SEARCH · Search NASA

Results for “mechanical challenges”

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.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 55 records · Page 3

All sources NASA NTRS DOE OSTI

NASA NTRS2019

Solar Power System and Radioisotope Thermoelectric Generation Technologies at Jupiter-Saturn-Uranus Environments: New Insights and Paradigms

Power system selection for outer planet destinations, such as Jupiter, Saturn, and Uranus and beyond, is complex, involving and dependent on many interdisciplinary factors such as power system mass, specific power, cost, mechanical and electrical integration, and natural radiation environment. Low solar irradiance at Jupiter, Saturn, and Uranus systems (i.e., 50, 15, and 4 W/m2 , respectively) makes solar power systems challenging in mechanical / electrical integration and accommodating radiation environments. More costly radioisotope thermoelectric generator (RTG) systems can help proposed missions overcome radiation environment and spacecraft control challenges at Jupiter, Saturn, and Uranus. NASA’s Jet Propulsion Laboratory (JPL) has recently made significant strides in demonstrating high-efficiency, radiation-hard solar cell technologies for low-irradiance, low-temperature (LILT) applications, and high-efficiency thermoelectric (TE) materials and modules for higher-specific-power RTGs. Stateof-art multi-junction solar cells now routinely demonstrate high efficiencies of 30-34% at LILT (9.5AU and -165°C), making solar arrays a viable option for many near-term Saturn mission concepts. Emerging technologies like LILToptimized solar cells have recently demonstrated even higher efficiencies of 37% at 9.5AU and -165°C and 30% lower mass than the state-of-art, offering the prospect of ~3W/kg array-level, end-of-life specific powers under Saturn conditions. Having already demonstrated the tremendous utility of RTGs on Mars and in deep-space missions (e.g., Galileo at Jupiter, New Horizons at Pluto), NASA is now developing and demonstrating new TE materials and modules (e.g., skutterudites, La3-x Te4, and Zintls) for increasing RTG specific power (up to >8.5 W/kg), which strongly impacts an RTG’s mass, fuel utilization, and modularity in the power system trade domain. New accomplishments in both areas highlight the renewed requisite for updated comparisons and trade-offs in power output, specific power and mass, cost, mechanical and electrical integration, new technology timelines, and natural radiation impacts between new LILT-optimized photovoltaic technologies and next-generation RTG technologies. This work discusses and demonstrates how new LILT-based technologies are now allowing one to consider and design solar power systems for Saturn orbit and beyond, and are changing the potential cost-mass trade-offs between emerging solar power technologies and newly-envisioned RTG technologies. Key updated system mass and cost trade-offs between high-performance LILT solar technologies and new RTG technologies are presented, reinforcing and refining power selection criteria supporting possible future NASA deep-space science and exploration missions to Mars, the Jupiter system (Europa, Ganymede), the Saturn system (Titan, Enceladus), Uranus, and beyond. Key trade-offs in other above-mentioned interdisciplinary factors between these two power technologies are also discussed.

Bairstow, Brian K.↗

DOE OSTI2024

Cryogenic aspects of a 20 MW class low-temperature superconducting generator for the renewables industry

