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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
NASA NTRS2010

Compact Rare Earth Emitter Hollow Cathode

A compact, high-current, hollow cathode utilizing a lanthanum hexaboride (LaB6) thermionic electron emitter has been developed for use with high-power Hall thrusters and ion thrusters. LaB6 cathodes are being investigated due to their long life, high current capabilities, and less stringent xenon purity and handling requirements compared to conventional barium oxide (BaO) dispenser cathodes. The new cathode features a much smaller diameter than previously developed versions that permit it to be mounted on axis of a Hall thruster ( internally mounted ), as opposed to the conventional side-mount position external to the outer magnetic circuit ("externally mounted"). The cathode has also been reconfigured to be capable of surviving vibrational loads during launch and is designed to solve the significant heater and materials compatibility problems associated with the use of this emitter material. This has been accomplished in a compact design with the capability of high-emission current (10 to 60 A). The compact, high-current design has a keeper diameter that allows the cathode to be mounted on the centerline of a 6- kW Hall thruster, inside the iron core of the inner electromagnetic coil. Although designed for electric propulsion thrusters in spacecraft station- keeping, orbit transfer, and interplanetary applications, the LaB6 cathodes are applicable to the plasma processing industry in applications such as optical coatings and semiconductor processing where reactive gases are used. Where current electrical propulsion thrusters with BaO emitters have limited life and need extremely clean propellant feed systems at a significant cost, these LaB6 cathodes can run on the crudest-grade xenon propellant available without impact. Moreover, in a laboratory environment, LaB6 cathodes reduce testing costs because they do not require extended conditioning periods under hard vacuum. Alternative rare earth emitters, such as cerium hexaboride (CeB6) can be used in this configuration with possibly an even longer emitter life. This cathode is specifically designed to integrate on the centerline of a high-power Hall thruster, thus eliminating the asymmetries in the plasma discharge common to cathodes previously mounted externally to the thruster s magnetic circuit. An alternative configuration for the cathode uses an external propellant feed. This diverts a fraction of the total cathode flow to an external feed, which can improve the cathode coupling efficiency at lower total mass flow rates. This can improve the overall thruster efficiency, thereby decreasing the required propellant loads for different missions. Depending on the particular mission, reductions in propellant loads can lead to mission enabling capabilities by allowing launch vehicle step-down, greater payload capability, or by extending the life of a spacecraft.

Watkins, Ronald↗
NASA NTRS1985

Icing tunnel tests of Electro-Impulse De-Icing of an engine inlet and high-speed wings

A brief review is given of four earlier tests in the NASA Lewis Icing Research Tunnel and of flight tests in NASA's Icing Research Aircraft and in a Cessna 206 airplane. Details are given of recent icing tunnel tests of thicker-skinned wings, a Gates Learjet, a composite leading edge, and a Boeing 767, and of a Falcon Fanjet engine inlet. These were tested at speeds from 87 to 220 knots, air temperatures from -2 to -15 C, LWC values of 0.6 to 2.4 grams/cu meter, and median droplet diameters from 12 to 20 microns. Energy requirements are reported, as well as conclusions from comparisons of several Electro-Impulse De-Icing coil system designs. Fundamental studies of the structural dynamics and ice shedding of a 12.7 cm (5 inch) diameter semicylinder are described. Some potential problem areas are discussed: fatigue of skin and coil mountings, system weight and cost, electro-magnetic interference and noise.

Zumwalt, G. W.↗
NASA NTRS1983

Containerless electromagnetic levitation melting of Cu-Fe and Ag-Ni alloys

The feasibility of producing silver or copper alloys containing finely dispersed nickel or iron particles, respectively, by utilizing containerless electromagnetic levitation casting techniques was investigated. A levitation coil was designed to successfully levitate and melt a variety of alloys including Nb-Ge, Cu-Fe, Fe-C, and Ag-Ni. Samples of 70 Cu-30 Fe and 80 Ag-20 Ni (atomic %), prepared by mechanical pressing of the constituent powders, were levitated and heated either to the solid plus liquid range of the alloys or to the fully liquid region. The samples were then solidified by passing helium gas into the bell jar or they were dropped into a quenching oil. The structure of the samples which were heated to the solid plus liquid range consists of uniform distribution of Fe or Ni particle in their respective matrices. A considerable amount of entrapped gas bubbles were contained. Upon heating for longer periods or to higher temperatures, the bubbles coalesced and burst, causing the samples to become fragmented and usually fall out of the coil.

