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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 613 records · Page 34
All sourcesNASA NTRSDOE OSTI
NASA NTRS2007

Compact and Integrated Liquid Bismuth Propellant Feed System

Operation of Hall thrusters with bismuth propellant has been shown to be a promising path toward high-power, high-performance, long-lifetime electric propulsion for spaceflight missions [1]. There has been considerable effort in the past three years aimed at resuscitating this promising technology and validating earlier experimental results indicating the advantages of a bismuth-fed Hall thruster. A critical element of the present effort is the precise metering of propellant to the thruster, since performance cannot be accurately assessed without an accurate accounting of mass flow rate. Earlier work used a pre./post-test propellant weighing scheme that did not provide any real-time measurement of mass flow rate while the thruster was firing, and makes subsequent performance calculations difficult. The motivation of the present work is to develop a precision liquid bismuth Propellant Management System (PMS) that provides hot, molten bismuth to the thruster while simultaneously monitoring in real-time the propellant mass flow rate. The system is a derivative of our previous propellant feed system [2], but the present system represents a more compact design. In addition, all control electronics are integrated into a single unit and designed to reside on a thrust stand and operate in the relevant vacuum environment where the thruster is operating, significantly increasing the present technology readiness level of liquid metal propellant feed systems. The design of various critical components in a bismuth PMS are described. These include the bismuth reservoir and pressurization system, 'hotspot' flow sensor, power system and integrated control system. Particular emphasis is given to selection of the electronics employed in this system and the methods that were used to isolate the power and control systems from the high-temperature portions of the feed system and thruster. Open loop calibration test results from the 'hotspot' flow sensor are reported, and results of integrated thruster/PMS tests demonstrate operation of the feed system in the relevant environment.

Polzin, Kurt A.↗
NASA NTRS1993

Euhedral metallic-Fe-Ni grains in extraterrestrial samples

Metallic Fe-Ni is rare in terrestrial rocks, being largely restricted to serpentinized peridotites and volcanic rocks that assimilated carbonaceous material. In contrast, metallic Fe-Ni is nearly ubiquitous among extraterrestrial samples (i.e., meteorites, lunar rocks, and interplanetary dust particles). Anhedral grains are common. For example, in eucrites and lunar basalts, most of the metallic Fe-Ni occurs interstitially between silicate grains and thus tends to have irregular morphologies. In many porphyritic chondrules, metallic Fe-Ni and troilite form rounded blebs in the mesostasis because their precursors were immiscible droplets. In metamorphosed ordinary chondrites, metallic Fe-Ni and troilite form coarse anhedral grains. Some of the metallic Fe-Ni and troilite grains has also been mobilized and injected into fractures in adjacent silicate grains where local shock-reheating temperatures reached the Fe-FeS eutectic (988 C). In interplanetary dust particles metallic Fe-Ni most commonly occurs along with sulfide as spheroids and fragments. Euhedral metallic Fe-Ni grains are extremely rare. Several conditions must be met before such grains can form: (1) grain growth must occur at free surfaces, restricting euhedral metallic Fe-Ni grains to systems that are igneous or undergoing vapor-deposition; (2) the metal (+/-) sulfide assemblage must have an appropriate bulk composition so that taenite is the liquidus phase in igneous systems or the stable condensate phase in vapor-deposition systems; and (3) metallic Fe-Ni grains must remain underformed during subsequent compaction, thermal metamorphism, and shock. Because of these restrictions, the occurrence of euhedral metallic Fe-Ni grains in an object can potentially provide important petrogenetic information. Despite its rarity, euhedral metallic Fe-Ni occurs in a wide variety of extraterrestrial materials. Some of these materials formed in the solar nebula; others formed on parent body surfaces by meteoroid impacts.

