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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 577 records · Page 32
All sourcesNASA NTRSDOE OSTI
NASA NTRS2012

Non-Flow-Through Fuel Cell System Test Results and Demonstration on the SCARAB Rover

This presentation describes the results of the demonstration of a non-flow-through PEM fuel cell as part of a power system on the SCARAB rover at the NASA Glenn Research Center. A 16-cell non-flow-through fuel cell stack from Infinity Fuel Cell and Hydrogen, Inc. was incorporated into a power system designed to act as a range extender by providing power to the SCARAB rover s hotel loads. The power system, including the non-flow-through fuel cell technology, successfully demonstrated its goal as a range extender by powering hotel loads on the SCARAB rover, making this demonstration the first to use the non-flow-through fuel cell technology on a mobile platform.

Scheidegger, Brianne↗
NASA NTRS2006

Quantity Distance for the Kennedy Space Center Vehicle Assembly Building for Solid Propellant Fueled Launchers

The NASA KSC VAB was built to process Apollo launchers in the 1960's, and later adapted to process Space Shuttles. The VAB has served as a place to assemble solid rocket motors (5RM) and mate them to the vehicle's external fuel tank and Orbiter before rollout to the launch pad. As Space Shuttle is phased out, and new launchers are developed, the VAB may again be adapted to process these new launchers. Current launch vehicle designs call for continued and perhaps increased use of SRM segments; hence, the safe separation distances are in the process of being re-calculated. Cognizant NASA personnel and the solid rocket contractor have revisited the above VAB QD considerations and suggest that it may be revised to allow a greater number of motor segments within the VAB. This revision assumes that an inadvertent ignition of one SRM stack in its High Bay need not cause immediate and complete involvement of boosters that are part of a vehicle in adjacent High Bay. To support this assumption, NASA and contractor personnel proposed a strawman test approach for obtaining subscale data that may be used to develop phenomenological insight and to develop confidence in an analysis model for later use on full-scale situations. A team of subject matter experts in safety and siting of propellants and explosives were assembled to review the subscale test approach and provide options to NASA. Upon deliberations regarding the various options, the team arrived at some preliminary recommendations for NASA.

Stover, Steven↗
NASA NTRSDate not supplied

Automated Ply-by-Ply Lamination and In-Situ Consolidation of Thermoplastic Composite High-Contour Stiffeners for High-Rate Aircraft Manufacturing

To meet the future demand of the commercial aircraft market, composite aircraft manufacturing rates must significantly increase. NASA’s Hi-Rate Composites Aircraft Manufacturing (HiCAM) program addresses this need to advance aircraft composite manufacturing technologies. Thermoplastic composites offer a promising solution to these manufacturing demands and present an opportunity for Northrop Grumman to bring the benefits of its Automated Stiffener Forming (ASF) technology to thermoplastic processing. Within HiCAM, Northrop Grumman is evolving the ASF technology for ply-by-ply, in-situ processing of thermoplastic composite materials. The modular process accommodates flexibility in the laminate stacking, while allowing for ply drops, ply additions, and yaw, pitch, and roll in the laminate geometry. To adapt the ASF process for thermoplastics, heating technologies and roller compaction processes were investigated by manufacturing flat test coupons. These panels were evaluated by photo-microscopy, non-destructive inspection, and short beam shear tests and results were compared against baseline autoclave coupons. The results of the laminates fabricated via ASF are presented.

out of autoclave↗
DOE OSTI2025

Ion-Exchange Membrane-Centric Durability Testing and Degradation Characterization for Industry-Relevant CO 2 Reduction

Electrochemical CO 2 reduction is a promising conversion process for producing value-added fuels and chemicals from electricity and CO 2 as a sustainable carbon feedstock to domestically produce fuels and chemicals from industrial waste. Having reached industrially viable performance metrics with small-scale CO 2 electrolysis cells, the field must now increasingly focus on extending the device durability of large stacks to achieve equivalent metrics for 35,000+ hours to decrease maintenance and capital costs. Reported device lifetimes have increased in recent years, with the longest stability studies for CO, ethylene, and formic acid production being published in 2024–2025 with operation times of 4500, 1000, and 5200 h, respectively. Unfortunately, significant extension of the device durability is still required. Here, we provide an overview of ion-exchange membranes (IEMs) and provide insight into the variety of degradation mechanisms that must be overcome to enable the community to meet durability targets. In an effort to accelerate the extension of device lifetimes, we propose a general approach for characterizing CO 2 electrolysis cell degradation before and after durability testing to better elucidate the mechanisms and failure modes of IEMs in zero-gap cells. Furthermore, we encourage the adoption of operando characterizations in tandem with accelerated stress and durability tests, postulating that their combined applications will be increasingly valuable. We hope that this perspective motivates future durability studies to evaluate degradation across the entire electrolysis cell.

