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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
DOE OSTI2016

Clemson University Wind Turbine Drivetrain Test Facility

In November of 2009, Clemson University was awarded a competitive grant from the U.S. Department of Energy to design, build and operate a facility for full-scale, highly accelerated mechanical testing of next-generation wind turbine drivetrain technologies. The primary goal of the project was to design, construct, commission, and operate a state-of-the-art sustainable facility that permits full-scale highly accelerated testing of advanced drivetrain systems for large wind turbines. The secondary goal was to meet the objectives of the American Recovery and Reinvestment Act of 2009, especially in job creation, and provide a positive impact on economically distressed areas in the United States, and preservation and economic recovery in an expeditious manner. The project was executed according to a managed cooperative agreement with the Department of Energy and was an extraordinary success. The resultant new facility is located in North Charleston, SC, providing easy transportation access by rail, road or ship and operates on an open access model such that it is available to the U.S. Wind Industry for research, analysis, and evaluation activities. The 72 m by 97 m facility features two mechanical dynamometer test bays for evaluating the torque and blade dynamic forces experienced by the rotors of wind turbine drivetrains. The dynamometers are rated at 7.5 MW and 15 MW of low speed shaft power and are configured as independent test areas capable of simultaneous operation. All six degrees of freedom, three linear and three rotational, for blade and rotor dynamics are replicated through the combination of a drive motor, speed reduction gearbox and a controllable hydraulic load application unit (LAU). This new LAU setup readily supports accelerated lifetime mechanical testing and load analysis for the entire drivetrain system of the nacelle and easily simulates a wide variety of realistic operating scenarios in a controlled laboratory environment. The development of these two dynamometer test rigs is the first significant achievement for the project. These test rigs embody a new manner of test due to the system configuration and completely new design with a free floating loading hub in the LAU. This project provided the catalyst for the advancement to this new test rig configuration that has been adopted by every significant wind turbine test rig constructed since the inception of this project. There are currently two different vendors supplying these new systems. Catalyzing this new design is the second major success of the project. With the increased market penetration of wind energy over the past decade, many regions and countries have developed specific electrical grid specifications and performance codes for large wind farms to ensure operational reliability and stability. These grid codes provide requirements for interconnection with the grid during low or high voltage phenomena, typically encountered during and after system fault events. Given the installed infrastructure of the Wind Turbine Drivetrain Testing Facility (WTDTF), a natural expansion of facility capability was to include the necessary equipment for performing fault ride-through evaluations of wind turbines to the Low Voltage Ride Through (LVRT) codes. Once the decision was made to expand the scope of the original grant into fault ride-through testing, it was clear that there are several markets, not just wind, which could benefit from this type of test and that simple fault ride-through testing could be extended into a broader scope of electrical testing capabilities. It was at this point that Clemson University was awarded a second grant to build a 15 MW Hardware-In-the-Loop (HIL) Grid Simulator in order to establish world class electrical testing capabilities to compliment the mechanical testing at the WTDTF. This third significant achievement resulted in the 15 MW HIL Grid Simulator as the corner stone of the Duke Energy eGRID Center and is collocated with the WTDTF in the SCE&G Energy Innovation Center at the new Facility in North Charleston, SC, USA. Before the eGRID was completed, it was recognized that the ability to test solar farm equipment was but a small step away thru the addition of enhanced equipment to provide for DC testing. In yet another expansion/success, a 2.5 MW rectifier system was designed and implemented by Clemson staff to enhance the Center’s capabilities. The program required over 250,000 man-hours of on-site construction labor reworking the brownfield facility on the former Navy Base, clearly satisfying one of the major goals of the Reinvestment Act. This was done while winning numerous awards for design and construction of the facility, including the Top US Project for 2014 from the Trade Journal Engineering News Record. The project was a major collaborative developmental activity managed by Clemson University staff that involved the DOE and many partners and organizations.

