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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
DOE OSTI2026

Gear Test Assembly - Experimental Testing and Analysis of Gears and Bearings - FY2026

The Gear Test Assembly (GTA) is an experimental test apparatus built and installed in the Mechanisms and Engineering Test Loop (METL) at Argonne National Laboratory (ANL). While designed to accommodate a variety of components intended for use in advanced compact in-vessel transfer machine, the focus of GTA been the testing of large radial spur gears. The performance of the components used in GTA motivates the choices made in the design, components, and material choices for the forthcoming METL test articles; the Gripper Test Assembly (GrTA), and the Bearing Test Assembly (BTA). To date, GTA has completed nine experimental testing campaigns and achieved over 21 million revolutions under prototypic sodium fast reactor loads and operating conditions. This report provides an overview and results for the two most recent experiments Campaign #8 and Campaign #9. `Campaign #8 was the first campaign to make use of a set of nickel alloy radial spur gears, made from Hastelloy C-22HS, and combined with heat-treated tapered roller bearings. The bearings and torque profile used allowed Campaign #8 to be directly compared with Campaign #1 where Inconel 718 gears were used instead. Campaign #8 attained 1,058,880 shaft revolutions within 23% of the 1,314,855 revolutions achieved in Campaign #1. These results demonstrate that the heat-treated tapered roller bearings show consistent increased lifetimes, approximately three times longer than for non heat-treated taper rollers, and that the particular material of the gear does not play a substantial role in performance. Similar to Campaign #7 where bearing failure resulted in fragmentation and transport of bearing material into the gear teeth led to tooth damage in the Inconel gears, a similar process led to the damage of the Hastelloy gears. Subsequent NDE analysis showed that the damage was only limited to the tooth surface and does not extend into the gear interiors. Based on the NDE reports, the Hastelloy gears can be reconditioned and put back into service for future campaigns as was done for the Inconel gears. Reconditioned Inconel 718 gears damaged in Campaign #7 were returned to service in Campaign #9 and paired with non heat-treated tapered roller bearings. In Campaign #9 a novel set of operating conditions were implemented whereby the gears and bearings were cycled between hot, submerged refueling conditions where fuel handling operations occurred and cold, dry, and inert conditions where the sodium was drained and the vessel was allowed to cool simulating long, ex-vessel storage of the fuel handling machine. A total of eight of these operating cycles were achieved before a bearing failure occurred after the accumulation of 475,692 shaft revolutions were achieved. During Campaign #9, one of the drive motors was damaged and over the course of a 240 day standby period, the entire GTA drive system was upgraded from a 480VAC system to a 240VAC system that provided the opportunity to consolidate wall-space in the METL facility and provide more space for additional test articles being installed in the coming year. The over 475,000 shaft revolutions achieved in Campaign #9 eclipses the previous record for lifetime of non heat-treated tapered roller bearings held by Campaign #3 of 392,000 shaft revolutions. Further analysis and future campaigns hope to shed light on the cause of this approximately 17% increase in lifetime.

42 ENGINEERING↗
NASA NTRS1982

Update: Viking Lander NiCd batteries. Year six

The performance of NiCd batteries on the Viking Mars landers is discussed. During evaluation, three of the four batteries were maintained in the discharged state. Battery charge regimes and close-together, deep-discharge, reconditioning cycles to retard degradation of batteries are discussed. The effect of elevated temperatures during Martian summer on battery performance were also considered. Tabulated data for average battery capacity as a function of time are given. A design uplink to allow more frequent, greater depth of discharge reconditioning cycles was proposed.