09 BIOMASS FUELS↗
DOE OSTI2024

Additive manufacturing of an ultrastrong, deformable Al alloy with nanoscale intermetallics

Abstract Light-weight, high-strength, aluminum (Al) alloys have widespread industrial applications. However, most commercially available high-strength Al alloys, like AA 7075, are not suitable for additive manufacturing due to their high susceptibility to solidification cracking. In this work, a custom Al alloy Al 92 Ti 2 Fe 2 Co 2 Ni 2 is fabricated by selective laser melting. Heterogeneous nanoscale medium-entropy intermetallic lamella form in the as-printed Al alloy. Macroscale compression tests reveal a combination of high strength, over 700 MPa, and prominent plastic deformability. Micropillar compression tests display significant back stress in all regions, and certain regions have flow stresses exceeding 900 MPa. Post-deformation analyses reveal that, in addition to abundant dislocation activities in Al matrix, complex dislocation structures and stacking faults form in monoclinic Al 9 Co 2 type brittle intermetallics. This study shows that proper introduction of heterogeneous microstructures and nanoscale medium entropy intermetallics offer an alternative solution to the design of ultrastrong, deformable Al alloys via additive manufacturing.

Science & Technology - Other Topics↗
NASA NTRS1990

Effect of LEO cycling on 125 Ah advanced design IPV nickel-hydrogen battery cells

An advanced 125 Ah individual pressure vessel (IPV) nickel-hydrogen cell was designed. The primary function of the advanced cell, is to store and deliver energy for long term, low earth-orbit (LEO) spacecraft missions. The new features of this design are: (1) use of 26 percent rather than 31 percent potassium hydroxide (KOH) electrolyte, (2) use of a patented catalyzed wall wick, (3) use of serrated edge separators to facilitate gaseous oxygen and hydrogen flow within the cell, while still maintaining physical contact with the wall wick for electrolyte management, and (4) use of a floating rather than a fixed stack (state-of-the-art) to accommodate nickel electrode expansion. Six 125 Ah flight cells based on this design were fabricated by Eagle-Picher. Three of the cells contain all of the advanced features (test cells) and three are the same as the test cells except they don't have catalyst on the wall wick (control cells). All six cells are in the process of being evaluated in a LEO cycle life test. The cells have accumulated about 4700 LEO cycles (60 percent DOD 10 C). There have been no cell failures, the catalyzed wall wick cells however, are performing better.

Smithrick, John J.↗
NASA NTRS1990

Effect of LEO cycling on 125 Ah advanced design IPV nickel-hydrogen battery cells

An advanced 125 Ah individual pressure vessel (IPV) nickel-hydrogen cell was designed. The primary function of the advanced cell is to store and deliver energy for long-term, low earth-orbit (LEO) spacecraft missions. The new features of this design are: (1) use of 26 percent rather than 31 percent potassium hydroxide (KOH) electrolyte, (2) use of a patented catalyzed wall wick, (3) use of serrated-edge separators to facilitate gaseous oxygen and hydrogen flow within the cell, while still maintaining physical contact with the wall wick for electrolyte management, and (4) use of a floating rather than a fixed stack (state-of-the-art) to accommodate nickel electrode expansion. Six 125-Ah flight cells based on this design were fabricated by Eagle-Picher. Three of the cells contain all of the advanced features (test cells) and three are the same as the test cells except they don't have catalyst on the wall wick (control cells). All six cells are in the process of being evaluated in a LEO cycle life test. The cells have accumulated about 4700 LEO cycles (60 percent DOD 10 C). There have been no cell failures; the catalyzed wall wick cells, however, are performing better.

Smithrick, John J.↗
NASA NTRS1993

Surface hot-film method for the measurement of transition, separation and reattachment points

A real-time method of determining positions of laminar-to-turbulent transition region, separation and reattachment points and stagnation points using an array of simultaneously operated surface-mounted hot-film sensors has been developed and applied to a wind-tunnel test of a multielement airfoil model. Determination of various types of transitions and flow directions in various regimes of flows seen on multielement airfoils are possible without precise sensor calibration or laborious post-test data analysis. The results agree with established method and theoretical methods, but determination of turbulent reattachment points are not yet satisfactory.

