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

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NASA NTRS1989

Making Nozzles From Hard Materials

Proposed method of electrical-discharge machining (EDM) cuts hard materials like silicon carbide into smoothly contoured parts. Concept developed for fabrication of interior and exterior surfaces and internal cooling channels of convergent/divergent nozzles. EDM wire at skew angle theta creates hyperboloidal cavity in tube. Wire offset from axis of tube and from axis of rotation by distance equal to throat radius. Maintaining same skew angle as that used to cut hyperboloidal inner surface but using larger offset, cooling channel cut in material near inner hyperboloidal surface.

Wells, Dennis L.↗

NASA NTRSDate not supplied

Thermal Vacuum Chamber Demonstration of a Cryocooled, HTS Rotor for a 1.4 MW Electric Machine for Electrified Aircraft Propulsion

Aircraft with electrified propulsion systems require electric machines that are very lightweight and highly efficient. Advancements to the state of the art are required to meet this demand. This is particularly true for large transport aircraft with more than about 150 passengers, which will require electric machines with power ratings in the 1 to 30+ MW range. At this scale of power, superconducting technology becomes attractive for electrified aircraft propulsion to increase efficiency and reduce mass [1]. A mass reduction relative to non-superconducting machines can result from an increase in the specific power of the machine and indirectly through a significant reduction in the amount of waste heat generated on the aircraft, which reduces the mass of the thermal management system [2]. NASA’s high efficiency megawatt motor (HEMM) is a 1.4 MW partially superconducting machine that is being developed to achieve an efficiency greater than 98% and electromagnetic specific power greater than 16 kW/kg. HEMM contains a copper stator operating at an average temperature around 423 K and a superconducting rotor composed of no-insulation 2nd generation high temperature superconducting (HTS) coils that operates around 60 K. The superconducting coils are conductively cooled by a pulse tube cryocooler embedded inside and rotating with the rotor shaft. This paper presents a full-scale demonstration of the rotor in a thermal vacuum chamber at the designed operating temperature. The test was designed to validate the design of HEMM’s rotor, namely the ability to operate the 2G HTS coils at their rated direct current in a relevant thermal environment while being conductively cooled.

high temperature superconductors↗

NASA NTRS2019

Progress Toward the Critical Design of the Superconducting Rotor for NASA's 1.4 MW High-Efficiency Electric Machine

NASA Glenn Research Center is developing a 1.4 MW high-efficiency electric machine for future electrified aircraft to reduce energy consumption, emissions, and noise. This wound-field, synchronous machine employs a self-cooled, superconducting rotor to achieve excellent specific power and efficiency. This paper presents the progress made over the past year toward a critical design of the superconducting rotor, including refined analysis and risk reduction testing on prototype superconducting coils. A 3D finite element model of the rotor is developed to simulate the combined loading imposed by the initial cool down of the rotor from room temperature to cryogenic temperature and the subsequent rotation of the rotor up to the design speed. The model is evaluated to better predict the stress state in the critical components and the reduction in physical gap between the stator and rotor due to the resulting radial deflections. This model includes an enhanced model of the superconducting coil that considers the coil as an assembly of four individual coil layers. An improved coil fabrication process is described in detail. Two sub-scale test coils are fabricated and then tested under repeated thermal cycling between room temperature and liquid nitrogen temperature (77 K). It is demonstrated that the proposed coil fabrication procedure can produce no-insulation, high temperature superconducting coils that can survive several thermal cycles without apparent degradation.

electric machines↗

NASA NTRS1985

Variable force, eddy-current or magnetic damper

An object of the invention is to provide variable damping for resonant vibrations which may occur at different rotational speeds in the range of rpms in which a rotating machine is operated. A variable force damper in accordance with the invention includes a rotating mass carried on a shaft which is supported by a bearing in a resilient cage. The cage is attached to a support plate whose rim extends into an annular groove in a housing. Variable damping is effected by tabs of electrically conducting nonmagnetic material which extend radially from the cage. The tabs at an index position lie between the pole face of respective C shaped magnets. The magnets are attached by cantilever spring members to the housing.

Cunningham, R. E.↗

NASA NTRS1985

The Manned Maneuvering Unit - 'A nice flying machine'

The need for untethered maneuvers in extravehicular space was recognized early in the NASA manned spaceflight program, leading to experiments during the Gemini flights. The Space Shuttle crews are now equipped with a Manned Maneuvering Unit (MMU) which employs 24 gaseous nitrogen thrusters to furnish six-degree-of-freedom mobility and is fitted with fully redundant electronics, electrical, and propulsion subsystems. The MMU thrusters are operated with translational and rotational hand controllers at the ends of the MMU arms.