Rubin, Alan E.↗
NASA NTRS2017

Thermally-Conductive Metallic Coatings and Applications for Heat Removal on In-Space Cryogenic Vehicles

For large in-space cryogenic upper stages, substantial axial heat removal from a forward skirt by vapor-based heat interception may not be achieved by simple attachment methods unless sufficient thermal conductance from the skirt to the cooling fluid can be achieved. Preferable methods would allow for the addition of the cooling system to existing structure with minimal impact on the structure. Otherwise, significant modification to the basic structural design andor novel and complex attachment mechanisms with high effective thermal conductance are likely to be required. The approach being pursued by evolvable Cryogenics (eCryo) is to increase the thermal performance of a relatively simple attachment system by applying metallic or other thermally conductive material coatings to the mating surface area of the fluid channel where it is attached the skirt wall. The expectation of candidate materials is that the dramatic increase in conductivity of pure metals at temperatures close to liquid hydrogen vapor temperature will compensate for the reduced actual contact area typical of mechanical joints. Basic contact conductance data at low temperatures for candidate interface materials is required to enable the test approach. A test rig was designed at NASA Glenn Research Center to provide thermal contact resistance testing between small sample coupons coated with conductive material via electron beam evaporation, a low-temperature option that will not affect physical properties of base materials. Average coating thicknesses were 10 k. The test fixture was designed to mount directly to a cryocooler cold head within a vacuum test chamber. The purpose of this test was to determine qualitative contact conductance between various test samples. Results from this effort will be implemented in a sub-scale vapor-based heat interception test, where the applicability for increased heat removal on large structural skirts will be considered.

small scale testing↗
NASA NTRS2009

Improved Joining of Metal Components to Composite Structures

Systems requirements for complex spacecraft drive design requirements that lead to structures, components, and/or enclosures of a multi-material and multifunctional design. The varying physical properties of aluminum, tungsten, Invar, or other high-grade aerospace metals when utilized in conjunction with lightweight composites multiply system level solutions. These multi-material designs are largely dependent upon effective joining techAn improved method of joining metal components to matrix/fiber composite material structures has been invented. The method is particularly applicable to equipping such thin-wall polymer-matrix composite (PMC) structures as tanks with flanges, ceramic matrix composite (CMC) liners for high heat engine nozzles, and other metallic-to-composite attachments. The method is oriented toward new architectures and distributing mechanical loads as widely as possible in the vicinities of attachment locations to prevent excessive concentrations of stresses that could give rise to delaminations, debonds, leaks, and other failures. The method in its most basic form can be summarized as follows: A metal component is to be joined to a designated attachment area on a composite-material structure. In preparation for joining, the metal component is fabricated to include multiple studs projecting from the aforementioned face. Also in preparation for joining, holes just wide enough to accept the studs are molded into, drilled, or otherwise formed in the corresponding locations in the designated attachment area of the uncured ("wet') composite structure. The metal component is brought together with the uncured composite structure so that the studs become firmly seated in the holes, thereby causing the composite material to become intertwined with the metal component in the joining area. Alternately, it is proposed to utilize other mechanical attachment schemes whereby the uncured composite and metallic parts are joined with "z-direction" fasteners. The resulting "wet" assembly is then subjected to the composite-curing heat treatment, becoming a unitary structure. It should be noted that this new art will require different techniques for CMC s versus PMC's, but the final architecture and companion curing philosophy is the same. For instance, a chemical vapor infiltration (CVI) fabrication technique may require special integration of the pre-form and

Semmes, Edmund↗
NASA NTRS2018

Uninstalled Performance Predictions of a Magnesium-Fueled Ramjet Cycle in Carbon Dioxide Atmospheres

Evaluation of alternative propulsion cycles for planetary space exploration applications is motivated by ongoing emphasis of robotic science and human exploration missions and concepts. Atmosphere-breathing propulsion systems operating on their own or in a combined cycle with other engines offer the potential to increase overall propulsion efficiency and reduce the amount of propellant that must be carried on board the vehicle. The purpose of this paper is to evaluate the idealized uninstalled performance characteristics of metal-fueled ramjet systems operating in carbon dioxide atmospheres. Physics-based predictions are presented for critical and a range of supercritical conditions of the propulsion cycle.

