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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 OSTI2024

Reliability of Materials and Components for Solid Oxide Fuel Cells

Planar stack solid-oxide fuel cells (SOFCs) require seals that must operate reliably under demanding conditions for lifetimes of 40000 hours. This includes temperature fluctuations between 800°C and RT during on and off cycles, thermal stresses, oxidizing environments and chemical degradation to name a few. This comprehensive report provides results from long term testing of two commercially available multicomponent barium alkali silicate glasses: SCN and G6, chosen as sealing candidates. In this scope, the glass seals were deposited on YSZ and Al 2 O 3 substrates simulating electrolytes (Zrbased) and coatings (both zirconia and Al 2 O 3 ). The seal-substrate couples were subjected to 800°C under air and steam+H 2 +N 2 environments up to 40000 hours to test their integrity under real operating conditions. Extensive studies on the effects of exposure have been conducted over the span of testing at various time intervals. Within the context of characterization, mechanical properties such as density, roughness, thermal expansion and glass transition, viscosity and wettability behavior; and microstructural properties such as glass chemistries, defect formation (cracks and pores), phase transformations (devitrification) and glass-interface reactions are investigated. Results and discussions are provided with a focus on the degradation of the properties over long term interrupted testing.

30 DIRECT ENERGY CONVERSION↗
NASA NTRS1992

Lightweight bipolar storage battery

An apparatus [10] is disclosed for a lightweight bipolar battery of the end-plate cell stack design. Current flow through a bipolar cell stack [12] is collected by a pair of copper end-plates [16a,16b] and transferred edgewise out of the battery by a pair of lightweight, low resistance copper terminals [28a,28b]. The copper terminals parallel the surface of a corresponding copper end-plate [16a,16b] to maximize battery throughput. The bipolar cell stack [12], copper end-plates [16a,16b] and copper terminals [28a,28b] are rigidly sandwiched between a pair of nonconductive rigid end-plates [20] having a lightweight fiber honeycomb core which eliminates distortion of individual plates within the bipolar cell stack due to internal pressures. Insulating foam [30] is injected into the fiber honeycomb core to reduce heat transfer into and out of the bipolar cell stack and to maintain uniform cell performance. A sealed battery enclosure [ 22] exposes a pair of terminal ends [26a,26b] for connection with an external circuit.

Rowlette, John J.↗
DOE OSTI2024

Design and Validation of a High-Throughput Reductive Catalytic Fractionation Method

Reductive catalytic fractionation (RCF) is a promising method to extract and depolymerize lignin from biomass, and bench-scale studies have enabled considerable progress in the past decade. RCF experiments are typically conducted in pressurized batch reactors with volumes ranging between 50 and 1000 mL, limiting the throughput of these experiments to one to six reactions per day for an individual researcher. Here, we report a high-throughput RCF (HTP-RCF) method in which batch RCF reactions are conducted in 1 mL wells machined directly into Hastelloy reactor plates. The plate reactors can seal high pressures produced by organic solvents by vertically stacking multiple reactor plates, leading to a compact and modular system capable of performing 240 reactions per experiment. Using this setup, we screened solvent mixtures and catalyst loadings for hydrogen-free RCF using 50 mg poplar and 0.5 mL reaction solvent. The system of 1:1 isopropanol/methanol showed optimal monomer yields and selectivity to 4-propyl substituted monomers, and validation reactions using 75 mL batch reactors produced identical monomer yields. To accommodate the low material loadings, we then developed a workup procedure for parallel filtration, washing, and drying of samples and a 1H nuclear magnetic resonance spectroscopy method to measure the RCF oil yield without performing liquid-liquid extraction. As a demonstration of this experimental pipeline, 50 unique switchgrass samples were screened in RCF reactions in the HTP-RCF system, revealing a wide range of monomer yields (21-36%), S/G ratios (0.41-0.93), and oil yields (40-75%). These results were successfully validated by repeating RCF reactions in 75 mL batch reactors for a subset of samples. We anticipate that this approach can be used to rapidly screen substrates, catalysts, and reaction conditions in high-pressure batch reactions with higher throughput than standard batch reactors.