Britting, A. O., Jr.↗
NASA NTRS1983

Cycle life test and failure model of nickel-hydrogen cells

Six ampere hour individual pressure vessel nickel hydrogen cells were charge/discharge cycled to failure. Failure as used here is defined to occur when the end of discharge voltage degraded to 0.9 volts. They were cycled under a low earth orbit cycle regime to a deep depth of discharge (80 percent of rated ampere hour capacity). Both cell designs were fabricated by the same manufacturer and represent current state of the art. A failure model was advanced which suggests both cell designs have inadequate volume tolerance characteristics. The limited existing data base at a deep depth of discharge (DOD) was expanded. Two cells of each design were cycled. One COMSAT cell failed at cycle 1712 and the other failed at cycle 1875. For the Air Force/Hughes cells, one cell failed at cycle 2250 and the other failed at cycle 2638. All cells, of both designs, failed due to low end of discharge voltage (0.9 volts). No cell failed due to electrical shorts. After cell failure, three different reconditioning tests (deep discharge, physical reorientation, and open circuit voltage stand) were conducted on all cells of each design. A fourth reconditioning test (electrolyte addition) was conducted on one cell of each design. In addition post cycle cell teardown and failure analysis were performed on the one cell of each design which did not have electrolyte added after failure.

Smithrick, J. J.↗
NASA NTRS1982

Development of improved hydrogen recombination in sealed nickel-cadmium aerospace cells

The identification and measurement of a hydrogen recombination mechanism in nickel-cadmium cells has made deep reconditioning on a battery basis safe and feasible. Deep reconditioning has been shown to improve performance and increase life of nickel-cadmium batteries in geosynchronous orbit applications. The hydrogen recombination mechanism and data supporting the mechanism are presented. Parameteric cell design experiments are described which have lead to the definition of nickel-cadmium cells capable of high rate overdischarge. Nickel-cadmium cells with optimum hydrogen recombination capability were successfully cycled for 7 seasons in simulation of the geosynchronous orbit regime at 75 percent depth-of-discharge with extensive midseason and end-of-season overdischarge at rates ranging from C/4 to C/20.

Ritterman, P. F.↗
NASA NTRS1983

Cycle life test and failure model of nickel-hydrogen cells

Six ampere hour individual pressure vessel nickel hydrogen cells were charge/discharge cycled to failure. Failure as used here is defined to occur when the end of discharge voltage degraded to 0.9 volts. They were cycled under a low earth orbit cycle regime to a deep depth of discharge (80 percent of rated ampere hour capacity). Both cell designs were fabricated by the same manufacturer and represent current state of the art. A failure model was advanced which suggests both cell designs have inadequate volume tolerance characteristics. The limited existing data base at a deep depth of discharge (DOD) was expanded. Two cells of each design were cycled. One COMSAT cell failed at cycle 1712 and the other failed at cycle 1875. For the Air Force/Hughes cells, one cell failed at cycle 2250 and the other failed at cycle 2638. All cells, of both designs, failed due to low end of discharge voltage (0.9 volts). No cell failed due to electrical shorts. After cell failure, three different reconditioning tests (deep discharge, physical reorientation, and open circuit voltage stand) were conducted on all cells of each design. A fourth reconditioning test (electrolyte addition) was conducted on one cell of each design. In addition post cycle cell teardown and failure analysis were performed on the one cell of each design which did not have electrolyte added after failure. Previously announced in STAR as N83-25038

Smithrick, J. J.↗
NASA NTRS1994

Orbital management and design considerations for NiCd satellite power systems

Several recently manufactured 50 and 60 ampere hour aerospace NiCd battery cell lots, produced by Gates Aerospace Batteries, are prone to premature on orbit performance degradation. The failure mechanism is cadmium migration, and the consequent development of soft shorts. A Martin Marietta Astronautics satellite program instituted an orbital management strategy for a set of these batteries that reduced the rate of degradation and brought the system to stable operation. This strategy involves: (1) minimizing the accumulated battery overcharge; (2) regular discharge exercises; and (3) periodic battery reconditioning. Because of changes in the NiCd cell manufacturing process, the actual performance of subsequent lots of NiCd cells is open to question. Future NiCd based power system designs should therefore allow for fine control of charge parameters, and an on orbit battery reconditioning capability. To minimize risk, it is much better to perform a full life test to qualify the cells before launch, rather than in parallel with orbital operations. If there are any changes in the manufacturing process of cells, it is extremely important to maintain very strong cognizance of secondary subcontractors, recognizing that the cell and battery manufacturing discipline is easily atrophied.

