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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS1972

Attitude propulsion technology for TOPS

The thermoelectric outer planet spacecraft (TOPS) attitude propulsion subsystem (APS) effort is discussed. It includes the tradeoff rationale that went into the selection of an anhydrous hydrazine baseline system, followed by a discussion of the 0.22 N thruster and its integration into a portable, self-contained propulsion module that was designed, developed, and man rated to support the TOPS single-axis attitude control tests. The results of a cold-start feasibility demonstration with a modified thruster are presented. A description of three types of 0.44 thrusters that were procured for in-house evaluation is included along with the results of the test program. This is followed by a description of the APS feed system components, their evaluations, and a discussion of an evaluation of elastomeric material for valve seat seals. A list of new technology items which will be of value for application to future systems of this type is included.

Moynihan, P. I.↗
NASA NTRS1985

Spray applicator for spraying coatings and other fluids in space

A self contained spray application is developed for one handed operation in a zero gravity vacuum environment by a free flying astronaut not attached to any spacecraft. This spray applicator eliminates contamination of the operator by back spray. This applicator includes a rigid accumulator containment of a fluid within a flexible bladder the fluid being urged out of the accumulator under pressure through a spray gun. The spray gun includes a spring loaded lockable trigger which controls a valve. When in an open position, the fluid passes through the valve into the ambient environment in the form of a spray. A spray shield is provided which directs the flow of the spray from the applicator by trapping errant particles of spray yet allowing the passage of escaping gases through its material.

Kuminecz, J. F.↗
DOE OSTI2023

Heat pump water heater enhanced with phase change materials thermal energy storage: Modeling study

A promising solution to improve the first hour rating (FHR) of a heat pump water heater (HPWH) involves employing a secondary tank which contains phase change material (PCM) capsules. To better understand the influence of PCM thermal storage on the HPWH operational performance, a dynamic model was developed to simulate and analyze the behavior of a newly developed HPWH technology that incorporates PCM storage into a standard HPWH to optimize key parameters such as the uniform energy factor and FHR. Mathematical models of several key components of the proposed HPWH-PCM integrated thermal energy storage (TES) system, e.g., water heater tank, PCM TES tank, evaporator, compressor, and expansion valve, have been elaborated. Also, a model-based control co-simulation platform was developed to integrate a embed PCM storage HPWH dynamic model with a control model for better supporting control design, analysis, verification, and validation. The model accuracy has been validated through comparing simulation results with lab test results, with a mean average percentage error of <5.5% for most of the selected performance variables. In addition, using the developed co-simulation platform, the demand response control strategy was studied to evaluate the load flexibility of the combined HPWH-PCM storage system by shifting system power usage to outside of the 3.5 h peak load period.

25 ENERGY STORAGE↗
DOE OSTI2024

Experimental Operation of a Prototype 750C Advanced Chloride Molten Salt Bellows Valve

To achieve DOE 2030 SunShot targets that reduce the cost of liquid-based solar by an additional 40% to 70% beyond 2018 costs, a more reliable, highly manufacturable flow valve, capable of achieving operational temperatures of >700°C is required [1]. This paper investigates the development of an innovative high-temperature chloride molten salt valve, with operation up to 750°C. This valve is intended to be employed within Gen 3 CSP liquid-based thermal energy storage (TES) systems as well as Gen 4 modular salt reactor (MSR) technologies. This work details the general design and flow testing of a bellows-seal flow control valve (FCV). This design includes an integrated closed-loop thermal control system to ensure robust design for freeze-thaw cycles. The self-contained thermal management STM system, is unique in the salt valve industry since it is an integrated solution to provide a consistent, repeatable alternative to typical heat tracing. Additionally, the design includes the employment of a novel heat pipe valve stem to facilitate enhanced passive thermal management into the valve assembly. This valve stem heat pipe is designed to facilitate natural circulation within the bonnet to ensure robust operation, during both nominal and transient thermal operation. The valve body and trim will be designed using SS316H, consistent with Flowserve Corporation’s existing product base and is code qualified but will utilize clad material for materials corrosion, manufacturing cost reduction and compatibility to ensure design flexibility. A test campaign was performed in this investigation utilizing a novel 750°C ternary chloride (20%NaCl/40%MgCl2/40%KCl by mol. wt. %) molten salt flow loop. A discussion about the design and installation of the valves within this test bed is provided for this investigation. Valve test results from this study assessed Cv curves as well as multiple actuator cycles, under varying thermodynamic and operational mode conditions, which would be characteristic within a commercial molten salt facility. The results indicate nominal operation for the baseline design, though improved performance and reliability is expected with the full designed FCV.