BIOMASS FUELS,INORGANIC, ORGANIC, PHYSICAL, AND AN↗
NASA NTRS1985

Sealed bipolar multi-cell battery

A low maintenance battery comprises a sealed casing (102) having a cavity (204) receiving a stack (108) of monopolar and bipolar plates (110, 112) interspersed with mats (122) of fiberglass felt immobilizing electrolyte and forming a gas path for diffusion of oxygen to the negative electrode (112). The casing contains a single, resealable vent (202). During charging, oxygen generated at the positive plate (110) diffuses through the mat (122) and decomposes at the negative plate (112). The negative plate (112) has a larger capacity than the positive plate (110) to prevent evolution of hydrogen. Voltage potential is increased or decreased by placing one or more bipolar plates (120) in series relation between alternating positive and negative monopolar plates that are connected in parallel to respective positive and negative battery terminals (104, 106). The monoplates (110, 112) are connected in parallel to respective positive and negative battery terminals (104, 106) by way of bus plates (114, 116, 130, 132). The resealable vent permits operation by way of the oxygen cycle which prevents loss of electrolyte. The vent prevents invasion of oxygen from the ambient to discharge negative plates.

Rowlette, John J.↗
DOE OSTI2022

LEAKAGE CHARACTERISTICS OF A STEPPED BALANCE PISTON LABYRINTH SEAL IN SUPERCRITICAL CO2

In an integrally geared compressor, there is a net thrust load on the pinion shaft from gear loads and aerodynamic forces. The net thrust on the pinion is resolved with either a thrust bearing or a thrust collar (rider ring). As the pressure increases, this increases the aerodynamic force proportionally. In highpressure systems this can overwhelm the thrust bearing or thrust collar if thrust is mismanaged. In a recent test program for an sCO2 integrally geared compander (compressor/turbine), a balance piston was created on the opposite end of the turbine to provide an equalizing thrust; while this is not novel, the balance piston provided a test apparatus for measuring the leakage on a 20 tooth stepped labyrinth seal operating at pressures in excess of 250 bar (3600 psi). The stepped balance piston seal is a 20 tooth tooth-onrotor balance piston seal. This type of seal was selected since it was predicted to have substantially less leakage than a comparably sized straight through labyrinth seal. Comparisons between the two designs will be made, showing that the leakage of the stepped balance piston seal is considerably lower. The tooth clearance on the seal was selected to be 30 mils radial. While this seems large, a stack-up tolerance assessment showed that this magnitude of clearance was appropriate to prevent rotor stator contact. During the testing campaign, data was recorded showing the leakage across this stepped balance piston seal at pressures in excess of 250 bar (3600 psi) with a pressure ratio of 2. This leakage data was measured, and will be compared to leakage data predicted with CFD. Two measurement methods are presented for the stepped balance piston seal: an orifice plate and valve. The predicted seal leakage from a straight through seal was four times that of the predicted stepped labyrinth seal. The measured flow from the stepped seal was on the same order as the CFD prediction and offered adequate rotordynamic performance

wilkes, jason↗
DOE OSTI2022

Polymer film heat exchanger sealing system and method

A method of manufacturing a heat exchanger array that includes stacking a plurality of heat exchanger units in an aligned configuration with respective first ports of the plurality of heat exchanger units aligned. The method can further include generating heat in the first coupling elements at the same time and at a temperature sufficient to generate a first plurality of respective couplings between adjacent sheets of adjacent heat exchanger units about adjacent first ports and without a coupling being generated between the first and second sheets of a given heat exchanger unit.

Rutkowski, Adam↗
NASA NTRS1984

The Base Engine for Solar Stirling Power

A new concept in Stirling engine technology is embodied in the base engine now being developed at Stirling Thermal Motors, Inc. This is a versatile energy conversion unit suitable for many different applications and heat sources. The base engine, rated 40 kW at 2800 RPM, is a four-cylinder, double-acting variable displacement Stirling engine with pressurized crankcase and rotating shaft seal. Remote-heating technology is incorporated with a stacked-heat-exchanger configuration and a liquid metal heat pipe connected to a distinctly separate combustor or other heat source. High efficiency over a wide range of operating conditions, long life, low manufacturing cost and low material cost are specifically emphasized. The base engine, its design philosophy and approach, its projected performance, and some of its more attractive applications are described.