Nakayama, Akihiko↗
NASA NTRS1940

Flight Tests of Exhaust Gas Jet Propulsion, Special Report

Flight test s were conducted on the XP-41 airplane, equipped with a Pratt & Whitney R1830-19, 14-cylinder, air-cooled engine, to determine the increase in flight speed obtainable by the use of individual exhaust stacks directed rearwardly to obtain exhaust-gas thrust. Speed increases up to 18 miles per hour at 20,000 feet altitude were obtained using stacks having an exit area of 3.42 square inches for each cylinder. A slight increase in engine power and decrease in cylinder temperature at a given manifold pressure were obtained with the individual stacks as compared with a collector-ring installation. Exhaust-flame visibility was quite low, particularly in the rich range of fuel-air ratios.

Pnkel, Benjamin↗
NASA NTRS2012

NASA Tech Briefs, May 2012

Topics covered include: An "Inefficient Fin" Non-Dimensional Parameter to Measure Gas Temperatures Efficiently; On-Wafer Measurement of a Multi-Stage MMIC Amplifier with 10 dB of Gain at 475 GHz; Software to Control and Monitor Gas Streams; Miniaturized Laser Heterodyne Radiometer (LHR) for Measurements of Greenhouse Gases in the Atmospheric Column; Anomaly Detection in Test Equipment via Sliding Mode Observers; Absolute Position of Targets Measured Through a Chamber Window Using Lidar Metrology Systems; Goldstone Solar System Radar Waveform Generator; Fast and Adaptive Lossless Onboard Hyperspectral Data Compression System; Iridium Interfacial Stack - IrIS; Downsampling Photodetector Array with Windowing; Optical Phase Recovery and Locking in a PPM Laser Communication Link; High-Speed Edge-Detecting Line Scan Smart Camera; Optical Communications Channel Combiner; Development of Thermal Infrared Sensor to Supplement Operational Land Imager; Amplitude-Stabilized Oscillator for a Capacitance-Probe Electrometer; Automated Performance Characterization of DSN System Frequency Stability Using Spacecraft Tracking Data; Histogrammatic Method for Determining Relative Abundance of Input Gas Pulse; Predictive Sea State Estimation for Automated Ride Control and Handling - PSSEARCH; LEGION: Lightweight Expandable Group of Independently Operating Nodes; Real-Time Projection to Verify Plan Success During Execution; Automated Performance Characterization of DSN System Frequency Stability Using Spacecraft Tracking Data; Web-Based Customizable Viewer for Mars Network Overflight Opportunities; Fabrication of a Cryogenic Terahertz Emitter for Bolometer Focal Plane Calibrations; Fabrication of an Absorber-Coupled MKID Detector; Graphene Transparent Conductive Electrodes for Next- Generation Microshutter Arrays; Method of Bonding Optical Elements with Near-Zero Displacement; Free-Mass and Interface Configurations of Hammering Mechanisms; Wavefront Compensation Segmented Mirror Sensing and Control; Long-Life, Lightweight, Multi-Roller Traction Drives for Planetary Vehicle Surface Exploration; Reliable Optical Pump Architecture for Highly Coherent Lasers Used in Space Metrology Applications; Electrochemical Ultracapacitors Using Graphitic Nanostacks; Improved Whole-Blood-Staining Device; Monitoring Location and Angular Orientation of a Pill; Molecular Technique to Reduce PCR Bias for Deeper Understanding of Microbial Diversity; Laser Ablation Electrodynamic Ion Funnel for In Situ Mass Spectrometry on Mars; High-Altitude MMIC Sounding Radiometer for the Global Hawk Unmanned Aerial Vehicle; PRTs and Their Bonding for Long-Duration, Extreme-Temperature Environments; Mid- and Long-IR Broadband Quantum Well Photodetector; 3D Display Using Conjugated Multiband Bandpass Filters; Real-Time, Non-Intrusive Detection of Liquid Nitrogen in Liquid Oxygen at High Pressure and High Flow; Method to Enhance the Operation of an Optical Inspection Instrument Using Spatial Light Modulators; Dual-Compartment Inflatable Suitlock; Large-Strain Transparent Magnetoactive Polymer Nanocomposites; Thermodynamic Vent System for an On-Orbit Cryogenic Reaction Control Engine; Time Distribution Using SpaceWire in the SCaN Testbed on ISS; and Techniques for Solution- Assisted Optical Contacting.