Armijo, Kenneth (ORCID:0000000346832147)↗
NASA NTRS1989

Thermodynamic and fluid mechanic analysis of rapid pressurization in a dead-end tube

Three models have been applied to very rapid compression of oxygen in a dead-ended tube. Pressures as high as 41 MPa (6000 psi) leading to peak temperatures of 1400 K are predicted. These temperatures are well in excess of the autoignition temperature (750 K) of teflon, a frequently used material for lining hoses employed in oxygen service. These findings are in accord with experiments that have resulted in ignition and combustion of the teflon, leading to the combustion of the stainless steel braiding and catastrophic failure. The system analyzed was representative of a capped off-high-pressure oxygen line, which could be part of a larger system. Pressurization of the larger system would lead to compression in the dead-end line, and possible ignition of the teflon liner. The model consists of a large plenum containing oxygen at the desired pressure (500 to 6000 psi). The plenum is connected via a fast acting valve to a stainless steel tube 2 cm inside diameter. Opening times are on the order of 15 ms. Downstream of the valve is an orifice sized to increase filling times to around 100 ms. The total length from the valve to the dead-end is 150 cm. The distance from the valve to the orifice is 95 cm. The models describe the fluid mechanics and thermodynamics of the flow, and do not include any combustion phenomena. A purely thermodynamic model assumes filling to be complete upstream of the orifice before any gas passes through the orifice. This simplification is reasonable based on experiment and computer modeling. Results show that peak temperatures as high as 4800 K can result from recompression of the gas after expanding through the orifice. An approximate transient model without an orifice was developed assuming an isentropic compression process. An analytical solution was obtained. Results indicated that fill times can be considerably shorter than valve opening times. The third model was a finite difference, 1-D transient compressible flow model. Results from the code show the recompression effect but predict much lower peak temperatures than the thermodynamic model.

Leslie, Ian H.↗
NASA NTRS2005

Synthesizing Diamond from Liquid Feedstock

A relatively economical method of chemical vapor deposition (CVD) has been developed for synthesizing diamond crystals and films. Unlike prior CVD methods for synthesizing diamond, this method does not require precisely proportioned flows of compressed gas feedstocks or the use of electrical discharges to decompose the feedstocks to obtain free radicals needed for deposition chemical reactions. Instead, the feedstocks used in this method are mixtures of common organic liquids that can be prepared in advance, and decomposition of feedstock vapors is effected simply by heating. The feedstock used in this method is a solution comprising between 90 and 99 weight percent of methanol and the balance of one or more other oxyhydrocarbons that could include ethanol, isopropanol, and/or acetone. This mixture of compounds is chosen so that dissociation of molecules results in the desired proportions of carbon-containing radicals (principally, CH3) and of OH, H, and O radicals. Undesirably, the CVD temperature and pressure conditions thermodynamically favor the growth of graphite over the growth of diamond. The H radicals are desirable because they help to stabilize the growing surface of diamond by shifting the thermodynamic balance toward favoring the growth of diamond. The OH and O radicals are desirable because they preferentially etch graphite and other non-diamond carbon, thereby helping to ensure the net deposition of pure diamond. The non-methanol compounds are included in the solution because (1) methanol contains equal numbers of C and O atoms; (2) an excess of C over O is needed to obtain net deposition of diamond; and (3) the non-methanol molecules contain multiple carbon atoms for each oxygen atom and thus supply the needed excess carbon A typical apparatus used in this method includes a reservoir containing the feedstock liquid and a partially evacuated stainless-steel reaction chamber. The reservoir is connected to the chamber via tubing and a needle valve or other suitable flow controller. When the liquid enters the low-pressure environment inside the chamber, it evaporates to form a vapor mixture of the same chemical composition. In addition to the inlet for the feedstock liquid, the chamber is fitted with an outlet connected to a vacuum pump (not shown) through a throttle valve (also not shown) that is automatically controlled to keep the pressure at or near the required value throughout the deposition process. Inside the chamber, a spiral filament made of tungsten, tantalum, graphite, or other high-melting-temperature material is electrically heated to a temperature >2,000 C high enough to cause dissociation of vapor molecules into the aforementioned radicals. A deposition substrate typically, a diamond-polished silicon wafer about 2.5 cm square is positioned about 2 cm away from the filament. The exact location of the substrate is chosen so that the substrate becomes heated by the filament to a deposition temperature in the approximate range of 800 to 1,000 C.