In this paper we give a progress update on the cryogenic design for cooling a 20 MW class, partially superconducting generator with stationary field coils for offshore wind renewables industry [1-2]. This is a continuation of an earlier program on a 10 MW system dating back ten years. Whereas this new power rating increase leads to a radial diameter expansion of the superconducting field coils from 4 to > 9.5 m, it maintains the axial length. We show the design based on this scaled up with enlarged diameter. The field coil size increase asks for higher cooling power that leads to a bigger cold box size to accommodate the cryocoolers. In the design, as many as 8 cryocoolers can be accessed and serviced from the nacelle that houses the main cryogenic components. A typical thermal load balance sheet with all components is given and compared against the available cryocooler cooling power at different operating conditions. Due to the cryocoolers’ local point of contact cooling within the nacelle, the temperature gradient of the thermal shield that fully encloses the cold mass with its embedded field coils needs to be balanced out to minimize the heat burden on the field coils. This requires additional analytical efforts and implementation of further design features. The extended nacelle houses the cold box with its cryogenic infrastructure. The interface for the envisaged cryogenic pushbutton closed-loop circulating system remains invisible, requires no handling of cryogenic liquids and is hermetically closed. The field coil diameter increase also leads to a greater initial helium gas storage volume. In addition, it requires higher initial room temperature fill pressure within the toroidal helium vapor storage tanks and in cooling tubes connecting to the cryocoolers. The toroidal helium gas tanks are thermally coupled with the thermal shield so that helium convection inside the storage tank can improve heat transfer and reduce the temperature gradient of the thermal shield. Besides those heat transfer challenges, additional mechanical strain within this large structure is exerted on the torque tubes during initial cooldown and when energizing field coils. Some of those design challenges are quite unexpected, leading to novel workarounds in order to maintain the chosen cooling strategy. Finally, we assess those design limitations in view of further cryogenic scalability with emphasis on manufacturability and assembly.

cryogenics↗

NASA NTRS2002

Molten-Metal Droplet Deposition on a Moving Substrate in Microgravity: Aiding the Development of Novel Technologies for Microelectronic Assembly

Driven by advancements in microelectronics manufacturing, this research investigates the oblique (non-axisymmetric) impact of liquid-metal droplets on flat substrates. The problem of interest is relevant to the development of the novel technology of on-demand dispension (printing) of microscopic solder deposits for the surface mounting of microelectronic devices. The technology, known as solder jetting, features on-demand deposition of miniature solder droplets (30 to 120 microns in diameter) in very fine, very accurate patterns using techniques analogous to those developed for the ink-jet printing industry. Despite its promise, severe limitations exist currently with regards to the throughput rates of the technology; some of these limitations are largely due to the lack of the capability for reliable prediction of solder bump positioning and shapes, especially under ballistic deposition conditions where the droplet impact phenomena are inherently three-dimensional. The study consists of a theoretical and an experimental component. The theoretical work uses a finite element formulation to simulate numerically the non-axisymmetric (3-D) fluid mechanics and heat transfer phenomena of a liquid solder droplet impacting at an angle alpha on a flat substrate. The work focuses on the pre-solidification regime. The modeling of the most challenging fluid mechanics part of the process has been completed successfully. It is based upon the full laminar Navier-Stokes equations employing a Lagrangian frame of reference. Due to the large droplet deformation, the surface (skin) as well as the volumetric mesh have to be regenerated during the calculations in order to maintain the high accuracy of the numerical scheme. The pressure and velocity fields are then interpolated on the newly created mesh. The numerical predictions are being tested against experiments, for cases where wetting phenomena are not important. For the impact parameters used in the example shown (We = 2.38, Fr = 16300, Re = 157), the droplet rolls along the substrate, but its shape remains practically axisymmetric for all impact angles within the range from 0 to 60 deg. Interestingly, the substrate/droplet contact area during the recoiling phase of the impact is not a monotonically decreasing function of time. The experimental component of the research tests the numerical predictions and provides necessary input data (contact angles) for the theoretical model. The experiments are performed in microgravity (2.2s drop tower of the NASA GRC) in order to allow for the use of mm-size solder droplets, which make feasible the performance of accurate measurements, while maintaining similitude of the relevant fluid dynamic groups (Re, Fr, We, Ste). Preliminary oblique impact experiments have been performed using water droplets in normal gravity.