Bollendonk, W. W.↗

NASA NTRSDate not supplied

Electromagnetic Redesign of NASA’s High Efficiency Megawatt Motor

NASA’s High Efficiency Megawatt Motor (HEMM) is being developed to achieve the performance needed by single aisle class electrified aircraft. It is a 1.4 MW electric machine designed as a generator for NASA’s STARC-ABL concept vehicle. It has performance objectives of greater than 16 kW/kg electromagnetic specific power and efficiency of greater than 98%. A significant flaw in the preliminary electromagnetic design of HEMM was recently discovered. The stator teeth in the preliminary design cause the magnetic flux in the rotating components of HEMM to oscillate at a very high frequency (12,240 Hz). Two independent energy loss analyses are presented to show that the frequency is high enough to cause eddy current losses that significantly exceed the rotor’s loss limit (50 W), despite the very small magnitude of this flux oscillation (<0.01 T). To eliminate these rotor losses, while continuing to meet the target performance, it was determined that the stator teeth needed to be removed and the electromagnetic geometry of the motor needed to be revised. The revised, slotless HEMM motor design is summarized. Sensitivity of the new design to key unknown variables such as the temperature of and number of turns in the superconducting rotor coils and the stator winding’s average temperature.

Thomas T Tallerico↗

NASA NTRS1981

Heat Pipe Technology

The heat pipe, a sealed chamber whose walls are lined with a "wick," a thin capillary network containing a working fluid in liquid form was developed for a heat distribution system for non-rotating satellites. Use of the heat pipe provides a continuous heat transfer mechanism. "Heat tubes" that improve temperature control in plastics manufacturing equipment incorporated the heat pipe technology. James M. Stewart, an independent consultant, patented the heat tubes he developed and granted a license to Kona Corporation. The Kona Nozzle for heaterless injection molding gets heat for its operation from an external source and has no internal heating bands, reducing machine maintenance and also eliminating electrical hazards associated with heater bands. The nozzles are used by Eastman Kodak, Bic Pen Corporation, Polaroid, Tupperware, Ford Motor Company, RCA, and Western Electric in the molding of their products.

Source record↗

NASA NTRS2018

New Runtime Record Set for Free-Piston Stirling Machine

This article describes the recent progress GRC has made in the arena of long-life heat engines for power conversion. NASA has been interested in Stirling-cycle machines for power conversion since the 1970s. At that time, it was recognized that such a device could be designed to achieve long-life continuous operation with high reliability, by leveraging the free-piston configuration in favor of a kinematic engine. The free-piston variant eliminates the wear mechanisms associated with rolling-element bearings, piston rings, and connecting rods, typically found in kinematic Stirling engine designs. By restricting the moving components to linear motion only, there is no need to convert linear piston movement to rotating motion. With this, the moving components can be suspended within their cylinders by non-contacting bearings and seals can be effected with close clearances, also non-contacting. The use of a linear alternator attached directly to the piston enables direct conversion of heat, to mechanical, then to electrical energy, all in one hermetically sealed vessel, The electrical output only requires simple feedthroughs, and the complexity of sealed a rotating crankshaft is eliminated. In the free-piston variant, the displacer-to-piston phase is not implemented by a connection to a common rotating shaft. Instead, the pressure wave itself is used to drive the displacer. The displacer is designed to have a higher natural frequency of motion than the piston, which achieves a leading phase angle required for power production. The free-piston Stirling behaves like a spring-mass-damper system, with a forcing function created by the alternate heater and cooling of the working gas, and damping provided by the current flowing through the linear alternator. Two types of non-contacting bearings are available to designers: flexure and gas bearings. Flexure bearings consist of a spiral-cut disc of metal that has high radial stiffness but a deliberately engineering stiffness in the axial direction, to permit piston and displacer resonant motion. Gas bearings utilize a pressure source and precisely machined flow channels to provide a radial stiffness around the moving component. The pressure source can be supplied by the engine's pressure wave itself.

Oriti, Salvatore M.↗

NASA NTRS1994

Spline-Screw Payload-Fastening System

Payload handed off securely between robot and vehicle or structure. Spline-screw payload-fastening system includes mating female and male connector mechanisms. Clockwise (or counter-clockwise) rotation of splined male driver on robotic end effector causes connection between robot and payload to tighten (or loosen) and simultaneously causes connection between payload and structure to loosen (or tighten). Includes mechanisms like those described in "Tool-Changing Mechanism for Robot" (GSC-13435) and "Self-Aligning Mechanical and Electrical Coupling" (GSC-13430). Designed for use in outer space, also useful on Earth in applications needed for secure handling and secure mounting of equipment modules during storage, transport, and/or operation. Particularly useful in machine or robotic applications.