Tzeng, Yonhua↗
NASA NTRS1977

Spacecraft disinfectant/cleansing agent development

The sanitation agent container, which was selected in a trade off study, employs two chambers, a rigid outer container and an inner flexible bladder. The bladder contains the sanitation agent formulation and its release is controlled by a manually operated valve. The outer container holds a high pressure vapor. There is no void in the bladder which makes the package operation independent of orientation and therefore usable in zero gravity. Foam is developed by a low boiling point fluid or dissolved in the product. When the product is dispensed at atmospheric presure, the evolved gas or vapor whips up a goam in the valve. The sanitation agents were initially formulated with freons which produces an excellent foam. However freon is incompatible with the life support system and was replaced with carbon dioxide dissolved at high pressure. The CO2 system may limit high temperature exposure to prevent leakage or package distortion. The sanitation agents have been shown to be effective in cleaning soils from personnel and material.

Abbate, M.↗
NASA NTRS2017

The Quest for Engineering Innovation at NASA's Marshall Space Flight (MSFC)

A recent NASA team, chartered to examine innovation within the Agency, captured the meaning of the word innovation as the "application of creative ideas to improve and generate value for the organization". The former NASA Administrator Charles Bolden shared his own thoughts about innovation in a memo with all employees that stated, "At NASA, we are dedicated to innovation, bold ideas, and excellence." Innovation turns out to be one of the major driving forces behind the work produced at NASA. It seems failure is often what has driven NASA to be more innovative. Fifty years ago, the Apollo 1 tragedy killed three astronauts when fire erupted in their command module. NASA had to bear the responsibility of such loss and at the same time work smarter in order to obtain the dream to reach the moon by the end of the 1960s. Through this circumstance, NASA engineers developed a revolutionary replacement for the combustible nylon astronaut suits so the Apollo program could continue. A material called Beta Cloth was born. This material was used to produce noncombustible space suits for all Apollo astronauts, enabling the United States to ultimately land 12 Americans on the moon. Eventually this material was used as the roof system in the Denver International Airport, showing relevance and applications of NASA innovations to real-world need. Innovative ideas are also driven by the need to accomplish NASA missions and to improve the way we produce our products. MSFC engineers are advancing technologies in additive manufacturing of liquid rocket engines in order to reduce the number of parts, design time, and the cost of the engines. NASA is working with academia to eliminate the need for miles of sensor cables by investigating innovations in wireless sensors. In order to enable future exploration missions to Mars, MSFC engineers are pursuing innovative approaches in diverse areas such as the use of ionic liquids for life support systems and composite cryogenic tanks, very low leakage valves to contain propulsion fluids, and natural, non-toxic inhibitors to eliminate the buildup of biofilms in the water systems planned for future crewed Mars missions. Although results are encouraging, we cannot rest on our past accomplishments. In order to overcome breathtaking technical challenges in space exploration, we must continue to promote a culture supporting growth, breakthroughs and disruptive innovations.

Turner, James E.↗
DOE OSTI2025

Conceptual Design of a Water Tank Critical Facility for SPARC

Critical experiments, sometimes referred to zero-power reactors, are crucial tools in developing and validating nuclear physics predictions and thus an indispensable capability to ensure criticality safety during all parts of the nuclear fuel cycle and in reducing uncertainties in reactor physics predictions toward optimizing nuclear energy production. The System Physics Advanced Reactor Facility (SPARC) project was recently initiated to enable large-scale criticality experiments using a horizontal split table machine well suited toward solid core materials systems (fuel, moderator, reflector). The facility selected for this mission was a former pool-type research reactor building and thus also well suited toward a second critical experiment capability able to house full-size light-water reactor (LWR) fuel bundles. A conceptual design study was undertaken to review past water tank critical experiments used for LWR physics experiments and to develop an early engineering design for a new critical assembly tank (CAT). The work described here shows that a relatively simple CAT concept can be constructed and deployed in the SPARC facility to meet the urgent demands for new critical experiments on advanced LWR fuel bundles designs. The SPARC facility layout is conducive to the receipt and upending of LWR fuel bundles using existing containers and equipment from the LWR industry. The facility’s overhead crane can then be used to handle fuel bundles and place them in a vertical storage rack or in the CAT for critical experiments, both of which fit within the building’s “open basement” alongside other equipment planned for SPARC and the horizontal split table. A slightly lower area in the basement can serve as a large drain tank so that fail-safe valves drain the CAT reactor tank for safe shutdown. Neutronic configurations were determined where a 3 × 3 array of fuel bundles can be surrounded by full-length “loose rods” to adjust reactivity so that critical is achieved when the bundles are fully submerged. Viable configurations were determined for both pressurized- and boiling-water-reactor-type fuel bundles. This design concept was used to develop an early planning basis for establishing the CAT capability alongside the otherwise planned SPARC project in order to help streamline the process. Recent presidential executive orders have highlighted the need to achieve power uprates in LWR plants and the CAT capability will be a crucial element of these initiatives. Based on the work described herein, it is recommended that an earnest and timely project begin in order to establish this urgently needed capability.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Pressurizing Hagan and SAVY containers to 30-psig (air) to measure the release of analytical cerium oxide test powder