Abbaschian, G. J.↗
NASA NTRS1992

Correction-free radiometry on specular spheres for containerless processing in microgravity

An analysis is presented that establishes how correction-free radiance measurements or pyrometry can be performed on targets in furnaces where there may be significant additional radiance from heated furnace walls or from reflecting surfaces close to the target. These configurations are common in microgravity and containerless processing applications where a specular target is radiantly heated in a hot-wall furnace, or inductively heated from the fields arising from nearby closely spaced electromagnetic coils. Proper design requires that the pyrometer does not view any images of the background features in the specular target so that stray radiation will not be reflected into the viewing optics of the pyrometer. To analyze the problem, conventional paraxial optics analysis is shown to be significantly in error. Instead a method of nonparaxial ray tracing, based on the derivatives of the ray paths, shows how the images must be located. This leads to analytical results that can be used to design such systems. The findings are applied to the furnace geometries that are presently being considered for flight in LEO.

Thomas, A. S. W.↗
NASA NTRS2013

High-Powered, Ultrasonically Assisted Thermal Stir Welding

This method is a solid-state weld process capable of joining metallic alloys without melting. The weld workpieces to be joined by thermal stir welding (TSW) are drawn, by heavy forces, between containment plates past the TSW stir tool that then causes joining of the weld workpiece. TSW is similar to friction stir welding (FSW) in that material is heated into a plastic state (not melted) and stirred using a stir rod. The FSW pin tool is an integrated geometrical structure consisting of a large-diameter shoulder, and a smaller-diameter stir pin protruding from the shoulder. When the pin is plunged into a weld workpiece, the shoulder spins on the surface of the weld workpiece, thus inducing frictional heat into the part. The pin stirs the fraying surfaces of the weld joint, thus joining the weld workpiece into one structure. The shoulder and stir pin of the FSW pin tool must rotate together at a desired rotational speed. The induced frictional energy control and stir pin control of the pin tool cannot be de-coupled. The two work as one integrated unit. TSW, on the other hand, de-couples the heating and stirring of FSW, and allows for independent control of each process element. A uniquely designed induction coil heats the weld workpiece to a desired temperature, and once heated, the part moves into a stir rod whose RPM is also independently controlled. As the weld workpiece moves into the stir rod, the piece is positioned, or sandwiched, between upper and lower containment plates. The plate squeezes together, thus compressing the upper and lower surfaces of the weld workpiece. This compressive force, also called consolidation force, consolidates the plastic material within the weld nugget material as it is being stirred by the stir rod. The stir rod is positioned through the center of the top containment plate and protrudes midway through the opposite lower containment plate where it is mechanically captured. The upper and lower containment plates are separated by a distance equal to the thickness of the material being welded. The TSW process can be significantly improved by reducing the draw forces. This can be achieved by reducing the friction forces between the weld workpieces and the containment plates. High-power ultrasonic (HPU) vibrations of the containment plates achieve friction reduction in the TSW process. Furthermore, integration of the HPU energy into the TSW stir rod can increase tool life of the stir rod, and can reduce shear forces to which the stir rod is subjected during the welding process. TSW has been used to successfully join 0.500-in (≈13-mm) thick commercially pure (CP) titanium, titanium 6AL- 4V, and titanium 6AL-4V ELI in weld joint lengths up to 9 ft (≈2.75-m) long. In addition, the TSW process was used to fabricate a sub-scale hexagonally shaped gun turret component for the U.S. Navy. The turret is comprised of six 0.5000-in (≈13-mm) thick angled welds. Each angled weld joint was prepared by machining the mating surfaces to 120deg. The angled weld joint was then fixtured using an upper and lower containment plate of the same geometry of the angled weld joint. The weld joint was then stirred by the stir rod as it and the upper and lower containment plates traverse through the angled joint prep.