Megaridis, C. M.↗

DOE OSTI2024

Autonomous hybrid optimization of a SiO 2 plasma etching mechanism

Computational modeling of plasma etching processes at the feature scale relevant to the fabrication of nanometer semiconductor devices is critically dependent on the reaction mechanism representing the physical processes occurring between plasma produced reactant fluxes and the surface, reaction probabilities, yields, rate coefficients, and threshold energies that characterize these processes. The increasing complexity of the structures being fabricated, new materials, and novel gas mixtures increase the complexity of the reaction mechanism used in feature scale models and increase the difficulty in developing the fundamental data required for the mechanism. This challenge is further exacerbated by the fact that acquiring these fundamental data through more complex computational models or experiments is often limited by cost, technical complexity, or inadequate models. In this paper, we discuss a method to automate the selection of fundamental data in a reduced reaction mechanism for feature scale plasma etching of SiO 2 using a fluorocarbon gas mixture by matching predictions of etch profiles to experimental data using a gradient descent (GD)/Nelder–Mead (NM) method hybrid optimization scheme. These methods produce a reaction mechanism that replicates the experimental training data as well as experimental data using related but different etch processes.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Global variability in atmospheric new particle formation mechanisms

A key challenge in aerosol pollution studies and climate change assessment is to understand how atmospheric aerosol particles are initially formed. Although new particle formation (NPF) mechanisms have been described at specific sites, in most regions, such mechanisms remain uncertain to a large extent because of the limited ability of atmospheric models to simulate critical NPF processes. Here we synthesize molecular-level experiments to develop comprehensive representations of 11 NPF mechanisms and the complex chemical transformation of precursor gases in a fully coupled global climate model. Combined simulations and observations show that the dominant NPF mechanisms are distinct worldwide and vary with region and altitude. Previously neglected or underrepresented mechanisms involving organics, amines, iodine oxoacids and HNO 3 probably dominate NPF in most regions with high concentrations of aerosols or large aerosol radiative forcing; such regions include oceanic and human-polluted continental boundary layers, as well as the upper troposphere over rainforests and Asian monsoon regions. These underrepresented mechanisms also play notable roles in other areas, such as the upper troposphere of the Pacific and Atlantic oceans. Accordingly, NPF accounts for different fractions (10–80%) of the nuclei on which cloud forms at 0.5% supersaturation over various regions in the lower troposphere. The comprehensive simulation of global NPF mechanisms can help improve estimation and source attribution of the climate effects of aerosols.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS1994

A force-controllable macro-micro manipulator and its application to medical robots

This paper describes an 8-degrees-of-freedom macro-micro robot. This robot is capable of performing tasks that require accurate force control, such as polishing, finishing, grinding, deburring, and cleaning. The design of the macro-micro mechanism, the control algorithms, and the hardware/software implementation of the algorithms are described in this paper. Initial experimental results are reported. In addition, this paper includes a discussion of medical surgery and the role that force control may play. We introduce a new class of robotic systems collectively called Robotic Enhancement Technology (RET). RET systems introduce the combination of robotic manipulation with human control to perform manipulation tasks beyond the individual capability of either human or machine. The RET class of robotic systems offers new challenges in mechanism design, control-law development, and man/machine interface design. We believe force-controllable mechanisms such as the macro-micro structure we have developed are a necessary part of RET. Work in progress in the area of RET systems and their application to minimally invasive surgery is presented, along with future research directions.

Marzwell, Neville I.↗

DOE OSTI2025

In‐Scribe Silane Bonding for Mechanical Reinforcement of Perovskite Photovoltaic Modules

Despite the extraordinary rise in power conversion efficiency over the last decade, metal halide perovskite (MHP) photovoltaics remain more mechanically fragile than other PV technologies. In this work, the scribe area, created by the monolithic interconnection of thin-film solar cells, is used to extrinsically reinforce the mechanical robustness of packaged MHP solar modules. In contrast to the epoxy-based chemistries often leveraged in the MHP literature, silane-grafted polyolefin encapsulants are designed to form strong covalent bonds to oxide surfaces, specifically to glass and the transparent conductive oxide at the base of the scribe line. Pseudo-modules encapsulated with silane-grafted polyolefin are measured with more than an order-of-magnitude enhancement infracture energy from 0.27 ± 0.01 J·m −2 (no scribes) to 5.97 ± 0.42 J·m −2 (scribes perpendicular to delamination directioncovering ≈2.2% of the module area). The silane-grafted polyolefin retains strong adhesion even after undergoing an accelerated IEC 61215 thermal cycling test consisting of 250 cycles. We find that the in-scribe bonding allows perovskite modules to have adhesion strength comparable to commercial c-Si and CdTe technologies with only 5% reduction in the active module area. This manufacturing-compatible approach offers a practical solution to address the mechanical integrity challenges in MHP solar modules, regardless of cell architecture.