In response to an ESS surrounding the storage of sealed sources at TA-55, personnel from RP-SVS (Radiation Protection Services) and ORI-2 (Operational Readiness & Execution) were approached by ES-55 (Facility System Engineering) to provide technical testing of known nuclear material storage containers. Testing criteria were determined by SB-PF (Safety Basis for Plutonium Facilities). Tests were conducted in conjunction with multiple related projects at the Aerosol Sciences Laboratory (TA-03-0130-0103). An experimental system was quickly developed to deliver a pressure pulse (30-psig) that mimics a sealed source burst scenario. A series of twelve tests was conducted. Six tests were done with two different 5QT SAVY-4000 containers, where each SAVY filter-lid combination was subjected to three successive test insults. Three tests were done with a (0.375" diameter filter) 8Q.T Hagan container, and three tests with a (0.625" diameter filter) 8QT Hagan container. An unused, fresh container filter was used for each tested Hagan container, each receiving only one test insult per filter. Cerium oxide (CeO 2 ) powder was loaded (100 grams per test) into a nozzle in the tested Hagan and SAVY containers, and the nozzle was hard-plumbed to a ball valve and a pressure source. This system was installed into the Los Alamos RRFMC (Respirable Release Measurement Chamber), which is an integrated multipurpose aerosol wind tunnel that satisfies NQA-1 subpart 2.4 for R&D work. The ball valve was fitted with a mechanical linkage for operation from outside the wind tunnel. An aerodynamic particle sizer counted the particle concentrations and size distributions of released aerosol. Respirable aerosol released during the tests was measured and a correction factor for wind tunnel flowrate and internal duct deposition was applied.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS2022

Scientific Value of Including an Atmospheric Sample as Part of Mars Sample Return (MSR)

The Perseverance rover is meant to collect samples of the martian surface for eventual return to Earth. The headspace gas present over the solid samples within the sample tubes will be of significant scientific interest for what it reveals about the interactions of the solid samples with the trapped atmosphere and for what it will reveal about the martian atmosphere itself. However, establishing the composition of the martian atmosphere will require other dedicated samples. The headspace gas as the sole atmospheric sample is problematic for many reasons. The quantity of gas present within the sample tube volume is insufficient for many investigations, and there will be exchange between solid samples, headspace gas, and tube walls. Importantly, the sample tube materials and preparation were not designed for optimal Mars atmospheric gas collection and storage as they were not sent to Mars in a degassed evacuated state and have been exposed to both Earth's and Mars' atmospheres. Additionally, there is a risk of unconstrained seal leakage in transit back to Earth, which would allow fractionation of the sample (leak-out) and contamination (leak-in). The science return can be improved significantly (and, in some cases, dramatically) by adding one or more of several strategies listed here in increasing order of effectiveness and difficulty of implementation: (1) Having Perseverance collect a gas sample in an empty sample tube, (2) Collecting gas in a newly-designed, valved, sample-tube-sized vessel that is flown on either the Sample Fetch Rover (SFR) or the Sample Retrieval Lander (SRL), (3) Adding a larger (50-100 cc) dedicated gas sampling volume to the Orbiting Sample container (OS), (4) Adding a larger (50-100 cc) dedicated gas sampling volume to the OS that can be filled with compressed martian atmosphere.