17 WIND ENERGY↗
DOE OSTI2022

The Dual-Axis Radiographic Hydrodynamic Test Facility Capability Expansion (DCX) Strategy

The Dual-Axis Radiographic Hydrodynamic Test (DARHT) facility is a vital and important part of the Nation’s nuclear security enterprise. With more than two decades of operations, DARHT has a storied history. Conceived in the 1970s, constructed in the 1990s, and operational since 2000, DARHT has advanced from open-air hydrodynamic experiments (hydros) to foam-confined hydros, to vessel-confined hydros, and in 2022, the 75th hydro was successfully completed. Radiography has advanced from a single-axis, single-pulse system to a dual-axis, multi-pulse capability to variable fields of view (VFV) on both accelerators. The culmination of these experiences, accomplishments, and advancements has brought us to a very important question: What do the next two decades at DARHT look like? The world is not the same place it was in the 1990s when construction at DARHT was in progress. Evolving threats, an expanding mission, and technology changes necessitate adaptation. To adapt, the aging facility, accelerators, vessels, and detector systems require improvements to ensure DARHT remains the Nation’s hydrodynamic data foundation for stockpile certification, safety, surety, and global security threats.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
DOE OSTI2022

The Dual-Axis Radiographic Hydrodynamic Test Facility Capability eXpansion (DCX) Strategy

The Dual-Axis Radiographic Hydrodynamic Test (DARHT) facility is a vital and important part of the Nation’s nuclear security enterprise. The Department of Energy/National Nuclear Security Administration (DOE/ NNSA) Stockpile Stewardship Management Plan (SSMP) identifies DARHT as a weapons mission critical facility along with the need to modernize DARHT to support weapons modernization efforts. With more than two decades of operations, DARHT has a storied history. Conceived in the 1970s, constructed in the 1990s, and operational since 2000, DARHT has advanced from open-air hydrodynamic experiments (hydros) to foam-confined hydros, to vessel-confined hydros, and in 2022, the 75 th hydro was successfully completed. Radiography has advanced from a single-axis, single-pulse system to a dual-axis, multi-pulse capability to variable fields of view (VFV) on both accelerators. The culmination of these experiences, accomplishments, and advancements has brought us to a very important question: What do the next two decades at DARHT look like? The world is not the same place it was in the 1990s when construction at DARHT was in progress. Evolving threats, an expanding mission, and technology changes necessitate adaptation. The 2018 Nuclear Posture Review (NPR) states that the nuclear weapons infrastructure has suffered the effects of age and underfunding with no margin for further delay in recapitalizing the physical infrastructure. To adapt, the aging facility, accelerators, vessels, and detector systems require improvements to ensure DARHT remains the Nation’s hydrodynamic data foundation for stockpile certification, safety, surety, and global security threats.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
NASA NTRS1996

Analysis and Modeling of a Two-Phase Jet Pump of a Flow Boiling Test Facility for Aerospace Applications

Jet pumps are devices capable of pumping fluids to a higher pressure employing a nozzle/diffuser/mixing chamber combination. A primary fluid is usually allowed to pass through a converging-diverging nozzle where it can accelerate to supersonic speeds at the nozzle exit. The relatively high kinetic energy that the primary fluid possesses at the nozzle exit is accompanied by a low pressure region in order to satisfy Bernoulli's equation. The low pressure region downstream of the nozzle exit permits a secondary fluid to be entrained into and mixed with the primary fluid in a mixing chamber located downstream of the nozzle. Several combinations may exist in terms of the nature of the primary and secondary fluids in so far as whether they are single or two-phase fluids. Depending on this, the jet pump may be classified as gas/gas, gas/liquid, liquid/liquid, two-phase/liquid, or similar combinations. The mixing chamber serves to create a homogeneous single-phase or two-phase mixture which enters a diffuser where the high kinetic energy of the fluid is converted into pressure energy. If the fluid mixture entering the diffuser is in the supersonic flow regime, a normal shock wave usually develops inside the diffuser. If the fluid mixture is one that can easily change phase, a condensation shock would normally develop. Because of the overall rise in pressure in the diffuser as well as the additional rise in pressure across the shock layer, condensation becomes more likely. Associated with the pressure rise across the shock is a velocity reduction from the supersonic to the subsonic range. If the two-phase flow entering the diffuser is predominantly gaseous with liquid droplets suspended in it, it will transform into a predominantly liquid flow containing gaseous bubbles (bubbly flow) somewhere in the diffuser. While past researchers have been able to model the two-phase flow jet pump using the one-dimensional assumption with no shock waves and no phase change, there is no research known to the authors apart from that of Anand (1992) which accounted for condensation shocks. One of the objectives of this research effort is to develop a comprehensive model in which the effects of phase slip and inter-phase heat transfer as well as the wall friction and shock waves are accounted for. While this modeling effort is predominantly analytical in nature and is primarily intended to provide a parametric understanding of the jet pump performance under different operating scenarios, another parallel effort employing a commercial CFD code is also implemented. The latter effort is primarily intended to model an axisymmetric counterpart of the problem in question. The viability of using the CFD code to model a two-phase flow jet pump will be assessed by attempting to recreate some of the existing performance data of similar jet pumps. The code will eventually be used to generate the jet pump performance characteristics of several scenarios involving jet pump geometries as well as flow regimes in order to be able to determine an optimum design which would be suitable for a two-phase flow boiling test facility at NASA-Marshall. Because of the extensive nature of the analytical model developed, the following section will only provide very brief highlights of it, while leaving the details to a more complete report submitted to the NASA colleague. This report will also contain some of the simulation results obtained using the CFD code.