14 SOLAR ENERGY↗

DOE OSTI2024

Nano-enhanced solid-state hydrogen storage: Balancing discovery and pragmatism for future energy solutions

Nanomaterials have revolutionized the battery industry by enhancing energy storage capacities and charging speeds, and their application in hydrogen (H 2 ) storage likewise holds strong potential, though with distinct challenges and mechanisms. H 2 is a crucial future zero-carbon energy vector given its high gravimetric energy density, which far exceeds that of liquid hydrocarbons. However, its low volumetric energy density in gaseous form currently requires storage under high pressure or at low temperature. This review critically examines the current and prospective landscapes of solid-state H 2 storage technologies, with a focus on pragmatic integration of advanced materials such as metal-organic frameworks (MOFs), magnesium-based hybrids, and novel sorbents into future energy networks. These materials, enhanced by nanotechnology, could significantly improve the efficiency and capacity of H 2 storage systems by optimizing H 2 adsorption at the nanoscale and improving the kinetics of H 2 uptake and release. We discuss various H 2 storage mechanisms—physisorption, chemisorption, and the Kubas interaction—analyzing their impact on the energy efficiency and scalability of storage solutions. The review also addresses the potential of “smart MOFs”, single-atom catalyst-doped metal hydrides, MXenes and entropy-driven alloys to enhance the performance and broaden the application range of H 2 storage systems, stressing the need for innovative materials and system integration to satisfy future energy demands. High-throughput screening, combined with machine learning algorithms, is noted as a promising approach to identify patterns and predict the behavior of novel materials under various conditions, significantly reducing the time and cost associated with experimental trials. In closing, we discuss the increasing involvement of various companies in solid-state H 2 storage, particularly in prototype vehicles, from a techno-economic perspective. In conclusion, this forward-looking perspective underscores the necessity for ongoing material innovation and system optimization to meet the stringent energy demands and ambitious sustainability targets increasingly in demand.

25 ENERGY STORAGE↗

DOE OSTI2025

Modeling of melting and erosion in high velocity microparticle impacts

High velocity collisions can cause melting, a situation involving elasticity, plasticity, and phase transformations in tandem, which is very challenging for mechanical modeling. Here, this paper advances the use of smoothed particle hydrodynamics (SPH) simulations for this complex situation, investigating stainless steel microspheres impacting a tin substrate. After extensive validation against a range of mechanical and geometrical measurements of experimental impacts, the model provides a detailed, quantitative view of melt volume production over a broad range of impact velocities. It also enables direct decomposition of the impact energy partitioning, including analysis of the energy absorbed by plasticity in the impactor, the system kinetic energy, and the adiabatic heating of the substrate in addition to the melting itself. Since these quantities are not available experimentally, SPH modeling substantially enhances the quantitative understanding of such impacts. Finally, the model speaks to the phase characteristics of the ejecta formed during impact, confirming the experimental inference that the ejected material likely contains a significant fraction of solid material.

Constitutive modeling↗

DOE OSTI2024

Revisiting the electrochemical reduction of CO 2 on Au 25 (SR)$\overline{_{18}}$ nanocluster

Experiments show that Au25(SR)$\overline{_{18}}$ is a potential electrocatalyst for the electrochemical reduction of CO 2 , but elucidation of the reaction mechanisms remain challenging experimentally. We evaluate key steps in the active site formation, CO 2 reduction, and H 2 evolution on the nanocluster employing density functional theory coupled with an explicit solvent model of the electrochemical interface to calculate activation barriers. The predicted preferred pathway for activating the nanocluster involves dethiolation, resulting in an exposed Au site that is both active and selective for CO 2 reduction. Finally, the alternative S site is found to be kinetically prohibitive and does not facilitate CO 2 reduction.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2026

