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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 541 records · Page 30

Experimental study of vibration isolation in thin-walled structural assemblies with embedded total-internal-reflection metasurfaces

The concept of total-internal-reflection elastic metasurface (TIR-MS) was recently proposed [1] and employed within flexible planar waveguides in order to create highly subwavelength sound-hard barriers impenetrable to low frequency elastic waves. The underlying physical mechanism relies on the design of engineered interfaces exhibiting extreme phase gradients such that any incoming wave at, approximately, any incidence will experience total-internal-reflection conditions. At the design frequency, the metasurface exhibits a large phase gradient such that, in accordance with the generalized Snell's law, the first critical angle is virtually always exceeded. It is worth noting that in practical realizations, the actual total reflection performance might vary depending on the angle of incidence. This dependence is due to the discrete implementation of the metasurface which results in diffraction effects. This paper presents the results of an experimental study that explores the vibration isolation performance of TIR-MS when applied to structures made of complex combinations of different elastic waveguides (e.g. bolted assemblies of beams, plates, and shells). Such system can be seen as a prototypical structure emulating mechanical assemblies of practical interest for many engineering applications. Experimental results confirm that, when the TIR-MS is embedded in the host waveguide, significant vibration isolation capabilities are achieved under quasi-omnidirectional incidence and highly subwavelength excitation conditions (i.e. the ratio of the operating wavelength to the width of the TIR-MS is approximately 5.25). Furthermore, these experimental results suggest new interesting directions to achieve vibration isolation and mechanical energy filtering for practical engineering systems.

42 ENGINEERING↗

Advances in the Lightweight Air-Liquid Composite Heat Exchanger Development for Space Exploration Applications

An advanced, lightweight composite modular Air/Liquid (A/L) Heat Exchanger (HX) Prototype for potential space exploration thermal management applications was successfully designed, manufactured, and tested. This full-scale Prototype consisting of 19 modules, based on recommendations from its predecessor Engineering Development unit (EDU) but with improved thermal characteristics and manufacturability, was 11.2 % lighter than the EDU and achieves potentially a 42.7% weight reduction from the existing state-of-the-art metallic HX demonstrator. However, its higher pressure drop (0.58 psid vs. 0.16 psid of the metal HX) has to be mitigated by foam material optimizations and design modifications including a more systematic air channel design. Scalability of the Prototype design was validated experimentally by comparing manufacturability and performance between the 2-module coupon and the 19-module Prototype. The Prototype utilized the thermally conductive open-cell carbon foam material but with lower density and adopted a novel high-efficiency cooling system with significantly increased heat transfer contact surface areas, improved fabricability and manufacturability compared to the EDU. Even though the Prototype was required to meet both the thermal and the structural specifications, accomplishing the thermal requirement was a higher priority goal for this first version. Overall, the Prototype outperformed both the EDU and the corresponding metal HX, particularly in terms of specific heat transfer, but achieved 93.4% of the target. The next generation Prototype to achieve the specification target, 3,450W would need 24 core modules based on the simple scaling factor. The scale-up Prototype will weigh about 14.7 Kg vs. 21.6 Kg for the metal counterpart. The advancement of this lightweight composite HX development from the original feasibility test coupons to EDU to Prototype is discussed in this paper.

Shin, E. Eugene↗

Heterogeneous Integration Technologies for High-temperature, High-density, Low-profile Power Modules of Wide Bandgap Devices in Electric Drive Applications (Final Technical Report)