Vranish, John M.↗

NASA NTRS2010

iLIDS Simulations and Videos for Docking TIM

The video shows various aspects of the International Low Impact Docking System, including team members, some production, configuration, mated androgynous iLIDS, SCS Lockdown system, thermal analysis, electrical engineering aspects, the iLIDS control box and emulator, radiation testing at BNL, component environmental testing, component vibration testing, 3G processor board delivery system, GTA vibe test, EMA testbed, hook and hook disassembly, flex shaftdrive assembly, GSE cradle MISSE-6 Columbus, MISSE 6 and 7 seal experiments, actuated full scale seal test rig, LIDS on Hubble, dynamics test prep, EDU 54 mass emulation and SCS, load ring characterization, 6DOF proof test, SCS at 6DOF, machining EEMS and inner ring assembly, APAS assembly, inner ring fitting, rotation stand assembly, EEMS mating, and EEMS proof of concept demonstration.

Lewis, James L.↗

NASA NTRS1985

Mod-2 wind turbine field operations experiment

The three-machine, 7.5 MW Goodnoe Hills located near Goldendale, Washington and is now in a research/experimental operations phase that offers a unique opportunity to study the effects of single and multiple wind turbines interacting with each other, the power grid; and the environment. Following a brief description of the turbine and project history, this paper addresses major problem areas and research and development test results. Field operations, both routine and nonroutine, are discussed. Routine operation to date has produced over 13,379,000 KWh of electrical energy during 11,064 hr of rotation. Nonroutine operation includes suspended activities caused by a crack in the low speed shaft that necessitated a redesign and reinstallation of this assembly on all three turbines. With the world's largest cluster back in full operation, two of the turbines will be operated over the next years to determine their value as energy producer. The third unit will be used primarily for conducting research tests requiring configuration changes to better understand the wind turbine technology. Technical areas summarized pertain to system performance and enhancements. Specific research tests relating to acoustics, TV interference, and wake effects conclude the paper.

Gordon, L. H.↗

NASA NTRS2000

Reduction of Sample Rotation in Electrostatic Levitation

In many containerless processing systems, control of sample rotation is an important issue. Sample rotation is even more important for microgravity containerless processing systems, where the centrifugal acceleration can approach 1 g for even a small rotation rate. Prior work on rotation control by Rhim focused on driving the sample rotation at a controlled rate for droplet dynamics experiments and measurement of electrical conductivity. His technique allows controlled, fast rotation, but for many microgravity experiments the goal is zero rotation. To minimize sample rotation, two approaches are apparent: first, to identify and balance or eliminate the driving forces for undesired sample rotation, or second, implement a feedback-based rotation control loop in parallel with the position control loop. In this work, we have taken the first approach. To minimize sample rotation, the simplest approach is to identify and balance or eliminate the driving forces for undesired sample rotation. Our experiments show that the dominant driving force for rotation of machined Zr spheres in the MSFC ESL is photon pressure from the heating laser. Experimental results showing the correlation between heating power and torque are compared to theoretical predictions, and a strategy for minimizing the torque due to photon pressure is presented.

Hyers, R. W↗

NASA NTRS2019

Progress Toward the Critical Design of the Superconducting Rotor for NASA's 1.4 MW High Efficiency Electric Machine

Scheidler, Justin↗

NASA NTRS1976

Insulation end life determination for completed form-wound generators

Tests were conducted to predict remaining electrical insulation life of a polyimide-epoxy insulated 60 kW form-wound homopolar inductor generator following completion of 23,130 hours of turbo-generator endurance tests. The generator stator was sectioned to provide five sections, designated statorettes, and to permit 33 coil dielectric measurements on each section. Thermal aging tests were conducted on each section at select elevated temperatures to establish an Arrhenius life-temperature plot for end-life prediction and product or application use. The statorette fabrication technique is considered novel and provides means to establish insulation life-temperature profiles on completed electromagnetic components of rotating machines.

Penn, W. B.↗

NASA NTRS2024

Effect of High-Speed Rotation on High-Temperature Superconducting Coils for High Efficiency Megawatt Motor

The use of a superconducting rotor in the High Efficiency Megawatt Motor (HEMM) comes with a number of challenges. The HEMM’s rotor must be designed so that the superconducting coil can tolerate the forces it will encounter during operation. These forces introduce considerable risk to the design of the HEMM. Because this risk cannot be adequately addressed through refined analysis, a set of experiments was deemed necessary to demonstrate that the HEMM’s superconducting coils can survive the stresses imparted by the centrifugal forces acting on the coil during full-speed operation of the machine. These experiments required spin testing a full-scale HEMM coil on a representative rotor structure at room temperature and sequentially higher rotation speeds and measuring the superconductivity response of the coil in liquid nitrogen (LN2) before and after each spin test. Tests were carried out to the full centripetal loading of a recent HEMM design. According to finite element analysis, this load produced stress components in the coil that exceed their design limit by a factor of 1 to 7.4. Although not yet confirmed, the current HEMM design is expected to produce even smaller stresses in the coil due to a 20 percent reduction in the coil’s mass and an increased volume of structural material. The only degradation of the coil that occurred during this testing resulted from a test rig failure and from the voltage taps, which are not part of the final coil design.