Dispersion Suppression for Wedge-Based Final Cooling at a 10 TeV Muon Collider

Achieving a luminosity of $\gtrsim 10^{34} cm^{-2} s^{-1}$ in a $10 \text{ } TeV$ Muon Collider, given the short lifetime of a muon, requires reducing the 6D emittance of the muon beam through a process known as ionization cooling. In the final stage of this cooling process, the transverse emittance must be reduced to $22 \text{ } μm$, typically by allowing longitudinal emittance growth up to downstream acceptance limits. While the current International Muon Collider Collaboration designs involve $40 \text{ } T$ solenoids to reach the transverse emittance target, such high-field solenoids come with several challenges, including mechanical stress management, quench protection, and potential limitations in relying on High Temperature Superconductor technology. Designed as an alternative to using such solenoids while simultaneously reaching target transverse emittance, the previously proposed wedge-based, reverse emittance-exchange cooling scheme requires excellent dispersion suppression. In this study, we design and simulate a dispersion suppressor channel for the wedge-based final cooling design that reduces dispersion in the target direction to a target value of $D_x \sim 0.001 \text{ } m$.

Karaaslan, I. [Chicago U.] (ORCID:0000000337849879↗

DOE OSTI2025

Spectrally Stabilized Interface Capturing Formulation and Implementation in Nek5000/NekRS

This report documents the formulation of a novel level-set method for incompressible two-phase flows in the continuous Galerkin (CG) high order spectral element framework. The overall method hinges on a novel implementation of the spectral vanishing viscosity (SVV) operator for the stabilization of linear/non-linear hyperbolic problems. The multidimensional SVV convolution kernels, which in essence, have a similar effect as a high pass filter applied to the derivatives, are formulated by exploiting the tensor product form, analogous to the construction of the usual stiffness matrix system. The resulting kernels are directionally decoupled and ensure a linear, symmetric positive definite, elliptic matrix operator. The SVV formulation is demonstrated to provide a robust stabilizing mechanism through challenging linear and non-linear hyperbolic problems, including problems pertinent to the level-set formulation. The two-phase framework conceptualized herein is based on the conservative level-set (CLS) method which represents the interface between the fluids by the 0.5 iso-contour of the smoothed Heaviside function. The CLS method is augmented with a preconditioning procedure for interface normals using the signed distance function which precludes the manifestation of spurious oscillations in the vicinty of the interface. Further, the existing mixed explicit-implicit approach for the solution of Navier-Stokes equations in Nek5000, as described in Tomboulides et al, is augmented with a pressure coefficient splitting approach for the Poisson equation, which greatly accelerated the convergence of pressure solver for two-phase systems with large density ratio. The robustness and accuracy of the overall two-phase method is demonstrated through canonical challenging problems involving high density and viscosity ratios, with and without surface tension. The two-phase formulation is wholly implemented in Nek5000 and the SVV stabilization method is implemented in NekRS, which is the essential precursor to the two-phase framework, undergoing active development.

97 MATHEMATICS AND COMPUTING↗

NASA NTRS1992

Novel position sensor technologies for microaccelerometers

An important new approach for vehicle guidance and control is based on the use of compact, low-mass, low-cost sensors integrated with the vehicle structure. Many advantages of this approach lead to new capabilities. However, the development of compact guidance and control sensors leads to a variety of fundamental physical problems associated with sensor sensitivity and noise. For example, as sensor size is reduced, it becomes necessary to improve the sensitivity of the sensor signal detection mechanism. These challenges to sensor development will be described. Recent developments at JPL, based on new position sensor principles such as electron tunneling, have produced a series of novel, ultra-high sensitivity micro-sensors and micro-instruments. Included among the applications demonstrated, are a high sensitivity micro-accelerometer and micro-seismometer. In this paper, the fundamental limits of conventional position sensors will be discussed and a new position sensor for advanced accelerometers will be described.