Axdahl, Erik L.↗
NASA NTRS1975

Creep analysis capability for stiffened panel structures

A method of analysis developed for predicting permanent cyclic creep deflections in stiffened panel structures is presented. The resulting computer program (TPSC, for Thermal Protection System Creep) applies either the time hardening or strain hardening theories of creep accumulation, using iterative techniques to determine structural rotations, creep strains, and stresses as a function of time. Deflections are determined by numerical integration of structural rotations along the panel length. The analytical approach was developed for purposes of analyzing thin gage entry vehicle metallic thermal protection system panels subjected to cyclic bending loads at high temperatures. The method is applicable to any panel subjected to bending loads. Predicted panel creep deflections are compared with results from cyclic tests of subsize and full size corrugation and rib stiffened panels. Empirical equations used in the analysis were developed for each material based on correlation with tensile cyclic creep data.

Cramer, B. A.↗
NASA NTRS1984

Insulation bonding test system

A method and a system for testing the bonding of foam insulation attached to metal is described. The system involves the use of an impacter which has a calibrated load cell mounted on a plunger and a hammer head mounted on the end of the plunger. When the impacter strikes the insulation at a point to be tested, the load cell measures the force of the impact and the precise time interval during which the hammer head is in contact with the insulation. This information is transmitted as an electrical signal to a load cell amplifier where the signal is conditioned and then transmitted to a fast Fourier transform (FFT) analyzer. The FFT analyzer produces energy spectral density curves which are displayed on a video screen. The termination frequency of the energy spectral density curve may be compared with a predetermined empirical scale to determine whether a igh quality bond, good bond, or debond is present at the point of impact.

Beggs, J. M.↗
NASA NTRS1991

Alkali metal pool boiler life tests for a 25 kWe advanced Stirling conversion system

The overall operating temperature and efficiency of solar-powered Stirling engines can be improved by adding an alkali metal pool boiler heat transport system to supply heat more uniformly to the heater head tubes. One issue with liquid metal pool boilers is unstable boiling. Stable boiling is obtained with an enhanced boiling surface containing nucleation sites that promote continuous boiling. Over longer time periods, it is possible that the boiling behavior of the system will change. An 800-h life test was conducted to verify that pool boiling with the chosen fluid/surface combination remains stable as the system ages. The apparatus uses NaK boiling on a - 100 + 140 stainless steel sintered porous layer, with the addition of a small amount of xenon. Pool boiling remained stable to the end of life test. The pool boiler life test included a total of 82 cold starts, to simulate startup each morning, and 60 warm restarts, to simulate cloud cover transients. The behavior of the cold and warm starts showed no significant changes during the life test. In the experiments, the fluid/surface combination provided stable, high-performance boiling at the operating temperature of 700 C. Based on these experiments, a pool boiler was designed for a full-scale 25-kWe Stirling system.

Anderson, W. G.↗
NASA NTRS1975

Prediction and verification of creep behavior in metallic materials and components for the space shuttle thermal protection system. Volume 2: Phase 2 subsize panel cyclic creep predictions

A method for predicting permanent cyclic creep deflections in stiffened panel structures was developed. The resulting computer program may be applied to either the time-hardening or strain-hardening theories of creep accumulation. Iterative techniques were used to determine structural rotations, creep strains, and stresses as a function of time. Deflections were determined by numerical integration of structural rotations along the panel length. The analytical approach was developed for analyzing thin-gage entry vehicle metallic-thermal-protection system panels subjected to cyclic bending loads at high temperatures, but may be applied to any panel subjected to bending loads. Predicted panel creep deflections were compared with results from cyclic tests of subsize corrugation and rib-stiffened panels. Empirical equations were developed for each material based on correlation with tensile cyclic creep data and both the subsize panels and tensile specimens were fabricated from the same sheet material. For Vol. 1, see N75-21431.

Cramer, B. A.↗
NASA NTRS1992

Metal- and intermetallic-matrix composites for aerospace propulsion and power systems

The requirements for high specific strength refractory materials of prospective military, civil, and space propulsion systems are presently addressed in the context of emerging capabilities in metal- and intermetallic-matrix composites. The candidate systems encompass composite matrix compositions of superalloy, Nb-Zr refractory alloy, Cu-base, and Ti-base alloy types, as well as such intermetallics as TiAl, Ti3Al, NiAl, and MoSi2. The brittleness of intermetallic matrices remains a major consideration, as does their general difficulty of fabrication.

