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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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All sourcesNASA NTRSDOE OSTI
NASA NTRS2006

Decision Support Methods and Tools

This paper is one of a set of papers, developed simultaneously and presented within a single conference session, that are intended to highlight systems analysis and design capabilities within the Systems Analysis and Concepts Directorate (SACD) of the National Aeronautics and Space Administration (NASA) Langley Research Center (LaRC). This paper focuses on the specific capabilities of uncertainty/risk analysis, quantification, propagation, decomposition, and management, robust/reliability design methods, and extensions of these capabilities into decision analysis methods within SACD. These disciplines are discussed together herein under the name of Decision Support Methods and Tools. Several examples are discussed which highlight the application of these methods within current or recent aerospace research at the NASA LaRC. Where applicable, commercially available, or government developed software tools are also discussed

Green, Lawrence L.↗
NASA NTRS1993

Telemetry ground system development via the component approach

NASA's deployment of major space projects such as the Earth Observing System (EOS) will demand increased functionality and ground-based telemetry processing performance well above current capabilities. At the NASA/Goddard Space Flight Center, custom hardware and software components have been developed and combined into a unique architecture to address this problem. The hardware components utilize Application Specific Integrated Circuits (ASIC's) developed specifically to support NASA's telemetry data systems needs and designed to handle data rates up to 300 Mbps. A generalized set of software components, called the Telemetry Processing Control Environment facilitate the rapid construction of control and monitoring functions for the ground-based telemetry processing systems. This combination of hardware and software elements enables rapid construction of flexible, cost-effective telemetry processing systems capable of meeting the performance requirements facing NASA in the coming decade.

Thorn, Karen E.↗
NASA NTRS2016

HIAD Advancements and Extension of Mission Applications

The Hypersonic Inflatable Aerodynamic Decelerator (HIAD) technology has made significant advancements over the last decade with flight test demonstrations and ground development campaigns. The first generation (Gen-1) design and materials were flight tested with the successful third Inflatable Reentry Vehicle Experiment flight test of a 3-m HIAD (IRVE-3). Ground development efforts incorporated materials with higher thermal capabilities for the inflatable structure (IS) and flexible thermal protection system (F-TPS) as a second generation (Gen-2) system. Current efforts and plans are focused on extending capabilities to improve overall system performance and reduce areal weight, as well as expand mission applicability. F-TPS materials that offer greater thermal resistance, and ability to be packed to greater density, for a given thickness are being tested to demonstrated thermal performance benefits and manufacturability at flight-relevant scale. IS materials and construction methods are being investigated to reduce mass, increase load capacities, and improve durability for packing. Previous HIAD systems focused on symmetric geometries using stacked torus construction. Flight simulations and trajectory analysis show that symmetrical HIADs may provide L/D up to 0.25 via movable center of gravity (CG) offsets. HIAD capabilities can be greatly expanded to suit a broader range of mission applications with asymmetric shapes and/or modulating L/D. Various HIAD concepts are being developed to provide greater control to improve landing accuracy and reduce dependency upon propulsion systems during descent and landing. Concepts being studied include a canted stack torus design, control surfaces, and morphing configurations that allow the shape to be actively manipulated for flight control. This paper provides a summary of recent HIAD development activities, and plans for future HIAD developments including advanced materials, improved construction techniques, and alternate geometry concepts that will greatly expand HIAD mission applications.

Johnson, R. Keith↗
DOE OSTI2024

National Reactor Innovation Center (NRIC) Chobani

Authorized by the Nuclear Energy Innovation Capabilities Act (NEICA) Partner with industry to bridge the gap between research and commercial deployment Leverage national lab expertise and infrastructure Manage demonstrations to success