Meijer, R. J.↗
NASA NTRS1985

Bipolar nickel-hydrogen battery design

The initial design for the NASA-Lewis advanced nickel-hydrogen battery is discussed. Fabrication of two 10-cell boilerplate battery stacks will soon begin. The test batteries will undergo characterization testing and low Earth orbit life cycling. The design effectively deals with waste heat generated in the cell stack. Stack temperatures and temperature gradients are maintained to acceptable limits by utilizing the bipolar conduction plate as a heat path to the active cooling fluid panel external to the edge of the cell stack. The thermal design and mechanical design of the battery stack together maintain a materials balance within the cell. An electrolyte seal on each cell frame prohibits electrolyte bridging. An oxygen recombination site and electrolyte reservoir/separator design does not allow oxygen to leave the cell in which it was generated.

Koehler, C. W.↗
NASA NTRS1984

Advanced Gas Turbine (AGT) powertrain system development for automotive applications

Rotor dynamic instability investigations were conducted. Forward ball bearing hydraulic mount configurations were tested with little effect. Trial assembly of S/N 002 ceramic engine was initiated. Impeller design activities were completed on the straight line element (SLE) blade definition to address near-net-shape powder metal die forging. Performance characteristics of the Baseline Test 2A impeller were closely preserved. The modified blading design has been released for tooling procurement. Developmental testing of the diffusion flame combustor (DFC) for initial use in the S/N 002 2100 F ceramic structures engine was completed. A natural gas slave preheater was designed and fabricated. Preliminary regenerator static seal rig testing showed a significant reduction in leakage and sensitivity to stack height. Ceramic screening tests were completed and two complete sets of ceramic static structures were qualified for engine testing. Efforts on rotor dynamics development to resolve subsynchronous motion were continued.

Source record↗
NASA NTRS1969

Evaluation, construction and endurance testing of compression sealed pyrolytic boron nitride slot insulation

A high-temperature statorette, consisting of an iron-27 percent cobalt magnetic lamination stack and nickel-clad silver conductors, was tested with pyrolytic boron nitride slot insulation. Temperatures were measured in each test to determine characteristics of slot linear heat conductance from statorette conductors. Testing was carried out to temperatures of approximately 1500 F in a vacuum environment of 10-8 torr. Three assemblies were built and tested, each having a different room temperature slot clearance. The final statorette assembly was subjected to a 100-hour vacuum aging test at 1400 F followed by 25 thermal cycles. Temperature data from the three assemblies showed that decreasing slot clearance and increasing compression loading did enhance heat transfer. The temperature difference between slot and lamination at 1400 F increased 4 F during the thermal aging and an additional 10 F during the 25 thermal cycles.

Grant, W. L.↗
DOE OSTI2023

Stacked Greenfield and Brownfield ROZ Fairways in the Illinois Basin Geo-Laboratory: Co-Optimization of EOR and Associated CO 2 Storage

Residual oil zones (ROZs) are economically viable targets for carbon dioxide enhanced oil recovery (CO 2 -EOR); thick, carbonate ROZs in the San Andres Formation in the Wasson Field of the Permian Basin are an example. Incremental oil produced from CO 2 -EOR can be carbon negative via associated storage of injected CO 2 . Given the regional extent of ROZ fairways and generally higher net utilization of CO 2 (compared to conventional CO 2 -EOR), ROZs provide the opportunity for significant carbon neutral to carbon negative oil production with associated CO 2 storage, and therefore should be a priority target for exploration. However, ROZs have not been widely recognized or identified due to poor or no conventional oil production. Hence, in places like the Illinois Basin (ILB), exploratory analyses are required to recognize the existence of an ROZ. As part of this study, four formations were selected for detailed regional characterization and analysis: Carper Sandstone (part of the Borden Siltstone), Tar Springs Sandstone, Cypress Sandstone, and Middle Devonian (Geneva Dolomite and associated Dutch Creek Sandstone). The four formations underwent regional geological characterization to develop a regional geologic framework for the ROZs and their overlying seals. Findings of this study are supported by data from two field laboratory sites, one with stacked greenfield ROZs and the other with a stacked complex that includes a brownfield ROZ and depleted conventional reservoirs. The field laboratory sites were used to collect data and conduct tests to validate ROZ detection methodologies and identify economic field-deployable strategies to co-optimize CO 2 -EOR and associated storage in stacked ROZs. Findings from these field sites were extrapolated to characterize the basin-wide stacked ROZ fairway resource.