Doychak, J.↗
NASA NTRS2014

Low-Cost, Class D Testing of Spacecraft Photovoltaic Systems Can Reduce Risk

The end-to-end verification of a spacecraft photovoltaic power generation system requires light! Specifically, the standard practice for doing so is the Large Area Pulsed Solar Simulation (LAPSS). A LAPSS test can characterize a photovoltaic system's efficiency via its response to rapidly applied impulses of simulated sunlight. However, a Class D program on a constrained budget and schedule may not have the resources to ship an entire satellite for a LAPSS test alone. Such was the case with the Lunar Atmospheric and Dust Environment Explorer (LADEE) program, which was also averse to the risk of hardware damage during shipment. When the Electrical Power System (EPS) team was denied a spacecraft-level LAPSS test, the lack of an end-to-end power generation test elevated to a project-level technical risk. The team pulled together very limited resources to not only eliminate the risk, but build a process to monitor the health of the system through mission operations. We discuss a process for performing a low-cost, end-to-end test of the LADEE photovoltaic system. The approach combines system-level functional test, panel-level performance results, and periodic inspection (and repair) up until launch. Following launch, mission operations tools are utilized to assess system performance based on a scant amount of data. The process starts in manufacturing at the subcontractor. The panel manufacturer provides functional test and LAPSS data on each individual panel. We apply an initial assumption that the per-panel performance is sufficient to meet the power generation requirements. The manufacturer's data is also carried as the performance allocation for each panel during EPS system modeling and initial mission operations. During integration and test, a high-power, professional theater lamp system provides simulated sunlight to each panel on the spacecraft, thereby permitting a true end-to-end system test. A passing test results in a step response to nearly full-rated current at the appropriate solar array switch in the power system. A metal-halide bulb, infrared imagers, and onboard spacecraft measurements are utilized to minimize risk of thermal damage during test. Data is provided to support test results for both passing and marginal panels. Prior to encapsulation in the launch vehicle, each panel is inspected for damage by the panel manufacturer. Cracked cells or other damage is amended on-site. Because the photovoltaic test system is inexpensive and portable, each repaired panel can be re-verified immediately. Post-launch, the photovoltaic system is again characterized for per-panel deviations from the manufacturer's performance test. This proved especially tricky as the LADEE spacecraft performs only one current measurement on the entire array. The algorithm for Matlab tools to assess panel performance based on spacecraft attitude is discussed. While not as precise and comprehensive as LAPSS, the LADEE approach leverages minimal resources into an ongoing assessment program that can be applied through numerous stages of the mission. The project takes a true Class D approach in assessing the technical value of a spacecraft level performance test versus the programmatic risk of shipping the spacecraft to another facility. The resources required are a fraction of that for a LAPSS test, and is easy to repeat. Further, the test equipment can be handed down to future projects without building an on-site facility.

photovoltaic↗
NASA NTRS1999

X-33 Experimental Aeroheating at Mach 6 Using Phosphor Thermography

The goal of the NASA Reusable Launch Vehicle (RLV) technology program is to mature and demonstrate essential, cost effective technologies for next generation launch systems. The X-33 flight vehicle presently being developed by Lockheed Martin is an experimental Single Stage to Orbit (SSTO) demonstrator that seeks to validate critical technologies and insure applicability to a full scale RLV. As with the design of any hypersonic vehicle, the aeroheating environment is an important issue and one of the key technologies being demonstrated on X-33 is an advanced metallic Thermal Protection System (TPS). As part of the development of this TPS system, the X-33 aeroheating environment is being defined through conceptual analysis, ground based testing, and computational fluid dynamics. This report provides an overview of the hypersonic aeroheating wind tunnel program conducted at the NASA Langley Research Center in support of the ground based testing activities. Global surface heat transfer images, surface streamline patterns, and shock shapes were measured on 0.013 scale (10-in.) ceramic models of the proposed X-33 configuration in Mach 6 air. The test parametrics include angles of attack from -5 to 40 degs, unit Reynolds numbers from 1x106 to 8x106/ft, and body flap deflections of 0, 10, and 20 deg. Experimental and computational results indicate the presence of shock/shock interactions that produced localized heating on the deflected flaps and boundary layer transition on the canted fins. Comparisons of the experimental data to laminar and turbulent predictions were performed. Laminar windward heating data from the wind tunnel was extrapolated to flight surface temperatures and generally compared to within 50 deg F of flight prediction along the centerline. When coupled with the phosphor technique, this rapid extrapolation method would serve as an invaluable TPS design tool.