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS2001

Development of Electronics for Low-Temperature Space Missions

Electronic systems that are capable of operating at cryogenic temperatures will be needed for many future NASA space missions, including deep space probes and spacecraft for planetary surface exploration. In addition to being able to survive the harsh deep space environment, low-temperature electronics would help improve circuit performance, increase system efficiency, and reduce payload development and launch costs. Terrestrial applications where components and systems must operate in low-temperature environments include cryogenic instrumentation, superconducting magnetic energy storage, magnetic levitation transportation systems, and arctic exploration. An ongoing research and development project for the design, fabrication, and characterization of low-temperature electronics and supporting technologies at NASA Glenn Research Center focuses on efficient power systems capable of surviving in and exploiting the advantages of low-temperature environments. Supporting technologies include dielectric and insulating materials, semiconductor devices, passive power components, optoelectronic devices, and packaging and integration of the developed components into prototype flight hardware. An overview of the project is presented, including a description of the test facilities, a discussion of selected data from component testing, and a presentation of ongoing research activities being performed in collaboration with various organizations.

Patterson, Richard L.↗
DOE OSTI2025

Effect of post-weld heat treatment on microstructure and mechanical properties of rotary inertia friction welded dissimilar 422-4140 martensitic steel piston joints

The study investigated how post‐weld heat treatment (PWHT) temperature affects the microstructure and localized deformation/fracture during bend testing of rotary inertia friction welds (RIFW) between AISI 422 stainless steel and AISI 4140 steel. RIFW produced a fully martensitic interface with approximately 550 HV hardness in both the thermo-mechanically affected (TMAZ) and heat‐affected zones (HAZ). Due to differences in temper resistance, the 4140 TMAZ/HAZ softened progressively under PWHT temperatures from 525 °C to 700 °C, while the 422 TMAZ unexpectedly maintained about 550 HV up to 600 °C before significantly softening at temperatures ≥625 °C. This asymmetric softening generated steep hardness gradients across the interface at temperatures ≤600 °C. Furthermore, carbon migration across the interface was minimal up to 600 °C, moderate at 625 °C, and by 700 °C produced a carbide‐rich eutectoid layer in the 422 TMAZ alongside a carbon‐depleted soft ferrite layer in the 4140 TMAZ. Strain during bending was PWHT‐dependent, concentrating on the 4140 side; in as-welded joints, the high hardness led to deformation and crack initiation in the base metals, whereas in PWHT samples, cracking initiated in the softened 4140 TMAZ near the interface. The intermediate PWHT temperature of 625 °C offered the best balance of limited carbon diffusion across the interface, relatively low peak weld hardness and minimized hardness gradients across the interface, more homogenous deformation, and good bend test performance.

4140 low-alloy steel↗
DOE OSTI2025

Overcoming the thermal conductivity versus oxidation resistance barrier in high-temperature steels

Heat-resistant steels with high chromium additions (≥5 weight percent) are critical for many high temperature energy and manufacturing applications, including heat exchangers, pistons for engines, and dies for metal working and casting. However, while high chromium additions increase oxidation resistance at elevated temperatures, they also compromise thermal conductivity, resulting in a metallurgical trade-off between these two important properties. Here we show that a microstructure with both higher thermal conductivity and improved oxidation resistance at elevated temperatures is achieved in a unique steel with only 1 weight percent chromium, thereby overcoming the long-standing metallurgical trade-off. This is accomplished through a tailored thermal treatment that produces a tempered martensitic matrix with low solute content and a fine dispersion of copper precipitates and molybdenum enriched carbides. A further discovery is that the resultant thermally grown oxide includes an iron-copper-manganese-enriched outer layer that provides high-temperature oxidation protection equivalent to heat-resistant steels with five times the chromium content and 25% lower thermal conductivity.

Pierce, Dean T. [Oak Ridge National Laboratory (OR↗
DOE OSTI2025

Rotary Inertia Friction Welding of Dissimilar High-Strength 422 Martensitic Stainless Steel and 4140 Low Alloy Steel for Heavy-Duty Engine Piston Fabrication