Timothy D. Swindle↗
DOE OSTI2025

Tritium Containment Vessel Response to Thermal and Mechanical Abuse Environments for Fire Safety Assessments

This report evaluates leakage behavior from tritium containment vessels under thermal abuse and combined thermal-mechanical abuse conditions to better understand safety implications for releases occurring in a fire scenario. Surrogate gases were used for all tests in this report. Leakage through the valves from thermal pressurization was observed when heating rates >0.8°C/s were sustained to >300°C. Gas plumes were visualized from vessels that were heated above 260°C and then dropped.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1995

Integrated Microreactor for Chemical and Biochemical Applications

A completely integrated microreactor was developed that allows for the processing of very small amounts of chemical solutions. The entire system comprises several pumps and valves arranged in different branches as well as a mixing unit and a reaction chamber. The streaming path of each branch contains two valves and one pump each. The pumps are driven by piezoelectric elements mounted on thin glass membranes. Each pump is about 3.5 mm x 3.5 mm x 0.7 mm. A pumping rate up to 25 microliters per hour can be achieved. The operational voltage ranges between 40 and 200 V. A volume stroke up to 1.5 millimeter is achievable from the membrane structures. The valves are designed as passive valves. Sealing is by thin metal films. The dimension of a valve unit is 0.8 x 0.8. 07 mm. The ends of the separate streaming branches are arranged to meet in one point. This point acts as the beginning of a mixer unit which contains several fork-shaped channels. The arrangement of these channels allows for the division of the whole liquid stream into partial streams and their reuniting. A homogeneous mixing of solutions and/or gases can be observed after having passed about 10 of the fork elements. A reaction chamber is arranged behind the mixing unit to support the chemical reaction of special fluids. This unit contains heating elements placed outside of the chamber. The complete system is arranged in a modular structure and is built up of silicon. It comprises three silicon wafers bonded together by applying the silicon direct bonding technology. The silicon structures are made only by wet chemical etching processes. The fluid connections to the outside are realized using standard injection needles glued into v-shaped structures on the silicon wafers. It is possible to integrate other components, like sensors or electronic circuits using silicon as the basic material.

Schwesinger, N.↗
DOE OSTI2020

Tracking Radioactive Isotopes in HVAC and Application for Hot Cell Analyses - 20155