Tausch, Benjamin J., II↗
NASA NTRS1997

On-Orbit Health Check of Hubble Space Telescope Nickel-Hydrogen Batteries

The Hubble Space Telescope is a one-of-a-kind spacecraft that pushes technology to its limits. Housing an 8-foot (2.4 meter) mirror and several sophisticated cameras and detectors the telescope is the largest orbital astronomy observatory ever placed in space. It has two modules each containing three 88 Ah NiH2 batteries (six total). Reconditioning has traditionally been used as a means of maintaining the performance of normal cells and batteries. This paper describes the objective, procedure, and results of a reconditioning processes that used to improve the performance of an HST nickel-hydrogen batteries.

Rao, Gopalakrishna M.↗
DOE OSTI2025

Genetically engineered poplar wood effectively enhances the efficiency of deep eutectic solvent-mediated one-pot processing

Although lignocellulosic biomass is a renewable resource with the potential to replace fossil-derived fuels and chemicals, its recalcitrance, largely due to lignin, limits its utilization. Recent advancements in genetic engineering have produced transgenic trees with reduced lignin content and/or modified lignin structure without compromising growth traits. Here, three engineered poplar varieties are evaluated as feedstocks using a biocompatible one-pot deep eutectic solvent-mediated process that integrates biomass fractionation and enzymatic saccharification within a single reactor, eliminating water washing and reconditioning. All transgenic poplars exhibit higher fermentable sugar yields than wild-type (WT) trees. Notably, QsuB poplar, incorporating 3,4-dihydroxybenzoate in lignin, achieves the highest glucose conversion yield of 91.3% (vs. 73.0% from WT). AT5 and MdCHS3 poplars, incorporating ferulate esters and naringenin, also demonstrate improved glucose yields (86.7 and 84.7%, respectively), confirming reduced biomass recalcitrance. Additionally, residual lignins are valorized via hydrogenolysis into phenolic compounds, with comparable alkylphenol production across all lines. These findings demonstrate that the transgenic poplar lines not only serve as superior feedstocks for sugar conversion but also provide a rich resource for phenolic compound production, enhancing the operational and economic viability of integrated biorefinery processes.

biomasses↗
NASA NTRS1973

Gas chromatography of volatile organic compounds

System has been used for problems such as analysis of volatile metabolities in human blood and urine, analysis of air pollutants, and in tobacco smoke chemistry. Since adsorbent is reusable after porper reconditioning, method is both convenient and economical. System could be used for large scale on-site sampling programs in which sample is shipped to central location for analysis.

Zlatkis, A.↗
NASA NTRS1974

High-efficiency, 200 watt, 12-gigahertz traveling wave tube

Design and performance of a highly efficient experimental 200-watt traveling wave tube for space communications are described. The tube uses a coupled cavity slow wave structure with periodic permanent magnet focusing. A two-step velocity taper is incorporated in the slow wave structure for velocity resynchronization with the modulated beam. The spent beam is reconditioned in a refocusing section before it is collected in a novel multistage depressed collector. The collector is radiation cooled and heat insulated from the tube body. At saturation the tube provides peak output power of 240 watts with a 35-db gain and an overall maximum efficiency of 56 percent.

Kosmahl, H. G.↗
NASA NTRS1973

Development of a uninterrupted power system: ac and dc to dc converter

This program covered the design, fabrication and testing of an advanced development model uninterrupted power system. The input and output requirements imposed on the power processor were specified such that the unit is electrically interchangeable with existing power systems used by the Federal Aviation Administration in installations which have a history of failure due to electrical transient conditions. Input power is from either of two single-phase ac power sources or batteries with electronic selection and transfer between power sources. Battery reconditioning is automatic when either ac source is present. The output power is rated at 84OW; the nominal output is 24V at 35A. Within the 84OW limit, the regulated output voltage is adjustable from 22V to 30Vdc. Protection against continuous overloading or short circuit is provided. The unit is packaged in a standard 19-inch rack mount configuration with 7-inch panel height. Controls are on the front panel with power input and output through connectors on the rear surface. Cooling is by free convection from fin areas located on the side and rear panels. The packaged unit weighs 52.8 lbs., which can be reduced significantly if a three-phase ac power source is used.