AISI 422 martensitic stainless steel with superior high temperature performance (oxidation resistance and strength) is under evaluation for replacing current heavy-duty piston crown materials, AISI 4140 martensitic steel and micro alloyed steel (MAS) 38MnSiVS5, to fabricate a multimaterial piston. This multimaterial piston concept further improved power density and fuel economy by allowing heavyduty diesel engines to operate at higher temperatures and pressures. Joining AISI 422 steel piston crowns with AISI 4140 steel piston skirts is a key manufacturing step for this multimaterial piston. However, the significant differences in strength, elevated temperature flow stress, alloy chemistry, and temper resistance between these two martensitic steels cause some weldability issues (cracking) and metallurgical challenges (alloying element migration/segregation) when using conventional fusion-based welding processes. Rotary inertia friction welding (RIFW), a solid-state welding process, has been the preferred method to join 4140 crowns to 4140 skirts (and MAS crowns to MAS skirts) in high-volume production of current heavy-duty diesel engine pistons. It has been used to join these two materials with relatively comparable alloy chemistry to fabricate pistons with MAS skirts and 4140 crowns. Meanwhile, RIFW has also been a preferred method of dissimilar metal welding. However, RIFW of dissimilar high-strength martensitic steels has yet to be widely pursued. The interfacial microstructure complexities created by the thermomechanical process and highly nonequilibrium phase transformations during RIFW are a significant challenge for understanding and predicting their joining behavior and have not been reported in detail. Here, in this work, defect-free AISI 422 steel-AISI 4140 multimaterial pistons were successfully fabricated using the RIFW process. The interfacial microstructure and mechanical properties of dissimilar 422/4140 steel RIFW in the as-welded condition were experimentally studied in detail. The results provide critical baseline information for understanding RIFW mechanisms and guiding subsequent postweld heat treatment (PWHT) practice.

36 MATERIALS SCIENCE↗
NASA NTRS2011

Capabilities, Design, Construction and Commissioning of New Vibration, Acoustic, and Electromagnetic Capabilities Added to the World's Largest Thermal Vacuum Chamber at NASA's Space Power Facility

NASA s human space exploration plans developed under the Exploration System Architecture Studies in 2005 included a Crew Exploration Vehicle launched on an Ares I launch vehicle. The mass of the Crew Exploration Vehicle and trajectory of the Ares I coupled with the need to be able to abort across a large percentage of the trajectory generated unprecedented testing requirements. A future lunar lander added to projected test requirements. In 2006, the basic test plan for Orion was developed. It included several types of environment tests typical of spacecraft development programs. These included thermal-vacuum, electromagnetic interference, mechanical vibration, and acoustic tests. Because of the size of the vehicle and unprecedented acoustics, NASA conducted an extensive assessment of options for testing, and as result, chose to augment the Space Power Facility at NASA Plum Brook Station, of the John H. Glenn Research Center to provide the needed test capabilities. The augmentation included designing and building the World s highest mass capable vibration table, the highest power large acoustic chamber, and adaptation of the existing World s largest thermal vacuum chamber as a reverberant electromagnetic interference test chamber. These augmentations were accomplished from 2007 through early 2011. Acceptance testing began in Spring 2011 and will be completed in the Fall of 2011. This paper provides an overview of the capabilities, design, construction and acceptance of this extraordinary facility.

Motil, Susan M.↗
NASA NTRSDate not supplied

Radiative Heat Transfer Capability Implemented in OpenNCC for Conjugate Heat Transfer Applications

Thermal efficiency of gas turbine engine increases as the temperature and pressure at the combustor increases. Consequently, the materials used inside a combustor must survive an increasingly challenging environment. For this reason, accurate assessment of heat transfer is crucial for combustor design. While all three modes of heat transfer are present inside a combustor, the focus of this paper is the thermal radiation. Radiative heat transfer in a gas turbine combustors are particularly interesting from three reasons. Firstly, the radiative heat loss from the combustion region may affect the emission performance. Secondly, the cooling air will protect the liner from convection but not necessary from radiation. Finally, it is less frequently incorporated in CFD analysis than other forms of heat transfer. In this work, radiative heat transfer using discrete ordinate method has been incorporated in OpenNCC (a publicly releasable version of the National Combustion Code) developed at NASA Glenn Research Center. Aside from massively parallel computation capability using MPI and the ability to utilize unstructured mesh, the current implementation includes two types of spectral models, namely, the weighted some of gray gas model and the full spectrum correlated k-distribution model. After presenting the theory and the strategy of implementation, results of validation cases for gray gas and spectral models will be presented. While the implementation of the radiation solver is intended for gas turbine application, the radiation solver can run independently from the convection/combustion solver and the same theory can be applied to other application.