The goal of this project is to develop packaging technologies for making high-temperature, high-density, and low-profile wide-bandgap (WBG) power electronics modules for electric drives. These modules are aimed at enabling the DOE’s University Consortium to reach its 2025 inverter targets of ≥ 100 kW/L and ≤ 2.7 $/kW. The specific objectives are to: design and fabricate SiC half-bridge power modules with double-sided cooling and parasitic inductances < 5 nH, heat flux density > 400 W/cm 2 , and working junction temperature of 200 o C; design, fabricate, and deliver a gate driver with double-sided cooled modules for the construction of a 100 kW/L inverter at Oak Ridge National Lab; and design and prototype intelligent gate drivers with integrated current sensor and a low-profile DC-DC power supply with air-core transformer for testing power modules at 200 o C junction temperature. We followed an iterative technical approach of design, simulation, fabrication, and testing of various versions of modules, current sensors, and power supply. The state-of-the-art silicon carbide devices rated at 1.2 kV and 149 A were packaged by sintered-silver bonding on an aluminum nitride direct-bond-copper substrate for high thermal conductivity, high working temperature, and high joint reliability. Porous silver posts were used to interconnect the device’s source pads to the other direct-bond-copper substrate for low mechanical stresses, ease of manufacturing, and double-sided cooling. A current sensor based on package parasitic inductance was developed to measure switching current. A dynamic feedback scheme was developed to compensate the effect of parasitic resistance and temperature variation. A constant-current class-E dc-dc converter with air-core transformer was developed. Air-core transformer was used due to the unavailability of magnetic core at high temperatures. Gate driver and power supply were integrated with the double-side cooled, high temperature SiC power modules for testing the modules at 200 o C junction temperature. Double-pulse and continuous testing of the integrated technologies validated the design and fabrication of the three component technologies. Throughout the project, we overcame the challenge for design verification caused by low prototyping yield, which then helped train the graduate students, the future workforce, to learn the engineering know-how for low-cost manufacturing of reliable products. Below is a summary of the major accomplishments of this project: development of a prototyping process for fabricating double-side cooled (1200 V, 149 A) SiC phase-leg modules capable of working to 200 o C Tj; simulation and experimental verification of the improvement of thermo-mechanical reliability of the double-side cooled SiC phase-leg module by using rigid encapsulant; design and experimental validation of a current sensor based on package parasitic inductance and a compensation solution for eliminating the effect of parasitic resistance; design and experimental validation of a low-profile power supply with six-output air-core transformer for gate driver; functional demonstration of a SiC phase-leg module integrated with its gate driver, current sensor, and an air-core power supply at 200 o C Tj in a double-pulse switching test setup and Buck converter continuous test setup; successful completion of six PhD and two MS students who are or will work at Apple Inc., Tesla Inc., Wolfspeed Inc., Microchip Inc., Monolithic Power Systems Inc., and LG Magna Inc.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Compact Analyzer/Controller For Oxygen-Enrichment System

System controls hypersonic air-breathing engine tests. Compact analyzer/controller developed, built, and tested in small-scale wind tunnel prototype of the 8' HTT (High-Temperature Tunnel). Monitors level of oxygen and controls addition of liquid oxygen to enrich atmosphere for combustion. Ensures meaningful ground tests of hypersonic engines in range of speeds from mach 4 to mach 7.

Puster, Richard L.↗

Beyond the Prototype: The Design Evolution of a Deployed AI System

Our previous experiences with deployed intelligent control agents for NASA advanced life support systems (Schreckenghost et al., 2002) inspired us to develop the Distributed Collaboration and Interaction (DCI) system to help humans and mostly-autonomous software agents work together. We discovered many unaddressed needs for human interaction with control agents that operate continuously over months to years to monitor and perform process control for regenerative life support systems. These systems recover usable water or air from the waste products created by biological systems over time. Through the DCI project, we have addressed the needs for interaction between humans and autonomous control systems. This paper describes the software engineering aspects of our experiences, first, in designing and developing a prototype of the DCI system, and later, in adjusting the implementation to make the leap from initial prototype to a system ready to be applied under varying circumstances to meet different needs. The details in the paper focus primarily on the second stage of development. The DCI system is currently deployed, operating 24/7, to assist humans to interact with an advanced Water Recovery System (WRS). In addition, we have demonstrated an application of DCI to support ground personnel in mission support roles.

Martin, C.↗

Beyond the Prototype: The Design Evolution of a Deployed AI System

Our previous experiences with deployed intelligent control agents for NASA advanced life support systems (Schreckenghost et al., 2002) inspired us to develop the Distributed Collaboration and Interaction (DCI) system to help humans and mostly-autonomous software agents work together. We discovered many unaddressed needs for human interaction with control agents that operate continuously over months to years to monitor and perform process control for regenerative life support systems. These systems recover usable water or air from the waste products created by biological systems over time. Through the DCI project, we have addressed the needs for interaction between humans and autonomous control systems. This paper describes the software engineering aspects of our experiences, first, in designing and developing a prototype of the DCI system, and later, in adjusting the implementation to make the leap from initial prototype to a system ready to be applied under varying circumstances to meet different needs. The details in the paper focus primarily on the second stage of development. The DCI system is currently deployed, operating 24/7, to assist humans to interact with an advanced Water Recovery System (WRS). In addition, we have demonstrated an application of DCI to support ground personnel in mission support roles.