Source record↗
NASA NTRS1992

Validation test of advanced technology for IPV nickel-hydrogen flight cells: Update

Individual pressure vessel (IPV) nickel-hydrogen technology was advanced at NASA Lewis and under Lewis contracts with the intention of improving cycle life and performance. One advancement was to use 26 percent potassium hydroxide (KOH) electrolyte to improve cycle life. Another advancement was to modify the state-of-the-art cell design to eliminate identified failure modes. The modified design is referred to as the advanced design. A breakthrough in the low-earth-orbit (LEO) cycle life of IPV nickel-hydrogen cells has been previously reported. The cycle life of boiler plate cells containing 26 percent KOH electrolyte was about 40,000 LEO cycles compared to 3,500 cycles for cells containing 31 percent KOH. The boiler plate test results are in the process of being validated using flight hardware and real time LEO testing at the Naval Weapons Support Center (NWSC), Crane, Indiana under a NASA Lewis Contract. An advanced 125 Ah IPV nickel-hydrogen cell was designed. The primary function of the advanced cell is to store and deliver energy for long-term, LEO spacecraft missions. The new features of this design are: (1) use of 26 percent rather than 31 percent KOH electrolyte; (2) use of a patented catalyzed wall wick; (3) use of serrated-edge separators to facilitate gaseous oxygen and hydrogen flow within the cell, while still maintaining physical contact with the wall wick for electrolyte management; and (4) use of a floating rather than a fixed stack (state-of-the-art) to accommodate nickel electrode expansion due to charge/discharge cycling. The significant improvements resulting from these innovations are: extended cycle life; enhanced thermal, electrolyte, and oxygen management; and accommodation of nickel electrode expansion. The advanced cell design is in the process of being validated using real time LEO cycle life testing of NWSC, Crane, Indiana. An update of validation test results confirming this technology is presented.

Smithrick, John J.↗
NASA NTRS1985

Determination of the gaseous hydrogen ductile-brittle transition in copper-nickel alloys

A series of copper-nickel alloys were fabricated, notched tensile specimens machined for each alloy, and the specimens tested in 34.5 MPa hydrogen and in air. A notched tensile ratio was determined for each alloy and the hydrogen environment embrittlement (HEE) determined for the alloys of 47.7 weight percent nickel to 73.5 weight percent nickel. Stacking fault probability and stacking fault energies were determined for each alloy using the x ray diffraction line shift and line profiles technique. Hydrogen environment embrittlement was determined to be influenced by stacking fault energies; however, the correlation is believed to be indirect and only partially responsible for the HEE behavior of these alloys.

Parr, R. A.↗
NASA NTRS1991

Some recent studies with the solid-ionomer electrochemical capacitor

Giner, Inc. has developed a high-energy-density, all-solid-ionomer electrochemical capacitor, completely free of liquid electrolyte. The novel features of this device include 1) a three-dimensional metal oxide-particulate-ionomer composite electrode structure, and 2) a unitized repeating cell element. The composite electrode structures are bonded to opposite sides of a thin sheet of a solid proton-conducting ionomer membrane and form an integrally bonded membrane and electrode assembly (MEA). Individual MEAs can be stacked in series as bipolar elements to form a multiple cell device. The discharge characteristics and energy storage properties of these devices are described. Typical capacitance measured for a unit cell is 1 F/cm(exp 2). Life testing of a multicell capacitor on an intermittent basis has shown, that over a 10,000 hour period, the capacitance and resistance of the cell has remained invariant. There has been no maintenance required on the device since it was fabricated. Other multicell units of shorter life duration have exhibited similar reliable performance characteristics. Recent work has focused on increasing the capacitance of the unitized structure and improving the low-temperature characteristics. The approaches and experimental results will be presented. Some possible advanced NASA applications for these unique all-solid-ionomer devices will be discussed.

S Sarangapani↗
NASA NTRS2006

Finger Seal: A Novel Approach to Air to Air Sealing

The gas turbine industry used a variety of sealing mechanisms to contain and direct secondary flows into and around components for cooling, and to limit leakage into and from bearing and disk cavities. The function of these seals is very important to the component efficiencies and attendant engine performance. Most of these seals are labyrinth seals, which are high-leakage seals that are costly to manufacture. In recent years, brush seals have been introduced which have demonstrated significantly reduced leakage, although they are still expensive and have exhibited wear and hysteresis difficulties. A new innovative concept called finger seal, patented by AlliedSignal, has demonstrated leakage similar to brush seals and is cheaper. The finger seal is comprised of a stack of precision photo-etched sheet metal elements, which allows intricate features to be made at very low cost and with the potential to resist wear and provide the compliance necessary to accomodate rotor excursions. Initial testing in the high-speed/high-temperature seal test facility, at the NASA Lewis Research Center, has corroborated the finger seal performance. The testing also revealed hysteresis problems with the current design. A NASA funded research project is in progress to correct the functional deficiencies of the finger seal and to refine its features to provide sufficient seal life for commercial transport engines and other long-life applications. This research will benefit the aeronautical gas turbine industry as a whole in terms of fuel consumption, operational characteristics, and cost. The first phase of this research to reduce finger seal hysteresis has been in progress for the last one year. This paper presents the results of this research to date. In future the research program will address seal performance, manufacturing, cost and life issues. The research program is expected to be completed by December 1998.