OpenNCC↗
NASA NTRSDate not supplied

Radiative Heat Transfer Capability Implemented in OpenNCC for Conjugate Heat Transfer Applications

Thermal efficiency of gas turbine engine increases as the temperature and pressure at the combustor increases. Consequently, the materials used inside a combustor must survive an increasingly challenging environment. For this reason, accurate assessment of heat transfer is crucial for combustor design. While all three modes of heat transfer are present inside a combustor, the focus of this paper is the thermal radiation. Radiative heat transfer in a gas turbine combustors are particularly interesting from three reasons. Firstly, the radiative heat loss from the combustion region may affect the emission performance. Secondly, the cooling air will protect the liner from convection but not necessary from radiation. Finally, it is less frequently incorporated in CFD analysis than other forms of heat transfer. In this work, radiative heat transfer using discrete ordinate method has been incorporated in OpenNCC (a publicly releasable version of the National Combustion Code) developed at NASA Glenn Research Center. Aside from massively parallel computation capability using MPI and the ability to utilize unstructured mesh, the current implementation includes two types of spectral models, namely, the weighted some of gray gas model and the full spectrum correlated k-distribution model. After presenting the theory and the strategy of implementation, results of validation cases for gray gas and spectral models will be presented. While the implementation of the radiation solver is intended for gas turbine application, the radiation solver can run independently from the convection/combustion solver and the same theory can be applied to other application.

OpenNCC↗
NASA NTRS1992

A compressible Navier-Stokes solver with two-equation and Reynolds stress turbulence closure models

This report outlines the development of a general purpose aerodynamic solver for compressible turbulent flows. Turbulent closure is achieved using either two equation or Reynolds stress transportation equations. The applicable equation set consists of Favre-averaged conservation equations for the mass, momentum and total energy, and transport equations for the turbulent stresses and turbulent dissipation rate. In order to develop a scheme with good shock capturing capabilities, good accuracy and general geometric capabilities, a multi-block cell centered finite volume approach is used. Viscous fluxes are discretized using a finite volume representation of a central difference operator and the source terms are treated as an integral over the control volume. The methodology is validated by testing the algorithm on both two and three dimensional flows. Both the two equation and Reynolds stress models are used on a two dimensional 10 degree compression ramp at Mach 3, and the two equation model is used on the three dimensional flow over a cone at angle of attack at Mach 3.5. With the development of this algorithm, it is now possible to compute complex, compressible high speed flow fields using both two equation and Reynolds stress turbulent closure models, with the capability of eventually evaluating their predictive performance.

Navier-Stoke solver↗
NASA NTRS2009

JSC Case Study: Fleet Experience with E-85 Fuel

JSC has used E-85 as part of an overall strategy to comply with Presidential Executive Order 13423 and the Energy Policy Act. As a Federal fleet, we are required to reduce our petroleum consumption by 2 percent per year, and increase the use of alternative fuels in our vehicles. With the opening of our onsite dispenser in October 2004, JSC became the second federal fleet in Texas and the fifth NASA center to add E-85 fueling capability. JSC has a relatively small number of GSA Flex Fuel fleet vehicles at the present time (we don't include personal vehicles, or other contractor's non-GSA fleet), and there were no reasonably available retail E-85 fuel stations within a 15-minute drive or within five miles (one way). So we decided to install a small 1000 gallon onsite tank and dispenser. It was difficult to obtain a supplier due to our low monthly fuel consumption, and our fuel supplier contract has changed three times in less than five years. We experiences a couple of fuel contamination and quality control issues. JSC obtained good information on E-85 from the National Ethanol Vehicle Coalition (NEVC). We also spoke with Defense Energy Support Center, (DESC), Lawrence Berkeley Laboratory, and US Army Fort Leonard Wood. E-85 is a liquid fuel that is dispensed into our Flexible Fuel Vehicles identically to regular gasoline, so it was easy for our vehicle drivers to make the transition.