Ding, Robert↗
NASA NTRS1977

Design study of superconducting magnets for a combustion magnetohydrodynamic (MHD) generator

Design trade off studies for 13 different superconducting magnet systems were carried out. Based on these results, preliminary design characteristics were prepared for several superconducting magnet systems suitable for use with a combustion driven MHD generator. Each magnet generates a field level of 8 T in a volume 1.524 m (60 in.) long with a cross section 0.254 m x 0.254 m (10 in. x 10 in.) at the inlet and 0.406 m x .406 m (16 in. x 16 in.) at the outlet. The first design involves a racetrack coil geometry intended for operation at 4.2 K; the second design uses a racetrack geometry at 2.0 K; and the third design utilizes a rectangular saddle geometry at 4.2 K. Each case was oriented differently in terms of MHD channel axis and main field direction relative to gravity in order to evaluate fabrication ease. All cases were designed such that the system could be disassembled to allow for alteration of field gradient in the MHD channel by changing the angle between coils. Preliminary design characteristics and assembly drawings were generated for each case.

Thome, R. J.↗
NASA NTRS2007

Improved Sensing Coils for SQUIDs

An improvement in the design and fabrication of sensing coils of superconducting quantum interference device (SQUID) magnetometers has been proposed to increase sensitivity. It has been estimated that, in some cases, it would be possible to increase sensitivity by about half or to reduce measurement time correspondingly. The pertinent aspects of the problems of design and fabrication can be summarized as follows: In general, to increase the sensitivity of a SQUID magnetometer, it is necessary to maximize the magnetic flux enclosed by the sensing coil while minimizing the self-inductance of this coil. It is often beneficial to fabricate the coil from a thicker wire to reduce its self-inductance. Moreover, to optimize the design of the coil with respect to sensitivity, it may be necessary to shape the wire to other than a commonly available circular or square cross-section. On the other hand, it is not practical to use thicker superconducting wire for the entire superconducting circuit, especially if the design of a specific device requires a persistent-current loop enclosing a remotely placed SQUID sensor. It may be possible to bond a thicker sensing-coil wire to thinner superconducting wires leading to a SQUID sensor, but it could be difficult to ensure reliable superconducting connections, especially if the bonded wires are made of different materials. The main idea is to mold the sensing coil in place, to more nearly optimum cross sectional shape, instead of making the coil by winding standard pre-fabricated wire. For this purpose, a thin superconducting wire loop that is an essential part of the SQUID magnetometer would be encapsulated in a form that would serve as a mold. A low-melting-temperature superconducting metal (e.g., indium, tin, or a lead/tin alloy) would be melted into the form, which would be sized and shaped to impart the required cross section to the coil thus formed.

Penanen, Konstantin↗
NASA NTRS1978

Application of NASTRAN to TFTR toroidal field coil structures

The primary applied loads on the TF coils were electromagnetic and thermal. The complex structure and the tremendous applied loads necessitated computer type of solutions for the design problems. In the early stage of the TF coil design, many simplified finite element models were developed for the purpose of investigating the effects of material properties, supporting schemes, and coil case material on the stress levels in the case and in the copper coil. In the more sophisticated models that followed the parametric and scoping studies, the isoparametric elements, such as QUAD4, HEX8, and HEXA, were used. The analysis results from using these finite element models and the NASTRAN system were considered accurate enough to provide timely design information.

Chen, S. J.↗
NASA NTRS1975

Investigation of system integration methods for bubble domain flight recorders

System integration methods for bubble domain flight records are investigated. Bubble memory module packaging and assembly, the control electronics design and construction, field coils, and permanent magnet bias structure design are studied. A small 60-k bit engineering model was built and tested to demonstrate the feasibility of the bubble recorder. Based on the various studies performed, a projection is made on a 50,000,000-bit prototype recorder. It is estimated that the recorder will occupy 190 cubic in., weigh 12 lb, and consume 12 w power when all of its four tracks are operated in parallel at 150 kHz data rate.

Chen, T. T.↗
NASA NTRS2017

Design of Magnetic Shielding and Field Coils for a TES X-Ray Microcalorimeter Test Platform

The performance of Transition-Edge Sensors (TES) and their SQUID multiplexed read-outs are very sensitive to the ambient magnetic field from Earth and fluctuations that can arise due to fluctuating magnetic fields outside of the focal plane assembly from the Adiabatic Demagnetization Refrigerator (ADR).Thus, the experimental platform we are building to test the FPA of the X-ray Integral Field Unit (X-IFU) of the Athena mission needs to include a series of shields and a coil in order to meet the following requirement of magnetic field density and uniformity.