In recent years, the surge in the number of isotope production facilities under design has increased the need to analyze isotope migration in facility Heating, Ventilation, and Air Conditioning (HVAC) during normal operations and accident scenarios. These facilities are used to produce isotopes for medical, security, and industrial applications and as such are subject to license and regulatory requirements 10CFR20, 10CFR30, 10CFR50, and 10CFR70. GOTHIC, a general-purpose thermal-hydraulics software package, includes the ability to model isotopic tracers, radioactive decay and isotope migration as well as HEPA and charcoal filters for isotope retention. A GOTHIC model was developed by Zachry Nuclear Engineering (ZNE) to examine the effect of negative room pressure, HEPA filtration, and HVAC fluctuations on radiation areas, hot cells and gloveboxes. Radioactive tracers were used to simulate the concentration of spills within contaminated areas, track the migration of isotopes of interest, and determine the isotopic retention and buildup on facility HEPA filters. A variety of isotopes with concern to dose (e.g., Kr-85, Sr-90, I-131, etc.), including their decay and progeny, are included in the analysis. Negative pressures are maintained in the regions of interest by a representative central HVAC system equipped with a volumetric fan that exhausts to the environment after a series of isolation valves and HEPA filters. GOTHIC is an industry trusted tool for providing engineering solutions for a variety of applications, including fission product tracking, aerosol and particulate transport and ventilation assessments. The software provides an integrated analysis environment that includes a graphical user interface (GUI) for constructing analysis models, a numerical solver that includes parallel processing capabilities and a post-processor for evaluating simulation results. It solves the conservation equations for mass, momentum and energy for multicomponent, multi-phase flow in lumped parameter and multi-dimensional geometries (1, 2, or full 3D), including the effects of turbulence, diffusion and buoyancy. It has been developed and maintained under a Quality Assurance program in compliance with the requirements of 10CFR50 Appendix B and applicable portions of ASME NQA-1 since 1995. GOTHIC has been used for assessing both forced and natural convection conditions for a wide range of applications, including: - Tracking concentration of hazardous gases and chemicals for habitability and safety assessments - Determining ventilation and filtration requirements and optimizing location and arrangement of these systems - Room heat-up, including diverse and Flexible coping strategies for Extended Loss of AC Power (FLEX/ELAP) - Equipment Qualification (EQ) A distinctive feature of GOTHIC is the ability to track many different fields/substances in a simulation, including user defined tracer elements, in the liquid, vapor and droplet fields as well as surfaces and filters. This capability allows GOTHIC to model fission product transport and release or the removal of particulates or harmful toxins from exhaust gases using a spray scrubber or other types of filtration systems. GOTHIC also includes models for engineered equipment, such as fans, filters, charcoal filters, dryers/demisters, dampers, etc. The aerosols and other filtered material are removed or accumulated in these components. The range of aerosol and radiological applications that GOTHIC has been used for includes: - Source Term: Primary Coolant (Equilibrium) Activity; Non-Water Coolant Source/Leakage. - Conditions for Iodine Re-evolution: Sump/Suppression Pool Conditions and pH; - RWST Conditions and pH. - Isotope Removal Mechanisms: Containment Sprayed and Unsprayed Region Mixing; Charcoal Filter Heating due to Iodine decay. - Radionuclide Transport and Decay: Post-LOCA Release in containment; Transport between connected Compartments and vent systems; Groundwater transport of radionuclides. - Non-Newtonian Fluid modeling for sludge, waste tanks, etc. ADAMS ML071581053 (titled 'Best Practice Guidelines for the use of CFD in Nuclear Reactor Safety Applications') poses guidelines for applying single phase CFD codes in nuclear reactor safety problems and GOTHIC is listed as a 'tool for 3D flows' and 'dispersal and deposition of radionuclides.' The Nuclear Quality Assurance (NQA) pedigree of GOTHIC is an important aspect for applications in the nuclear industry. The fundamental tracer models (convective transport, molecular and turbulent diffusion, removal mechanisms, etc.) have been verified using analytical solutions and validated against applicable separate effects tests. Also, GOTHIC has been benchmarked to many integrated effects tests, including Phebus FP (Fission Product). GOTHIC gives good agreement for the buildup and decay of fission products in Phebus Test 3. The model developed by ZNE demonstrates GOTHIC's applicability and acceptability for use in analyzing the migration and retention of radioactive isotopes and their progeny in normal operation and accident scenario analyses for isotope production facilities, hot cells, and gloveboxes. The tracer activities calculated by GOTHIC can then be used in downstream radiation transport and shielding codes like RADTRAD-NAI{sup C}, MCNP{sup R}, and MicroShield{sup R} to determine on-site and of-site doses. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
NASA NTRS2003

Larger-Stroke Piezoelectrically Actuated Microvalve

A proposed normally-closed microvalve would contain a piezoelectric bending actuator instead of a piezoelectric linear actuator like that of the microvalve described in the preceding article. Whereas the stroke of the linear actuator of the preceding article would be limited to approximately equal to 6 micrometers, the stroke of the proposed bending actuator would lie in the approximate range of 10 to 15 micrometers-large enough to enable the microvalve to handle a variety of liquids containing suspended particles having sizes up to 10 m. Such particulate-laden liquids occur in a variety of microfluidic systems, one example being a system that sorts cells or large biomolecules for analysis. In comparison with the linear actuator of the preceding article, the bending actuator would be smaller and less massive. The combination of increased stroke, smaller mass, and smaller volume would be obtained at the cost of decreased actuation force: The proposed actuator would generate a force in the approximate range of 1 to 4 N, the exact amount depending on operating conditions and details of design. This level of actuation force would be too low to enable the valve to handle a fluid at the high pressure level mentioned in the preceding article. The proposal encompasses two alternative designs one featuring a miniature piezoelectric bimorph actuator and one featuring a thick-film unimorph piezoelectric actuator (see figure). In either version, the valve would consume a power of only 0.01 W when actuated at a frequency of 100 Hz. Also, in either version, it would be necessary to attach a soft elastomeric sealing ring to the valve seat so that any particles that settle on the seat would be pushed deep into the elastomeric material to prevent or reduce leakage. The overall dimensions of the bimorph version would be 7 by 7 by 1 mm. The actuator in this version would generate a force of 1 N and a stroke of 10 m at an applied potential of 150 V. The actuation force would be sufficient to enable the valve to handle a fluid pressurized up to about 50 psi (approximately equal to 0.35 MPa). The overall dimensions of the unimorph version would be 2 by 2 by 0.5 mm. In this version, an electric field across the piezoelectric film on a diaphragm would cause the film to pull on, and thereby bend, the diaphragm. At an applied potential of 20 V, the actuator in this version would generate a stroke of 10 micrometers and a force of 0.01 N. This force level would be too low to enable handling of fluids at pressures comparable to those of the bimorph version. This version would be useful primarily in microfluidic and nanofluidic applications that involve extremely low differential pressures and in which there are requirements for extreme miniaturization of valves. Examples of such applications include liquid chromatography and sequencing of deoxyribonucleic acid.