Arora, Gul↗
NASA NTRS1993

Measuring Tollmien-Schlichting Instabilities In Laminar Flow

NASA flight experiment conducted to evaluate surface-mounted hot-film sensors designed to detect Tollmien-Schlichting (T-S) instability in boundary layer in flight. New technique has considerable value in applied research aimed at extending regions of natural laminar flow on aircraft. Aids research into mechanisms leading to transition from laminar to turbulent boundary layers. Makes it practical to take measurements in many locations on wing surface for tests in flight. Useful in studying transitions in such flow as those in pipes, ducts, channels, compressors, and diffusers.

Lee, Cynthia C.↗
NASA NTRS1994

Manufacturing and testing of a magnetically suspended composite flywheel energy storage system

This paper presents the work performed to develop a multiring composite material flywheel and improvements of a magnetically suspended energy storage system. The flywheel is constructed of filament would graphite/epoxy and is interference assembled for better stress distribution to obtain higher speeds. The stationary stack in the center of the disk supports the flywheel with two magnetic bearings and provides power transfer to the flywheel with a motor/generator. The system operates under a 10(exp -4) torr environment and has been demonstrated to 20,000 rpm with a total stored energy of 15.9 Wh. When this flywheel cycles between its design speeds (45,000 to 90,000 rpm), it will deliver 242 Wh and have a usable specific energy density of 42.6 Wh/kg.

Wells, Stephen↗
DOE OSTI2025

Proximity ferroelectricity in wurtzite heterostructures

Proximity ferroelectricity is an interface-associated phenomenon in electric-field-driven polarization reversal in a non-ferroelectric polar material induced by one or more adjacent ferroelectric materials. Here, in this paper, we report proximity ferroelectricity in wurtzite ferroelectric heterostructures. In the present case, the non-ferroelectric layers are AlN and ZnO, whereas the ferroelectric layers are Al 1−x B x N, Al 1−x Sc x N and Zn 1−x Mg x O. The layered structures include nitride–nitride, oxide–oxide and nitride–oxide stacks that feature two-layer (asymmetric) and three-layer (symmetric) configurations. Ferroelectric switching in both layers is validated by multimodal characterization methods, including polarization hysteresis, anisotropic chemical etching, second harmonic generation, piezo response force microscopy, electromechanical testing and atomic resolution polarization orientation imaging in real space by scanning transmission electron microscopy. We present a physical switching model in which antipolar nuclei originate in the ferroelectric layer and propagate towards the internal non-ferroelectric interface. The domain wall leading edge produces elastic and electric fields that extend beyond the interface at close proximity, reducing the switching barrier in the non-ferroelectric layer, and allowing complete domain propagation without breakdown. Density functional theory calculations of polymorph energies, reversal barriers and domain wall energies support this model. Proximity ferroelectricity enables polarization reversal in wurtzites without the chemical or structural disorder that accompanies elemental substitution, opening new questions and opportunities regarding interface-based ferroelectricity.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Thermal Studies of CMS High-Granularity Calorimeter (HGCAL) Cassettes for the HL-LHC Upgrade

The CMS High Granularity Calorimeter (HGCAL) is a key endcap upgrade for the High-Luminosity LHC, designed to operate in an environment of extreme radiation and high particle rates. Each HGCAL cassette integrates silicon and scintillator modules, front-end ASICs, and a copper cooling plate that provides both mechanical integrity and thermal coupling using two-phase CO₂ cooling. Stable and uniform temperature control is essential to ensure reliable performance of the front-end electronics and to limit radiation-induced leakage currents in the silicon sensors. We present results from thermal characterization studies of pre-series HGCAL cassettes assembled and tested at Fermilab. Embedded RTD/PT1000 temperature sensors were used to measure gradients across copper cooling plates, module layers, and cassette edges under powering conditions representative of operation. The measured thermal behavior demonstrates effective heat transport through the cassette stack and highlights small but systematic variations correlated with geometry and assembly tolerances. These results validate the cooling performance of HGCAL cassettes.

Wang, Jinglu [Northwestern U.]↗