing efforts will advance from monolithic materials toward silicon carbide and carbon fiber reinforced composites for improved properties. Microstructural analysis and mechanical testing will be conducted on the PMC and CMC materials. System studies will assess the benefits of fully nonmetallic gas turbine engine in terms of fuel burn, emissions, reduction of part count, and cost. The proposed effort will be focused on a small 7000 lbf gas turbine engine. However, the concepts are equally applicable to large gas turbine engines. The proposed effort includes a multidisciplinary, multiorganization NASA - industry team that includes experts in ceramic materials and CMCs, polymers and PMCs, structural engineering, additive manufacturing, engine design and analysis, and system analysis.

manufacturing↗

NASA NTRS1995

Initial Closed Operation of the CELSS Test Facility Engineering Development Unit

As part of the NASA Controlled Ecological Life Support System (CELSS) Program, a CELSS Test Facility (CTF) is being planned for installation on the Space Station. The CTF will be used to provide data on the productivity and efficiency of a variety of CELSS higher plant crops grown sequentially from seed to harvest in the microgravity environment of the Space Station. Stringent environmental control will be maintained while fundamental crop productivity issues, such as carbon dioxide uptake and oxygen production rates, water transpiration rates, and biomass accumulation rates are obtained for comparison with ground-based data. In order to obtain an early realistic determination of the subsystem and system requirements necessary to provide the appropriate environmental conditions specified for CTF crop productivity experiments, an Engineering Development Unit (EDU) has been constructed and is undergoing initial operational testing at NASA Ames Research Center. The EDU is a ground-based testbed which will be used to characterize the integrated performance of major subsystem technologies, to evaluate hardware candidates and control strategies required for the CTF, and to further define the ability to meet CTF requirements within present Space Station constraints. This paper describes the initial closed operational testing of the EDU. Measured performance data are compared with the specified functional requirements and results from initial closed testing are presented. Plans for future science and technology testing are discussed.

Kliss, Mark↗

NASA NTRS2021

Risk Reduction of Orion Multi-Purpose Crew Vehicle (MPCV) Program Government-Furnished Equipment for Environmental Control and Life Support (ECLS)

The NASA Engineering and Safety Center (NESC) was requested to conduct technical risk-reduction activities for safety-critical government-furnished environmental control and life support (ECLS) equipment for the Multi-Purpose Crew Vehicle Program. These items include the post-landing anomaly gas monitor, the in-flight anomaly gas monitor, the emergency breathing mask, the 144-hour in-suit survival capability, the portable fire extinguisher, the smoke eater, and the post-landing carbon dioxide control system. This document contains the outcome of the NESC assessment.

Environmental Control and Life Support↗

NASA NTRS1992

Regenerative Life Support Systems Test Bed performance - Lettuce crop characterization

Two crops of lettuce (Lactuca sativa cv. Waldmann's Green) were grown in the Regenerative Life Support Systems (RLSS) Test Bed at NASA's Johnson Space Center. The RLSS Test Bed is an atmospherically closed, controlled environment facility for the evaluation of regenerative life support systems using higher plants. The chamber encloses 10.6 m 2 of growth area under cool-white fluorescent lamps. Lettuce was double seeded in 480 pots, each containing about 250 cm 3 of calcined-clay substrate. Each pot was irrigated with half-strength Hoagland's nutrient solution at an average total applied amount of 2.5 and 1.8 liters pot -1 , respectively, over each of the two 30-day crop tests. Average environmental and cultural conditions during both tests were 23°C air temperature, 72% relative humidity, 1000 ppm carbon dioxide (CO 2 ), 16h light/8h dark photoperiod, and 356 μmol m -2 s -1 photosynthetic photon flux. After 30 days from seeding, average yield (g pot -1 ) for the first and second crop tests were 72 and 49 edible (shoot) fresh mass, 3.65 and 2.56 edible dry mass, and 0.44 and 0.45 inedible (root) dry mass, respectively. Averaging over both crop tests, the test bed met the requirements of 2.1 person-days of oxygen production, 2.4 person days of CO 2 removal and 129 person days of potential potable water production. The satisfactory growth of both crops demonstrates the potential of lettuce for air revitalization and water production in a controlled ecological life support system. Differences in crop performance resulting from engineering system effects provides evidence of the resilience of biological systems.