Yang, Eui-Hyeok↗
NASA NTRS2019

Scale-Up of the Carbon Dioxide Removal by Ionic Liquid Sorbent (CDRILS) System

The Carbon Dioxide Removal by Ionic Liquid Sorbent (CDRILS) system is designed for efficient, safe and reliable carbon dioxide (CO2) removal from cabin air on long-duration missions to the Moon, deep space, and Mars. CDRILS integrates an ionic liquid sorbent with hollow fiber membrane contactors for rapid CO2 removal and recovery. The liquid-based system provides continuous CO2 delivery, which avoids complicated valve networks to switch between absorbing and desorbing beds and enables simpler integration to the Sabatier without the need for the CO2 Management System (CMS). Ionic liquids are particularly desirable as liquid absorbents for space applications since they are non-volatile, non-odorous, and have high oxidative stability. The hollow fiber membrane contactors offer both high contact area and rigorous containment between the gas and liquid phases in a microgravity environment. Scale-up of the CDRILS technology has presented a series of fascinating challenges, since the interaction between hollow fiber properties, ionic liquid properties and performance is complex. Properties measured with lab-scale hollow fiber contactors are used to estimate the performance of contactors that are similar in scale to flight-scale demonstrations. To accomplish this, component and system models have been built to relate the key scrubber and stripper design and operating variables with performance, and experiments directed to validate the models have been performed. System size, weight and power are determined by component selection, arrangement, and operating conditions. Reliability will be extremely important for any long-range mission and depends on the stability of the ionic liquids and hollow fiber contactors. We report on our continuing long term stability experiments for the ionic liquid and contactor materials and our investigation of the physical properties of additional ionic liquids.

Yates, Stephen F.↗
NASA NTRS2006

Promoted-Combustion Chamber with Induction Heating Coil

An improved promoted-combustion system has been developed for studying the effects of elevated temperatures on the flammability of metals in pure oxygen. In prior promoted-combustion chambers, initial temperatures of metal specimens in experiments have been limited to the temperatures of gas supplies, usually near room temperature. Although limited elevated temperature promoted-combustion chambers have been developed using water-cooled induction coils for preheating specimens, these designs have been limited to low-pressure operation due to the hollow induction coil. In contrast, the improved promoted-combustion chamber can sustain a pressure up to 10 kpsi (69 MPa) and, through utilization of a solid induction coil, is capable of preheating a metal specimen up to its melting point [potentially in excess of 2,000 F (approximately equal to 1,100 C)]. Hence, the improved promoted combustion chamber makes a greater range of physical conditions and material properties accessible for experimentation. The chamber consists of a vertical cylindrical housing with an inner diameter of 8 in. (20.32 cm) and an inner height of 20.4 in. (51.81 cm). A threaded, sealing cover at one end of the housing can be unscrewed to gain access for installing a specimen. Inlet and outlet ports for gases are provided. Six openings arranged in a helical pattern in the chamber wall contain sealed sapphire windows for viewing an experiment in progress. The base of the chamber contains pressure-sealed electrical connectors for supplying power to the induction coil. The connectors feature a unique design that prevents induction heating of the housing and the pressure sealing surfaces; this is important because if such spurious induction heating were allowed to occur, chamber pressure could be lost. The induction coil is 10 in. (25.4 cm) long and is fitted with a specimen holder at its upper end. At its lower end, the induction coil is mounted on a ceramic base, which affords thermal insulation to prevent heating of the base of the chamber during use. A sapphire cylinder protects the coil against slag generated during an experiment. The induction coil is energized by a 6-kW water-cooled power supply operating at a frequency of 400 kHz. The induction coil is part of a parallel-tuned circuit, the tuning of which is used to adjust the coupling of power to the specimen. The chamber is mounted on a test stand along with pumps, valves, and plumbing for transferring pressurized gas into and out of the chamber. In addition to multiple video cameras aimed through the windows encircling the chamber, the chamber is instrumented with gauges for monitoring the progress of an experiment. One of the gauges is a dual-frequency infrared temperature transducer aimed at the specimen through one window. Chamber operation is achieved via a console that contains a computer running apparatus-specific software, a video recorder, and real-time video monitors. For safety, a blast wall separates the console from the test stand.