Sherif, S. A.↗
DOE OSTI2020

14 MeV DT Neutron Test Facility at the Sandia Ion Beam Laboratory

A recently completed LDRD project has provided a new facility at Sandia for testing effects of energetic neutrons on electronic components. 14 MeV neutrons are produced with a deuterium ion beam onto a thin-film tritide target. The goal of the project was to increase the neutron fluence to levels needed for radiation effects testing and qualification. This goal was achieved through two technical advances. First, a new multi-layer target concept was developed to reduce the rate of tritium loss from the target by isotope exchange, thereby reducing tritium usage and increasing target lifetime. The second advance was the construction of a new test chamber designed to maximize neutron flux at test locations. Together, these increased the available neutron fluence by several orders of magnitude. This new capability is being used in tests for Sandia nuclear weapon programs, evaluation of commercial parts such as highly-scaled CMOS SRAM lCs, and tests of new devices under development at Sandia such as lll-V HBTs, gallium nitride high-voltage diodes, and for fundamental studies of physical mechanisms of device failure.

36 MATERIALS SCIENCE↗
NASA NTRS1992

Thermal-structural test facilities at NASA Dryden

The National Aero-Space Plane (NASP) has renewed interest in hypersonic flight and hot-structures technology development for both the airframe and engine. The NASA Dryden Thermostructures Research Facility is a unique national facility that was designed to conduct thermal-mechanical tests on aircraft and aircraft components by simulating the flight thermal environment in the laboratory. The layout of the facility is presented, which includes descriptions of the high-bay test area, the instrumentation laboratories, the mechanical loading systems, and the state-of-the-art closed-loop thermal control system. The hot-structures test capability of the facility is emphasized by the Mach-3 thermal simulation conducted on the YF-12 airplane. The Liquid-Hydrogen Structural Test Facility, which is presently in the design phase, will provide the capability of thermally testing structures containing hydrogen.

Deangelis, V. Michael↗
DOE OSTI2023

ULTIMATE FY22 Creep Test Facility Report (FY23 ARPA-E Milestone Report)

In the 18-month Phase 1 of this project, a facility was assembled for creep testing of refractory metals at 1300°C. This report focuses on the four creep frames that are operational and using an inert gas system (argon) to limit oxidation of the refractory metal specimens being tested. This report details the operations for the first period of operation including the results and lessons learned for Nb- and Mo-based alloy specimens tested by the ORNL team. For an alloy development program, a particularly unique feature of the ORNL facility is more than 40 years of experience conducting mechanical properties testing on sub-sized test specimens (25 mm long dogbones). Due to proprietary constraints, only one representative set of team data are provided. The primary concern for testing Nb-based alloys is oxygen ingress. Despite several strategies to reliably limit O ingress, including getters and Ar gas purity, the experimentally informed strategy currently being developed is a new load train design intended to better seal the system. Hardware for the new design is currently being fabricated.

36 MATERIALS SCIENCE↗
NASA NTRS2006

Hydrogen and Storage Initiatives at the NASA JSC White Sands Test Facility

NASA WSTF Hydrogen Activities: a) Aerospace Test; b) System Certification & Verification; c) Component, System, & Facility Hazard Assessment; d) Safety Training Technical Transfer: a) Development of Voluntary Consensus Standards and Practices; b) Support of National Hydrogen Infrastructure Development.