01 COAL, LIGNITE, AND PEAT↗
NASA NTRS1986

A position sensitive microchannel photomultiplier for ultraviolet space astronomy

The 25-mm microchannel-plate, position-sensitive UV astronomy photomultiplier tube presented is intended for the EOM-1 Spacelab Mission's FAUST payload and conducts wide-field imaging surveys in the VUV over the 1400-1800-A range. The sealed detector encompasses a CsI photocathode deposited on the inner surface of a MgF2 window, a stack of microchannel plates, and a wedge-and-strip two-dimensional position-sensing anode. Since the wedge-and-strip principle requires only three anode signals, flight electronics can be reduced to three charge amplifiers and three analog-to-digital converters.

Lampton, M.↗
NASA NTRS1989

Woven-grid sealed quasi-bipolar lead-acid battery construction and fabricating method

A quasi-bipolar lead-acid battery construction includes a plurality of bipolar cells disposed in side-by-side relation to form a stack, and a pair of monoplanar plates at opposite ends of the stack, the cell stack and monopolar plates being contained within a housing of the battery. Each bipolar cell is loaded with an electrolyte and composed of a bipolar electrode plate and a pair of separator plates disposed on opposite sides of the electrode plate and peripherally sealed thereto. Each bipolar electrode plate is composed of a partition sheet and two bipolar electrode elements folded into a hairpin configuration and applied over opposite edges of the partition sheet so as to cover the opposite surfaces of the opposite halves thereof. Each bipolar electrode element is comprised of a woven grid with a hot-melt strip applied to a central longitudinal region of the grid along which the grid is folded into the hairpin configuration, and layers of negative and positive active material pastes applied to opposite halves of the grid on opposite sides of the central hot-melt strip. The grid is made up of strands of conductive and non-conductive yarns composing the respective transverse and longitudinal weaves of the grid. The conductive yarn has a multi-stranded glass core surrounded and covered by a lead sheath, whereas the non-conductive yarn has a multi-stranded glass core surrounded and covered by a thermally activated sizing.

Rippel, Wally E.↗
NASA NTRS2004

Space Shuttle Upgrades: Long Life Alkaline Fuel Cell

NASA has utilized the alkaline fuel cell technology to provide electrical power for manned launch vehicles such as Gemini, Apollo, and the Space Shuttle. The current Shuttle alkaline fuel cells are procured from UTC Fuel Cells, a United Technologies Company. The alkaline fuel cells are very reliable but the operating life is limited to 2600 hours due to voltage degradation of the individual cells. The main limiting factor in the life of the cells is corrosion of the cell's fiberglass/epoxy frame by the aqueous potassium hydroxide electrolyte. To reduce operating costs, the orbiter program office approved the Long Life Alkaline Fuel Cell (LLAFC) program as a shuttle upgrade in 1999 to increase the operating life of the fuel cell powerplant to 5000 hours. The LLAFC program incorporates improving the cell by extending the length of the corrosion path, which reduces the cell frame corrosion. UTCFC performed analysis to understand the fundamental mechanisms that drive the cell frame corrosion. The analysis indicated that the corrosion path started along the bond line between the cathode and the cell frame. Analysis also showed that the oxygen available at the cathode, the catalyst on the electrode, and the electrode substrate all supported or intensified the corrosion. The new cell design essentially doubled the corrosion path to mitigate the problem. A 10-cell stack was tested for 5000 hours during the development phase of this program to verify improved cell performance. A complete 96-cell stack was then tested for 5000 hours during the full manned-space qualification phase of this program. Additional upgrades to the powerplant under this program are: replacing the aluminum body in the pressure regulator with stainless steel to reduce corrosion, improving stack insulator plate with improved resistance to stress failure and improved temperature capability, and replacing separator plate elastomer seals with a more durable material and improved seal retention.