Electrified Aircraft Propulsion↗

NASA NTRS1991

An investigation to determine the producibility of a 3-D braider and bias direction weaving loom

The development of prototype machines for the production of generalized braid patterns is described. Mechanical operating principles and control strategies are presented for two prototype machines which were fabricated and evaluated. Both machines represent advances over current techniques for forming composite material preforms by enabling near ideal control of fiber orientation. Furthermore, they overcome both the lack of general control of produced fiber architectures and the complexity of other weaving processes that were produced for the same purpose. One prototype, the modified Farley braider, consists of an array of turntables which can be rotated 90 degrees and returned; hence, they can form tracks in the x and y axis. Yarn ends are transported about the surface formed by the turntables using motorized tractors. These tractors are controlled using an optical link with a control circuit and host computer. The tractors are powered through electrical contact with the turntables. The necessary relative motions are produced by a series of linear tractor moves combined with a sequence of turntable rotations. The movement of the tractors about the surface causes the yarns to produce the desired braiding pattern. The second device, the shuttle plate braider, consists of a braiding surface formed by an array of square elements, each separated from its neighbor by a gap. Beneath this surface lies a shuttle plate, which reciprocates first in one axis and then in the other. As this movement takes place, yarn carrying shuttles engage and disengage the plate by means of solenoid activated pins. By selective engagement and disengagement, the shuttles can move the yarn ends in any desired pattern, forming the desired braid. Control power, and control signals, are transmitted from the electronic interface circuit and host computer, via the braiding surface through electrical contact with the shuttles. Motive power is proved to the shuttles by motion of the shuttle plate, which is passively driven using pneumatic rams. Each shuttle is a simple device that uses only a solenoid to engage the plate and is a simple device that uses only a solenoid to engage the plate and is independently controllable. When compared with each other, the modified Farley braider has the advantage of speed, and the shuttle plate braider the advantage of mechanical control and simplicity.

Huey, Cecil O., Jr.↗

NASA NTRS1983

Actively suspended counter-rotating machine

A counter-rotating machine, such as a positive displacement pump having a pair of meshed, non-contacting helical screws (10,12), subjects its rotating members to axial and radial thrust forces when used for such purposes as compression of liquid or gaseous phase fluids while transporting them through a pump cavity (11,13). Each helical screw (10,12) has a shaft (17,17') which is actively suspended at opposite ends (11a,11b) of the pump cavity by a servo-controlled magnetic bearing assembly (19) and a servo-controlled rotary drive motor (20). Both bearing assemblies and drive motors are mounted on the outside of the pump cavity (11,13). Opto-electric angular position sensors (250) provide synchronization between radial orientation of the drive motors. The bearing assemblies and drive motors conjugately provide axial stabilization and radial centering of the helical screws during volumetric compression of aspirated liquid or gaseous phase fluids.

Studer, Philip A.↗

NASA NTRS1997

Machine Phase Fullerene Nanotechnology: 1996

NASA has used exotic materials for spacecraft and experimental aircraft to good effect for many decades. In spite of many advances, transportation to space still costs about $10,000 per pound. Drexler has proposed a hypothetical nanotechnology based on diamond and investigated the properties of such molecular systems. These studies and others suggest enormous potential for aerospace systems. Unfortunately, methods to realize diamonoid nanotechnology are at best highly speculative. Recent computational efforts at NASA Ames Research Center and computation and experiment elsewhere suggest that a nanotechnology of machine phase functionalized fullerenes may be synthetically relatively accessible and of great aerospace interest. Machine phase materials are (hypothetical) materials consisting entirely or in large part of microscopic machines. In a sense, most living matter fits this definition. To begin investigation of fullerene nanotechnology, we used molecular dynamics to study the properties of carbon nanotube based gears and gear/shaft configurations. Experiments on C60 and quantum calculations suggest that benzyne may react with carbon nanotubes to form gear teeth. Han has computationally demonstrated that molecular gears fashioned from (14,0) single-walled carbon nanotubes and benzyne teeth should operate well at 50-100 gigahertz. Results suggest that rotation can be converted to rotating or linear motion, and linear motion may be converted into rotation. Preliminary results suggest that these mechanical systems can be cooled by a helium atmosphere. Furthermore, Deepak has successfully simulated using helical electric fields generated by a laser to power fullerene gears once a positive and negative charge have been added to form a dipole. Even with mechanical motion, cooling, and power; creating a viable nanotechnology requires support structures, computer control, a system architecture, a variety of components, and some approach to manufacture. Additional information is contained within the original extended abstract.

Globus, Al↗