Vanzandt, T. R.↗

NASA NTRS2005

Brazing in Space: The Next Frontier

This viewgraph presentation provides information on the challenges facing mechanically joining objects in space, as well as past, present, and future techniques for brazing. The sections of the presentation include: 1) Why do we need to join components in space; 2) Why brazing? 3) History of brazing in space; 4) Electron beam vacuum brazing; 5) Current effort at GSFC; 6) Future work.

Flom, Yury↗

NASA NTRS2011

Advances in Solid State Joining of High Temperature Alloys

Many of the metals used in the oil and gas industry are difficult to fusion weld including Titanium and its alloys. Solid state joining processes are being pursued as an alternative process to produce robust structures more amenable to high pressure applications. Various solid state joining processes include friction stir welding (FSW) and a patented modification termed thermal stir welding (TSW). The configuration of TSWing utilizes an induction coil to preheat the material minimizing the burden on the weld tool extending its life. This provides the ability to precisely select and control the temperature to avoid detrimental changes to the microstructure. The work presented in this presentation investigates the feasibility of joining various titanium alloys using the solid state welding processes of FSW and TSW. Process descriptions and attributes of each weld process will be presented. Weld process set ]up and welding techniques will be discussed leading to the challenges experienced. Mechanical property data will also be presented.

Ding, Jeff↗

NASA NTRS2015

Self-Cleaning Boudouard Reactor for Full Oxygen Recovery from CO2 Project

Oxygen recovery from respiratory CO2 is an important aspect of human spaceflight. Methods exist to sequester the CO2, but production of oxygen needs further development. The current ISS Carbon Dioxide Reduction System (CRS) uses the Sabatier reaction to produce water (and ultimately breathing air). Oxygen recovery is limited to 50% because half of the hydrogen used in the Sabatier reactor is lost as methane, which is vented overboard. The Bosch reaction is the only real alternative to the Sabatier reaction, but in the last reaction in the cycle (Boudouard) the resulting carbon buildup will eventually foul the nickel or iron catalyst, reducing reactor life and increasing consumables. To minimize this fouling, find a use for this waste product, and increase efficiency, we propose testing various self-cleaning catalyst designs in an existing MSFC Boudouard reaction test bed and to determine which one is the most reliable in conversion and lack of fouling. Challenges include mechanical reliability of the cleaning method and maintaining high conversion efficiency with lower catalyst surface area. The above chemical reactions are well understood, but planned implementations are novel (TRL 2) and haven't been investigated at any level.

Technology Portfolio System↗

NASA NTRS2015

In-Space Manufacturing: Pioneering a Sustainable Path to Mars

In order to provide meaningful impacts to exploration technology needs, the In-Space Manufacturing (ISM) Initiative must influence exploration systems design now. In-space manufacturing offers: dramatic paradigm shift in the development and creation of space architectures; efficiency gain and risk reduction for low Earth orbit and deep space exploration; and "pioneering" approach to maintenance, repair, and logistics leading to sustainable, affordable supply chain model. In order to develop application-based capabilities in time to support NASA budget and schedule, ISM must be able to leverage the significant commercial developments, which requires innovative, agile collaborative mechanisms (contracts, challenges, SBIR's, etc.); and NASA-unique investments to focus primarily on adapting the technologies and processes to the microgravity environment. We must do the foundational work - it is the critical path for taking these technologies from lab curiosities to institutionalized capabilities: characterize, certify, institutionalize, design for Additive Manufacturing (AM). Ideally, International Space Station (ISS) U.S. lab rack or partial rack space should be identified for in-space manufacturing utilization in order to continue technology development of a suite of capabilities required for exploration missions, as well as commercialization on ISS.

Werkheiser, Niki↗

NASA NTRS1981

Detection, Diagnosis and Prognosis: Contribution to the energy challenge: Proceedings of the Meeting of the Mechanical Failures Prevention Group

The contribution of failure detection, diagnosis and prognosis to the energy challenge is discussed. Areas of special emphasis included energy management, techniques for failure detection in energy related systems, improved prognostic techniques for energy related systems and opportunities for detection, diagnosis and prognosis in the energy field.

Shives, T. R.↗