Miniussi, Antoine R.↗
NASA NTRS1984

Laminar flow effects in the coil planet centrifuge

The coil planet centrifuge designed by Ito employs flow of a single liquid phase, through a rotating coiled tube in a centrifugal force field, to provide a separation of particles based on sedimentation rates. Mathematical solutions are derived for the linear differential equations governing particle behavior in the coil planet centrifuge device. These solutions are then applied as the basis of a model for optimizing particle separations.

Herrmann, F. T.↗
NASA NTRS2023

Static Testing of A Conductively-Cooled, High Temperature Superconducting Rotor for A 1.4 MW Electric Machine in a Thermal Vacuum Chamber

NASA’s high efficiency megawatt motor (HEMM) is a partially superconducting, 1.4 MW electric machine designed for electrified aircraft propulsion. HEMM’s high performance is enabled by a field winding composed of 2nd generation high temperature superconducting (HTS) coils that are designed to operate at temperatures below 62 K. The superconducting rotor is conductively cooled to cryogenic temperatures using a rotating cryocooler embedded inside the machine’s shaft. This paper presents a static test of the full-scale superconducting rotor in a thermal vacuum chamber. The experimental setup is described in detail. Thermal and electromagnetic 3D finite element analyses of the experimental setup are shown along with a comparison of the model results to model results for HEMM. The thermal response during cool down from room temperature is discussed. Electrical measurements are presented for operation at different dc current excitations up to the rated current of the rotor (57.2 A) and temperature limit of the HEMM design (62 K). The results suggest that minor damage to one superconducting coil occurred at 50 A and 61.2 K, causing increased resistance in the system, but that the system could still be stably operated at 57.2 A and 62 K when conductively cooled by a cryocooler.

electrified aircraft propulsion↗
NASA NTRSDate not supplied

Cryogenic Vacuum Chamber Testing of A Conductively-Cooled, High Temperature Superconducting Rotor for a 1.4 MW Electric Machine for Aeronautics Applications

This paper presents the second ever demonstration of a superconducting rotor cooled only via conductive connection to a cryocooler, i.e., without pumped or solid cryogens. The fullscale rotor was operated statically in its intended environment – about 1e-3 torr vacuum with only conductive cooling through mechanical connections to a cryocooler contained on the rotor. Stable operation of the rotor in a representative magnetic environment was demonstrated up to its rated direct current (57.2 A) and the designed temperature limit for the superconductor (62 K). Additional electrical measurements increased confidence that the superconducting coils functioned as intended. A collection of steady state temperature distributions was measured at operating and non-operating conditions. In all but one case, the observed temperature gradient between the cold tip and superconducting coils satisfies the design but with little margin. Opportunities to reduce the gradient are identified.

Electrified aircraft propulsion↗
NASA NTRSDate not supplied

Cryogenic Vacuum Chamber Testing of A Conductively-Cooled, High Temperature Superconducting Rotor for a 1.4 MW Electric Machine for Aeronautics Applications

This paper presents the first ever demonstration of a superconducting rotor cooled conductively without a cryogenic fluid or solid. The full-scale rotor was operated statically in its intended environment – about 1e-3 torr vacuum with only conductive cooling through mechanical connections to a cryocooler contained on the rotor. Stable operation of the rotor in a representative magnetic environment was demonstrated up to its rated direct current (57.2 A) and the designed temperature limit for the superconductor (62 K). Additional electrical measurements increased confidence that the superconducting coils functioned as intended. A collection of steady state temperature distributions was measured at operating and non-operating conditions. In all but one case, the observed temperature gradient between the cold tip and superconducting coils satisfies the design but with little margin. Opportunities to reduce the gradient are identified.

Electrified aircraft propulsion↗
NASA NTRS2009

Voice Coil Percussive Mechanism Concept for Hammer Drill

A hammer drill design of a voice coil linear actuator, spring, linear bearings, and a hammer head was proposed. The voice coil actuator moves the hammer head to produce impact to the end of the drill bit. The spring is used to store energy on the retraction and to capture the rebound energy after each impact for use in the next impact. The maximum actuator stroke is 20 mm with the hammer mass being 200 grams. This unit can create impact energy of 0.4 J with 0.8 J being the maximum. This mechanism is less complex than previous devices meant for the same task, so it has less mass and less volume. Its impact rate and energy are easily tunable without changing major hardware components. The drill can be driven by two half-bridges. Heat is removed from the voice coil via CO2 conduction.