Life support systems↗

NASA NTRS2010

Isolation of Resistance-Bearing Microorganisms

To better exploit the principles of gas transport and mass transport during the processes of cell seeding of 3D scaffolds and in vitro culture of 3D tissue engineered constructs, the oscillatory cell culture bioreactor provides a flow of cell suspensions and culture media directly through a porous 3D scaffold (during cell seeding) and a 3D construct (during subsequent cultivation) within a highly gas-permeable closed-loop tube. This design is simple, modular, and flexible, and its component parts are easy to assemble and operate, and are inexpensive. Chamber volume can be very low, but can be easily scaled up. This innovation is well suited to work with different biological specimens, particularly with cells having high oxygen requirements and/or shear sensitivity, and different scaffold structures and dimensions. The closed-loop changer is highly gas permeable to allow efficient gas exchange during the cell seeding/culturing process. A porous scaffold, which may be seeded with cells, is fixed by means of a scaffold holder to the chamber wall with scaffold/construct orientation with respect to the chamber determined by the geometry of the scaffold holder. A fluid, with/without biological specimens, is added to the chamber such that all, or most, of the air is displaced (i.e., with or without an enclosed air bubble). Motion is applied to the chamber within a controlled environment (e.g., oscillatory motion within a humidified 37 C incubator). Movement of the chamber induces relative motion of the scaffold/construct with respect to the fluid. In case the fluid is a cell suspension, cells will come into contact with the scaffold and eventually adhere to it. Alternatively, cells can be seeded on scaffolds by gel entrapment prior to bioreactor cultivation. Subsequently, the oscillatory cell culture bioreactor will provide efficient gas exchange (i.e., of oxygen and carbon dioxide, as required for viability of metabolically active cells) and controlled levels of fluid dynamic shear (i.e., as required for viability of shear-sensitive cells) to the developing engineered tissue construct. This bioreactor was recently utilized to show independent and interactive effects of a growth factor (IGF-I) and slow bidirectional perfusion on the survival, differentiation, and contractile performance of 3D tissue engineering cardiac constructs. The main application of this system is within the tissue engineering industry. The ideal final application is within the automated mass production of tissue- engineered constructs. Target industries could be both life sciences companies as well as bioreactor device producing companies.

Venkateswaran, Kasthuri, J.↗

NASA NTRS2010

Oscillating Cell Culture Bioreactor

Freed, Lisa E.↗

NASA NTRS1976

Avco Lycoming/NASA contract status

The standards promulgated by the Environmental Protection Agency (EPA) for carbon monoxide (CO), unburned hydrocarbon (HC), and oxides-of-nitrogen (NOx) emissions were the basis in a study of ways to reduce emissions from aircraft piston engines. A variable valve timing system, ultrasonic fuel atomization, and ignition system changes were postulated.

Duke, L. C.↗

NASA NTRS1980

Effect of ambient conditions on the emissions from a gas turbine combustor

The effect of variations in the ambient conditions of pressure, temperature, and relative humidity upon the emissions of a gas turbine combustion are investigated. A single combustor can from a Pratt and Whitney JT8D-17 engine was run at parametric inlet conditions bracketing the actual engine idle conditions. Data were correlated to determine the functional relationships between the emissions and ambient conditions. Mathematical modelling was used to determine the mechanism for the carbon monoxide and hydrocarbon emissions. Carbon monoxide emissions were modelled using finite rate chemical kinetics in a plug flow scheme. Hydrocarbon emissions were modelled by a vaporization scheme throughout the combustor.

Kauffman, C. W.↗