Hummel, Kirck↗
NASA NTRS2012

Simulation and Flight Test Capability for Testing Prototype Sense and Avoid System Elements

NASA Langley Research Center (LaRC) and The MITRE Corporation (MITRE) have developed, and successfully demonstrated, an integrated simulation-to-flight capability for evaluating sense and avoid (SAA) system elements. This integrated capability consists of a MITRE developed fast-time computer simulation for evaluating SAA algorithms, and a NASA LaRC surrogate unmanned aircraft system (UAS) equipped to support hardware and software in-the-loop evaluation of SAA system elements (e.g., algorithms, sensors, architecture, communications, autonomous systems), concepts, and procedures. The fast-time computer simulation subjects algorithms to simulated flight encounters/ conditions and generates a fitness report that records strengths, weaknesses, and overall performance. Reviewed algorithms (and their fitness report) are then transferred to NASA LaRC where additional (joint) airworthiness evaluations are performed on the candidate SAA system-element configurations, concepts, and/or procedures of interest; software and hardware components are integrated into the Surrogate UAS research systems; and flight safety and mission planning activities are completed. Onboard the Surrogate UAS, candidate SAA system element configurations, concepts, and/or procedures are subjected to flight evaluations and in-flight performance is monitored. The Surrogate UAS, which can be controlled remotely via generic Ground Station uplink or automatically via onboard systems, operates with a NASA Safety Pilot/Pilot in Command onboard to permit safe operations in mixed airspace with manned aircraft. An end-to-end demonstration of a typical application of the capability was performed in non-exclusionary airspace in October 2011; additional research, development, flight testing, and evaluation efforts using this integrated capability are planned throughout fiscal year 2012 and 2013.

Howell, Charles T.↗
NASA NTRS2016

Space Launch System Spacecraft and Payload Elements: Making Progress Toward First Launch

Significant and substantial progress continues to be accomplished in the design, development, and testing of the Space Launch System (SLS), the most powerful human-rated launch vehicle the United States has ever undertaken. Designed to support human missions into deep space, SLS is one of three programs being managed by the National Aeronautics and Space Administration's (NASA's) Exploration Systems Development directorate. The Orion spacecraft program is developing a new crew vehicle that will support human missions beyond low Earth orbit, and the Ground Systems Development and Operations program is transforming Kennedy Space Center into next-generation spaceport capable of supporting not only SLS but also multiple commercial users. Together, these systems will support human exploration missions into the proving ground of cislunar space and ultimately to Mars. SLS will deliver a near-term heavy-lift capability for the nation with its 70 metric ton (t) Block 1 configuration, and will then evolve to an ultimate capability of 130 t. The SLS program marked a major milestone with the successful completion of the Critical Design Review in which detailed designs were reviewed and subsequently approved for proceeding with full-scale production. This marks the first time an exploration class vehicle has passed that major milestone since the Saturn V vehicle launched astronauts in the 1960s during the Apollo program. Each element of the vehicle now has flight hardware in production in support of the initial flight of the SLS -- Exploration Mission-1 (EM-1), an un-crewed mission to orbit the moon and return. Encompassing hardware qualification, structural testing to validate hardware compliance and analytical modeling, progress in on track to meet the initial targeted launch date in 2018. In Utah and Mississippi, booster and engine testing are verifying upgrades made to proven shuttle hardware. At Michoud Assembly Facility in Louisiana, the world's largest spacecraft welding tool is producing tanks for the SLS core stage. This paper will particularly focus on work taking place at Marshall Space Flight Center (MSFC) and United Launch Alliance in Alabama, where upper stage and adapter elements of the vehicle are being constructed and tested. Providing the Orion crew capsule/launch vehicle interface and in-space propulsion via a cryogenic upper stage, the Spacecraft/Payload Integration and Evolution (SPIE) Element serves a key role in achieving SLS goals and objectives. The SPIE element marked a major milestone in 2014 with the first flight of original SLS hardware, the Orion Stage Adapter (OSA) which was used on Exploration Flight Test-1 with a design that will be used again on EM-1. Construction is already underway on the EM-1 Interim Cryogenic Propulsion Stage (ICPS), an in-space stage derived from the Delta Cryogenic Second Stage. Manufacture of the Orion Stage Adapter and the Launch Vehicle Stage Adapter is set to begin at the Friction Stir Facility located at MSFC while structural test articles are either completed (OSA) or nearing completion (Launch Vehicle Stage Adapter). An overview is provided of the launch vehicle capabilities, with a specific focus on SPIE Element qualification/testing progress, as well as efforts to provide access to deep space regions currently not available to the science community through a secondary payload capability utilizing CubeSat-class satellites.