Richardson, Erin↗
DOE OSTI2022

MAGNETICALLY SUSPENDED CANNED ROTOR PUMPS FOR THE INTEGRAL MOLTEN SALT REACTOR

This project developed a molten salt pump design for small modular reactors, concentrated solar, and Gen IV nuclear reactors with a magnetically levitated rotor that can operate at temperatures of up to 700 °C. This eliminates the need for rotating seals and roller element bearings which require maintenance and are prone to failure. The pump design is also more compact than existing molten salt pump designs which require long shafts to thermally isolate the electric motor. The aims of the project are to: 1) design and test the molten salt pump, 2) develop and test a high temperature position sensor needed for magnetic bearing control, and 3) develop and test high temperature coil fabrication methods for electric motor and magnetic bearing fabrication. To develop the high temperature coils, conductor materials were analyzed for oxidation, diffusion, cladding, and resistivity. Of the candidate conductor materials that met the requirements, silver was chosen. The long-term impact of radiation on silver resistivity was analyzed by developing a model of a generic molten salt fast reactor to model the conductor irradiation in worst case scenarios. The analysis showed that increased resistivity due to transmutation of silver decreases exponentially with the reactor reflector thickness. Different electrical insulation materials were tested and the final high temperature coils developed were able to withstand conductor to ground voltages up to 1800 V before insulation breakdown. Magnetic bearings require high-precision high-speed measurements of the rotor position to operate. Current commercial position sensors can only operate up to 550 °C so a novel position sensor was developed that can operate up to 800 °C. These sensors were also designed to measure the position of the metallic rotor through a thin metallic corrosion barrier that protects that coils, insulation, and magnetic cores so that the salt containment barrier does not have any penetrations. The high-temperature sensor was tested and had comparable performance to commercially available inductive position sensors. The sensor design and signal processing has led to several invention disclosures. The magnetically levitated molten salt pump design was completed and analyzed. The chloride salt test loop at Oak Ridge National Laboratory was chosen to test the pump and the pump hydraulics and power were designed for the test loop flow and pressure requirements. Classes of motor designs that do not utilize permanent magnetic were considered for the high-temperature motor. After extensive analysis of their performance, a synchronous reluctance motor was chosen for the pump. The design was refined and analyzed to optimize performance. The magnetic bearings were designed to meet the force and frequency requirements necessary to levitate the rotor and reject disturbances from rotor imbalance, motor forces, and hydraulic forces. Compliant mounts for the position sensors were designed that would not damage the ceramic sensor components and maintain sensor alignment over a wide temperature range. A thermal hydraulic analysis of the molten salt coolant flow used to cool the rotor and stator was performed to ensure that the maximum temperature in the rotor and stator will not exceed 725 °C. The corrosion barrier and casing were designed to maintain the salt fluid boundary by using compliant features to absorb large expansion mismatches due to different coefficients of thermal expansion (CTE). Finally, the salt drain and fill systems were designed along with the pump support structure, integration with the test loop, and thermal insulation and heating. Corrosion barrier fabrication experiments were performed to assess using laser cladding to apply a sub-millimeter corrosion barrier to the surface of a Fe-Co-V magnetic core material. The cladding method showed minimal mixing between materials at their interface and withstood temperature cycling without damage to the cladding. The technology commercialization is focused on the high-temperature position sensors and there has been significant interest from the nuclear industry in utilizing these sensors along with some interest from the aerospace industry. The project also led to a research collaboration with a fusion energy industrial partner to study barriers to scaling the pump design from the kW size to the MW size. This research collaboration will also study methods to create high-temperature coils that have conductor to ground breakdown voltages above 5 kV. The successful development of high-temperature electromagnetic coils and high-temperature position sensors greatly increases the temperature limits for electromagnetic devices that don’t rely on permanent magnets. This includes electric motors, magnetic bearings, linear actuators, rotary position and velocity sensing, actuated valves, and generators to name a few. This will fill a current need in molten salt reactors, concentrated solar, and fusion energy for these critical peripheral devices needed for practical reactor designs that do not currently have commercial solutions.

Hines, J Wesley↗