Cronin, D. L.↗
NASA NTRS1976

Compact reconditioner for Ni/Cd cells

Extension of life of multiple-cell nickel-cadium battery packs is accomplished by reconditioning method requiring discharge of each battery cell. Compact and lightweight dc-to-dc converter replaces relay-sensor system, protecting against voltage-reversal damage, and monitors overall cell condition.

Kapustka, R. E.↗
NASA NTRS1975

LST power system long life design techniques

The LST mission of up to 15 years plus about two years allotment for ground return maintenance could stretch the LST operation to the end of the century. This extended mission life, combined with the large power requirements of the telescope and the scientific instruments, imposes stringent requirements on the electrical power subsystem. The use of an onboard microprocessor for individual battery cell control and monitoring offers a technique that could improve the battery cycle life dramatically. The battery configuration includes spare battery cells which can be switched by the microprocessor to replace failed cells. The microprocessor can also be used for inflight reconditioning of the batteries to increase performance and verify ampere-hour capacity. The Flexible Roll-Up Solar Array (FRUSA) system offers a solar array at an acceptable cost that can stay within weight and volume constraints.

Smith, O. B.↗
NASA NTRS1978

Method and apparatus for conditioning of nickel-cadmium batteries

A method and apparatus are described for reconditioning batteries utilizing a dc-dc converter. During a discharge of the batteries, each cell is monitored by the converter. When the voltage of a cell decreases to a predetermined level, a converter will assume the load of this cell and inhibit the voltage from reaching zero, thereby preventing voltage reversal of that cell.

Kapustka, R. E.↗
NASA NTRS1977

Evaluation Program for Secondary Spacecraft Cells: Synchronous Orbit Testing of Sealed Nickel Cadmium Cells

Performance data concerning sealed nickel-cadmium cells operating under a synchronous orbit regime are presented. A space satellite maintaining a position over a fixed point on earth as the earth rotates on its axis and revolves about the sun was simulated. Results include: (1) exposure to synchronous orbit testing at a temperature of 40 C yields less than 6 years of life; (2) performance at -20 C presents a low capacity problem; (3) the capacity check, performed at the middle of each show period, provides a temporary red reconditioning effect on the cells in that the end-of-discharge voltages are higher, for approximately 7 to 10 days, following the capacity check than they were 7 to 10 days prior to the capacity check; (4) all the test packs at -20 C and 40 C have either failed or were discontinued because of low capacity; and (5) test packs at temperatures of 0 C and 10 C have delivered the best capacity during life and packs tested at 20 C showed better life capability than packs tested at -20 C and 40 C.

Harkness, J. D.↗
NASA NTRS1977

Storage effects on cells

The results of an experiment to test storage effects on electric cells of a battery are presented and discussed. The type of cells were the 20 amp-hour OAO type. The various modes that were tested were the integration type mode, the trickle charge, the discharge shorted and the discharged OCV (open current voltage). Every six months the cells were reconditioned and approximately two weeks of tests were performed. The tests included three capacity checks, two zero-degree overcharge tests and an internal short test (the cells are shunted for 16 hours, the shunt removed and allowed to stand on local circuit recovery for 24 hours). The integration pack was discontinued after three years and the trickle charge shorted packs after five years.

Harkness, J. M.↗
NASA NTRS1977

Effects of periodic discharges

Periodic capacity checks are assessed as well as the effects of periodic discharges on the cycle life and the performance of cells during the cycle life. Topics discussed include the effect of the amount of electrolyte on cell capacity at 35 C; battery design for spacecraft; electrolyte starvation theory; battery separator degradation; negative electrode stability; voltage regulation; operating temperatures; and integration of reconditioning systems using microprocessors.

Ford, F. E.↗