Martin, Cheryl↗

Structure of an engineered multidrug transporter MdfA reveals the molecular basis for substrate recognition

MdfA is a prototypical H + -coupled multidrug transporter that is characterized by extraordinarily broad substrate specificity. The involvement of specific H-bonds in MdfA-drug interactions and the simplicity of altering the substrate specificity of MdfA contradict the promiscuous nature of multidrug recognition, presenting a baffling conundrum. Here we show the X-ray structures of MdfA variant I239T/G354E in complexes with three electrically different ligands, determined at resolutions up to 2.2 Å. Our structures reveal that I239T/G354E interacts with these compounds differently from MdfA and that I239T/G354E possesses two discrete, non-overlapping substrate-binding sites. Our results shed new light on the molecular design of multidrug-binding and protonation sites and highlight the importance of often-neglected, long-range charge-charge interactions in multidrug recognition. Beyond helping to solve the ostensible conundrum of multidrug recognition, our findings suggest the mechanistic difference between substrate and inhibitor for any H + -dependent multidrug transporter, which may open new vistas on curtailing efflux-mediated multidrug resistance.

59 BASIC BIOLOGICAL SCIENCES↗

On the broadband vibration isolation performance of nonlocal total-internal-reflection metasurfaces

The concept of a nonlocal elastic metasurface has been recently proposed and experimentally demonstrated in Zhu et al. (2020). When implemented in the form of a total-internal-reflection (TIR) interface, the metasurface can act as an elastic wave barrier that is impenetrable to deep subwavelength waves over an exceptionally wide frequency band. The underlying physical mechanism capable of delivering this broadband subwavelength performance relies on an intentionally nonlocal design that leverages long-range connections between the units forming the fundamental supercell. This paper explores the design and application of a nonlocal TIR metasurface to achieve broadband passive vibration isolation in a structural assembly made of multiple dissimilar elastic waveguides. The specific structural system comprises shell, plate, and beam waveguides, and can be seen as a prototypical structure emulating mechanical assemblies of practical interest for many engineering applications. The study also reports the results of an experimental investigation that confirms the significant vibration isolation capabilities afforded by the embedded nonlocal TIR metasurface. We report these results are particularly remarkable because they show that the performance of the nonlocal metasurface is preserved when applied to a complex structural assembly and under non-ideal incidence conditions of the incoming wave, hence significantly extending the validity of the results presented in Zhu et al. (2020). Results also confirm that, under proper conditions, the original concept of a planar metasurface can be morphed into a curved interface while still preserving full wave control capabilities.

42 ENGINEERING↗

Project Accomplishments Summary - SC12/01790.00. Concentrating Photovoltaics Component and System Research

Sandia National Laboratories (Sandia) and Cool Earth Solar, Inc. (CES) collaborated to evaluate and validate a new Concentrating Photovoltaic (CPV) technology for the utility-scale power market. Project goals included demonstration of CES's tracking and energy production mechanism and operation in a realworld configuration to validate and evaluate mechanical reliability, uptime, operations and maintenance, and energy production models. The test facility was located at Sandia California’s Livermore Valley Open Campus (LVOC). The collaboration allowed CES to quickly move from design concept to system prototype deployment in an operational environment, with approximately 17kW of engineering samples deployed. However, economic pressure from inexpensive flat panel photovoltaic modules caused a major contraction in the broader CPV market. CES was ultimately unable to overcome this economic pressure and discontinued efforts to develop their novel CPV product.

14 SOLAR ENERGY↗

Study of the collector/heat pipe cooled externally configured thermionic diode

A collector/heat pipe cooled, externally configured (heated) thermionic diode module was designed for use in a laboratory test to demonstrate the applicability of this concept as the fuel element/converter module of an in-core thermionic electric power source. During the course of the program, this module evolved from a simple experimental mock-up into an advanced unit which was more reactor prototypical. Detailed analysis of all diode components led to their engineering design, fabrication, and assembly, with the exception of the collector/heat pipe. While several designs of high power annular wicked heat pipes were fabricated and tested, each exhibited unexpected performance difficulties. It was concluded that the basic cause of these problems was the formation of crud which interfered with the liquid flow in the annular passage of the evaporator region.