Kerri McCurdy↗
NASA NTRS1986

Lead-acid battery

A sealed, low maintenance battery (10, 100) is formed of a casing (14, 102) having a sealed lid (12, 104) enclosing cell compartments (22, 110) formed by walls (24, 132). The cells comprise a stack (26) of horizontally disposed negative active plates (30) and positive active plates (28) interspersed with porous, resilient separator sheets (30). Each plate has a set of evenly spaced tigs (40, 41) disposed on one side thereof; like polarity tigs being disposed on one side and opposite polarity tigs on the other. Columns of tigs are electrically and mechanically joined by vertical bus bars (46). The bus bars contain outwardly projecting arms (56) of opposite polarity which are electrically joined at each partition wall (24) to electrically connect the cells in series. The stack is compressed by biasing means such as resilient pad (58) attached to the lid or by joining the tigs (52) to the post (48) at a distance less than the thickness of the mat (124). The end bus bars (46) are joined to straps (60, 62) which connect to the terminals (16, 18). The negative plates contain more capacity than the positive plates and the starved electrolyte imbibed in the separator sheets permits pressurized operation during which oxygen diffuses through the separator sheet to the negative plate where it recombines. Excess pressure is relieved through the vent and pressure relief valve (20).

Edwards, Dean B.↗
DOE OSTI2020

How To Maintain Effective IAEA Safeguards While Reducing Facility Impact

For almost twenty years, inspectors from the International Atomic Energy Agency have been visiting the K-Area Material Storage facility at the Savannah River Site where excess plutonium has been placed under IAEA safeguards as part of the United States Volunatary Offer Agreement. During that time, the mission of K-Area Complex has expanded from storage of nuclear matieral to glovebox operations in support of the National Nuclear Security Administration’s Plutonium Disposition program. With this change in mission, it is becoming increasingly challenging to manage facility staff radiation exposure and operating activities during the IAEA’s annual Physcial Inventory Verifications (PIV). This study has identified both near-term and long-term recommendations for IAEA monitoring protocols that would allow the IAEA to maintain effective safeguards of the material while decreasing the impact to the facility. A statisitical analysis has shown that reducing the number of containers measured during an annual PIV from 12 to 4 still ensures a high level of confidence in the confidence while reducing the inspector time in the facility amd with a corresponding significant reduction in personnel radiation exposure. A modified installation pattern of Remotely Monitored Sealing Arrays (RMSAs) is also proposed utilizing only the outer rows of arrays of stored material containers in the Stack Area (SA). The modified RMSA placement will provide equivalent protection, while significantly reducing personnel radiological exposure, manpower requirements and associated costs. With advances in technology, there are additional potential options in containment/surveillance and continuity of knowledge that would allow the agency to be outside of the facility during PIV measurements and have confidence in the accuracy and authencitity of the results.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
NASA NTRS1989

Transient Pressure Test Article Test Program

The Transient Pressure Test Article (TPTA) test program is being conducted at a new test facility located in the East Test Area at the National Aeronautics and Space Administration's (NASA's) Marshall Space Flight Center (MSFC) in Huntsville, Alabama. This facility, along with the special test equipment (STE) required for facility support, was constructed specifically to test and verify the sealing capability of the Redesigned Solid Rocket Motor (RSRM) field, igniter, and nozzle joints. The test article consists of full scale RSRM hardware loaded with inert propellant and assembled in a short stack configuration. The TPTA is pressurized by igniting a propellant cartridge capable of inducing a pressure rise rate which stimulates the ignition transient that occurs during launch. Dynamic loads are applied during the pressure cycle to simulate external tank attach (ETA) strut loads present on the ETA ring. Sealing ability of the redesigned joints is evaluated under joint movement conditions produced by these combined loads since joint sealing ability depends on seal resilience velocity being greater than gap opening velocity. Also, maximum flight dynamic loads are applied to the test article which is either pressurized to 600 psia using gaseous nitrogen (GN2) or applied to the test article as the pressure decays inside the test article on the down cycle after the ignition transient cycle. This new test facility is examined with respect to its capabilities. In addition, both the topic of test effectiveness versus space vehicle flight performance and new aerospace test techniques, as well as a comparison between the old SRM design and the RSRM are presented.

Vibbart, Charles M.↗