Schorr, Andrew A.↗
NASA NTRS2015

The NASA MSFC Electrostatic Levitation (ESL) Laboratory: Summary of Capabilities, Recent Upgrades, and Future Work

The NASA Marshall Space Flight Center (MSFC) electrostatic levitation (ESL) laboratory has a long history of providing materials research and thermophysical property data. A summary of the labs capabilities, recent upgrades, and ongoing and future work will be provided. The laboratory has recently added two new capabilities to its main levitation chamber: a rapid quench system and an oxygen control system. The rapid quench system allows samples to be dropped into a quench vessel that can be filled with a low melting point material, such as a gallium or indium alloy. Thereby allowing rapid quenching of undercooled liquid metals. The oxygen control system consists of an oxygen sensor, oxygen pump, and a control unit. The sensor is a potentiometric device that determines the difference in oxygen activity between two gas compartments separated by an electrolyte, which is yttria-stabilized zirconia. The pump utilizes coulometric titration to either add or remove oxygen. The system is controlled by a desktop control unit, which can also be accessed via a computer. This system allows the oxygen partial pressure within the vacuum chamber to be measured and controlled, theoretically in the range from 10-36 to 100 bar. The ESL laboratory also has an emissometer, called the High-Temperature Emissivity Measurement System (HiTEMS). This system measures the spectral emissivity of materials from 600degC to 3,000degC. The system consists of a vacuum chamber, a black body source, and a Fourier Transform Infrared Spectrometer (FTIR). The system utilizes optics to swap the signal between the sample and the black body. The system was originally designed to measure the hemispherical spectral emissivity of levitated samples, which are typically 2.5mm spheres. Levitation allows emissivity measurements of molten samples, but more work is required to develop this capability. The system is currently setup measure the near-normal spectral emissivity of stationary samples, which has been used to take measurements of ablative materials, rocket nozzle coating materials, and materials for spacecraft instruments.

SanSoucie, Michael P.↗
DOE OSTI2023

Extending the distributed computing infrastructure of the CMS experiment with HPC resources

Particle accelerators are an important tool to study the fundamental properties of elementary particles. Currently the highest energy accelerator is the LHC at CERN, in Geneva, Switzerland. Each of its four major detectors, such as the CMS detector, produces dozens of Petabytes of data per year to be analyzed by a large international collaboration. The processing is carried out on the Worldwide LHC Computing Grid, that spans over more than 170 compute centers around the world and is used by a number of particle physics experiments. Recently the LHC experiments were encouraged to make increasing use of HPC resources. While Grid resources are homogeneous with respect to the used Grid middleware, HPC installations can be very different in their setup. In order to integrate HPC resources into the highly automatized processing setups of the CMS experiment a number of challenges need to be addressed. For processing, access to primary data and metadata as well as access to the software is required. At Grid sites all this is achieved via a number of services that are provided by each center. However at HPC sites many of these capabilities cannot be easily provided and have to be enabled in the user space or enabled by other means. At HPC centers there are often restrictions regarding network access to remote services, which is again a severe limitation. The paper discusses a number of solutions and recent experiences by the CMS experiment to include HPC resources in processing campaigns.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
NASA NTRS1991

Space Station Freedom payload operations in the 21st century

The modified approach to the accomodation of payload operations in light of both flight and ground systems changes to the operational concept for the Space Station Freedom is described. The challenges for the man-tended capability payload operations and those for the permanently manned capability are assessed. An overview of payload operations is presented including payload accomodations, operations modes, ground systems, the payload operations integration center, and the evolution from man-tended capability to permanent manning.

Griner, C. S.↗