Horvath, Thomas J.↗
NASA NTRS1992

Review of two-phase flow liquid metal MHD and turbine energy conversion concepts for space applications

Two-phase energy conversion systems could be liquid metal magnetohydrodynamic (LMMHD) with no moving parts or two-phase turbines. Both of them are inherently simple and reliable devices which can operate in a wide range of temperatures. Their thermal efficiency is significantly higher than for conventional cycles due to reheat of vapor by liquid phase during the energy converting expansion. Often they can be more easily coupled to heat sources. These features make two-phase systems particularly promising for space application. Insufficient research has been done in the past. So far achieved LMMHD generator and two-phase turbine efficiencies are in the 40 to 45 percent range. However if certain fluid dynamic and design problems are resolved these efficiencies could be brought into the range of 70 percent. This would make two-phase systems extremely competitive as compared to present or other proposed conversion system for space. Accordingly, well directed research effort on potential space applications of two-phase conversion systems would be a wise investment.

Fabris, Gracio↗
NASA NTRS1988

Channel formation in Pb-Sn, Pb-Sb, and Pb-Sn-Sb alloy ingots and comparison with the system NH4Cl-H2O

The formation of segregation channels during the unidirectional solidification of base chilled ingots has been studied as a function of composition in binary Pb-Sn and Pb-Sb and ternary Pb-Sn-Sb alloys. The patterns of channel distribution were characterized in the binary and ternary systems and are described as functions of temperature gradients, growth rates, dendrite spacings, and interdendritic permeabilities. Channels appear to nucleate at random across a dendritic front and subsequently to interact as they propagate, decreasing in density across the front. Assuming that the interdendritic spacing is the characteristic distance for a liquid perturbation, yields critical effective Rayleigh numbers which lie within a factor of x 40 for both metallic and aqueous systems. This correlation is close, considering the sensitivity to any assumed dimension and the range of material properties involved, and is taken to support a model for channel nucleation occurring close to the dendritic growth front.

Hellawell, A.↗
NASA NTRS2007

Assembly and Thermal Hydraulic Test of a Stainless Steel Sodium-Potassium Circuit

Early Flight Fission Test Facilities (EFF-TF) team has been tasked by the NASA Marshall Space Flight Center Nuclear Systems Office to design, fabricate, and test an actively pumped alkali metal flow circuit. The system was originally built for use with lithium, but due to a shift in focus, it was redesigned for use with a eutectic mixture of sodium potassium (NaK). Basic circuit components include: reactor segment, NaK to gas heat exchanger, electromagnetic (EM) liquid metal pump, load/drain reservoir, expansion reservoir, instrumentation, and a spill reservoir. A 37-pin partial-array core (pin and flow path dimensions are the same as those in a full design) was selected for fabrication and test. This paper summarizes the first fill and checkout testing of the Stainless Steel NaK-Cooled Circuit (SNaKC).

Garber, A.↗
NASA NTRS1999

The X-33 Flight Test Challenge

Low cost access to space has eluded present launch system technologies. Our objective is to reduce the cost of putting a payload into space from $10,000 per pound to $1000 per pound. In July 1996, a cooperative agreement was initiated between the Lockheed Martin Skunk Works and NASA to help accomplish this goal. The X-33 is the first step in the process to make low cost space access a reality. The X-33 is a suborbital, hypersonic lifting body, proof of concept of a reusable launch vehicle. The X-33 flight test program will validate technologies such as a metallic thermal protection system, Linear Aerospike Engines, use of tanks and struts as fundamental structural elements, as well as quick turnaround time. Flight testing will begin in July 2000, with launches originating from Edwards Air Force Base and initial landings at Michael Army Airfield in Utah. Data collected from these flight tests will aid in the decision to build an economically viable single stage to orbit reusable launch vehicle. This paper will explore the technical challenges facing the X-33 Flight Test Team.

Borden, David↗