Okon, Avi↗
NASA NTRS2019

Magnet Architectures and Active Radiation Shielding Study (MAARSS)

This report describes the analysis of several magnetic radiation shield architectures and the spacecraft systems associated with them, such as quench detection, thermal management, and compensation coils. This work was performed as part of the NASA Institute of Advanced Concepts (NIAC) Grant Phase II effort. Because radiation exposure during long duration space missions poses a significant risk for crewed space-flight, Advanced Magnetic Lab, Inc. (AML) and NASA are studying magnetic radiation shielding, which may generate low-mass protection. Recent technological developments in high-temperature superconducting technology suggest the possibility of such shielding. This report analyzes some of the technical difficulties involved in such a system and identifies technology areas where further investment would be warranted. Most analysis was performed on a baseline configuration (8-meter diameter coils, with 1 tesla field). However, a baseline design with an expandable coil configuration (16 meter diameter coils, 1.5 tesla field) has a significant potential to increase shielding efficiency. The magnetic forces on the magnetic shield's components are large enough to require detailed structural design. Analysis of the thermal structural response of a yttrium-barium-copper-oxide (YBCO) high-temperature, superconducting (HTS) tape in a large-scale solenoid magnet showed that structural and thermal performance improved by replacing Hastelloy® with graphene in the tape. Integrating graphene into the high-strength fiber (HSF) support structure brings even greater benefits. The energy stored in a shield system's magnetic field must be safely dissipated if a quench-type failure occurs. Analysis of quench detection by fiber-optic thermal sensing and improvement of quench characteristics using graphene showed quench is manageable. Low-temperature superconductors can quench when subjected to movement, but lab tests of coil expansion testing showed that HTS materials do not quench when subject to the movement associated with coil expansion. Compensation coils are necessary to reduce the magnetic field in the crew habitat. Analysis showed that subdividing the compensation coil into individually controlled sections allows for a robust, adjustable system. AML analyzed the forces on an approaching capsule that were a result of eddy currents in its structure induced by its motion through the magnetic field from the coils. AML also analyzed coil-to-coil forces. Thermal control to maintain the HTS material at a suitable temperature is challenging. The sunshield technology review revealed a greater possibility of thermal insulation of the coils and use of passive cooling. The availability of suitable cryocoolers was also reviewed. A parametric graph estimating mass and shielding effectiveness for strength and thickness was developed, and allows spacecraft designers to assess the tradeoffs of using a magnetic radiation shield.

Spacecraft↗
NASA NTRS2007

Design of a Low-Energy FARAD Thruster

The design of an electrodeless thruster that relies on a pulsed, rf-assisted discharge and electromagnetic acceleration using an inductive coil is presented. The thruster design is optimized using known performance,scaling parameters, and experimentally-determined design rules, with design targets for discharge energy, plasma exhaust velocity; and thrust efficiency of 100 J/pulse, 25 km/s, and 50%, respectively. Propellant is injected using a high-speed gas valve and preionized by a pulsed-RF signal supplied by a vector inversion generator, allowing for current sheet formation at lower discharge voltages and energies relative to pulsed inductive accelerators that do not employ preionization. The acceleration coil is designed to possess an inductance of at least 700 nH while the target stray (non-coil) inductance in the circuit is 70 nH. A Bernardes and Merryman pulsed power train or a pulse compression power train provide current to the acceleration coil and solid-state components are used to switch both powertrains.

Polzin, K. A.↗
NASA NTRSDate not supplied

Thermal Design, Analysis, and Testing of a Conductively-Cooled, High Temperature Superconducting Rotor for a 1.4 MW Electric Machine for Aeronautics Applications

This presentation covers the second ever demonstration of a superconducting rotor cooled only via conductive connection to a cryocooler, i.e., without pumped or solid cryogens. The full-scale rotor was operated statically in its intended environment – about 1e-3 torr vacuum with only conductive cooling through mechanical connections to a cryocooler contained on the rotor. Stable operation of the rotor in a representative magnetic environment was demonstrated up to its rated direct current (57.2 A) and the designed temperature limit for the superconductor (62 K). In all but one case, the observed temperature gradient between the cold tip and superconducting coils satisfies the design but with little margin. Thermal modeling and correlation with test data is presented identifying the areas of largest discrepancy. Opportunities to reduce the temperature gradient are identified.

electrified aircraft propulsion↗