Source record↗

Results of static tests of a 1/4 scale model of the Boeing YC-14 powered-lift system

One quarter scale static ground tests of the Boeing YC-14 powered lift system were conducted for correlation with full scale test results. The 1/4 scale model utilized a JT-15D turbofan engine to represent the CF6-50D engine employed on the YC-14 advanced medium STOL transport prototype aircraft. The tests included evaluation of static turning performance, static surface pressure and temperature distributions, fluctuating loads, and accelerations of portions of the wing, flaps, and fuselage. Results are presented for the landing flap configuration over an appropriate range of fan pressure ratio as affected by several variables including ground height and vortex generator modifications. Static turning angles of the order of 60 deg were obtained. The highest surface pressures and temperatures were concentrated over the upper surface of the flaps in the region immediately aft of the upper surface blown nozzle.

Hassell, J. L., Jr.↗

Fiber optic wavelength multiplexing for civil aviation applications

Research is being conducted to accelerate the acceptance of advanced technologies by the airframe manufacturers. These technologies will make the aircraft of the 1990-2000 period more efficient and less expensive to operate. The implementation of advanced control functions requires the employment of suitable onboard flight electronics systems. The present investigation is concerned with a concept for reliable onboard data distribution which is focused around the use of fiber optic wavelength division multiplexing (WDM). Attention is given to aircraft control and data distribution, the wavelength division multiplexing data bus, semiconductor lasers and optical transmitters, an optical coupler-multiplexer, and optical demultiplexers. Results of tests on the prototype WDM systems indicate that the WDM concept can be engineered into a successful system with currently available components.

Hendricks, H. D.↗

The TAME Project: Towards improvement-oriented software environments

Experience from a dozen years of analyzing software engineering processes and products is summarized as a set of software engineering and measurement principles that argue for software engineering process models that integrate sound planning and analysis into the construction process. In the TAME (Tailoring A Measurement Environment) project at the University of Maryland, such an improvement-oriented software engineering process model was developed that uses the goal/question/metric paradigm to integrate the constructive and analytic aspects of software development. The model provides a mechanism for formalizing the characterization and planning tasks, controlling and improving projects based on quantitative analysis, learning in a deeper and more systematic way about the software process and product, and feeding the appropriate experience back into the current and future projects. The TAME system is an instantiation of the TAME software engineering process model as an ISEE (integrated software engineering environment). The first in a series of TAME system prototypes has been developed. An assessment of experience with this first limited prototype is presented including a reassessment of its initial architecture.

Basili, Victor R.↗

Real-time application of knowledge-based systems

The Rapid Prototyping Facility (RPF) was developed to meet a need for a facility which allows flight systems concepts to be prototyped in a manner which allows for real-time flight test experience with a prototype system. This need was focused during the development and demonstration of the expert system flight status monitor (ESFSM). The ESFSM was a prototype system developed on a LISP machine, but lack of a method for progressive testing and problem identification led to an impractical system. The RPF concept was developed, and the ATMS designed to exercise its capabilities. The ATMS Phase 1 demonstration provided a practical vehicle for testing the RPF, as well as a useful tool. ATMS Phase 2 development continues. A dedicated F-18 is expected to be assigned for facility use in late 1988, with RAV modifications. A knowledge-based autopilot is being developed using the RPF. This is a system which provides elementary autopilot functions and is intended as a vehicle for testing expert system verification and validation methods. An expert system propulsion monitor is being prototyped. This system provides real-time assistance to an engineer monitoring a propulsion system during a flight.

Brumbaugh, Randal W.↗

CONFIG - Adapting qualitative modeling and discrete event simulation for design of fault management systems

CONFIG is a modeling and simulation tool prototype for analyzing the normal and faulty qualitative behaviors of engineered systems. Qualitative modeling and discrete-event simulation have been adapted and integrated, to support early development, during system design, of software and procedures for management of failures, especially in diagnostic expert systems. Qualitative component models are defined in terms of normal and faulty modes and processes, which are defined by invocation statements and effect statements with time delays. System models are constructed graphically by using instances of components and relations from object-oriented hierarchical model libraries. Extension and reuse of CONFIG models and analysis capabilities in hybrid rule- and model-based expert fault-management support systems are discussed.

Malin, Jane T.↗

The next generation

The next generation of computer systems are studied by examining the processes and methodologies. The present generation is ok for small projects, but not so good for large projects. They are not good for addressing the iterative nature of requirements, resolution, and implementation. They do not address complexity issues of requirements stabilization. They do not explicitly address reuse opportunities, and they do not help with people shortages. Therefore, there is a need to define and automate improved software engineering processes. Some help may be gained by reuse and prototyping, which are two sides of the same coin. Reuse library parts are used to generate good approximations to desired solutions, i.e., prototypes. And rapid prototype composition implies use of preexistent parts, i.e., reusable parts.

Yudkin, Howard↗