Maes, Miguel↗
NASA NTRS1997

Operation of the 25kW NASA Lewis Research Center Solar Regenerative Fuel Cell Tested Facility

Assembly of the NASA Lewis Research Center(LeRC)Solar Regenerative Fuel Cell (RFC) Testbed Facility has been completed and system testing has proceeded. This facility includes the integration of two 25kW photovoltaic solar cell arrays, a 25kW proton exchange membrane (PEM) electrolysis unit, four 5kW PEM fuel cells, high pressure hydrogen and oxygen storage vessels, high purity water storage containers, and computer monitoring, control and data acquisition.

Solar Regenerative Fuel Cell electrolyzer↗
NASA NTRS2009

An Update of the Nation's Long-Term Strategic Needs for NASA's Aeronautics Test Facilities

The National Aeronautics and Space Administration's (NASA's) major wind tunnel (WT), propulsion test (PT), and simulation facilities exist to serve NASA's and the nation's aeronautics needs. RAND Corporation researchers conducted a prior study of these facilities from 2002 to 2003, identifying (1) NASA's continuing ability to serve national needs, (2) which facilities appear strategically important from an engineering perspective given the vehicle classes the nation investigates and produces, and (3) management challenges and issues. This documented briefing (DB) is the final report from a new, one-year study (conducted from September 2006 through January 2008), partially updating the prior assessment. The study focuses on updating the list of facilities in the prior study that were deemed to be strategically important (again, from an engineering perspective) in serving those needs. This update also adds a new assessment of national needs for six major aeronautics simulators at NASA and lists those deemed strategically important.

NASA FACILITIES↗
DOE OSTI2015

SINGLE EVENT EFFECTS TEST FACILITY AT OAK RIDGE NATIONAL LABORATORY

Increasing use of microelectronics of ever diminishing feature size in avionics systems has led to a growing Single Event Effects (SEE) susceptibility arising from the highly ionizing interactions of cosmic rays and solar particles. Single event effects caused by atmospheric radiation have been recognized in recent years as a design issue for avionics equipment and systems. To ensure a system meets all its safety and reliability requirements, SEE induced upsets and potential system failures need to be considered, including testing of the components and systems in a neutron beam. Testing of ICs and systems for use in radiation environments requires the utilization of highly advanced laboratory facilities that can run evaluations on microcircuits for the effects of radiation. This paper provides a background of the atmospheric radiation phenomenon and the resulting single event effects, including single event upset (SEU) and latch up conditions. A study investigating requirements for future single event effect irradiation test facilities and developing options at the Spallation Neutron Source (SNS) is summarized. The relatively new SNS with its 1.0 GeV proton beam, typical operation of 5000 h per year, expertise in spallation neutron sources, user program infrastructure, and decades of useful life ahead is well suited for hosting a world-class SEE test facility in North America. Emphasis was put on testing of large avionics systems while still providing tunable high flux irradiation conditions for component tests. Makers of ground-based systems would also be served well by these facilities. Three options are described; the most capable, flexible, and highest-test-capacity option is a new stand-alone target station using about one kW of proton beam power on a gas-cooled tungsten target, with dual test enclosures. Less expensive options are also described.

atmospheric radiation↗
NASA NTRS2001

Recent National Transonic Facility Test Process Improvements (Invited)

This paper describes the results of two recent process improvements; drag feed-forward Mach number control and simultaneous force/moment and pressure testing, at the National Transonic Facility. These improvements have reduced the duration and cost of testing. The drag feedforward Mach number control reduces the Mach number settling time by using measured model drag in the Mach number control algorithm. Simultaneous force/moment and pressure testing allows simultaneous collection of force/moment and pressure data without sacrificing data quality thereby reducing the overall testing time. Both improvements can be implemented at any wind tunnel. Additionally the NTF is working to develop and implement continuous pitch as a testing option as an additional method to reduce costs and maintain data quality.

Kilgore, W. A.↗
NASA NTRS2001

Recent National Transonic Facility Test Process Improvements (Invited)

This paper describes the results of two recent process improvements; drag feed-forward Mach number control and simultaneous force/moment and pressure testing, at the National Transonic Facility. These improvements have reduced the duration and cost of testing. The drag feed-forward Mach number control reduces the Mach number settling time by using measured model drag in the Mach number control algorithm. Simultaneous force/moment and pressure testing allows simultaneous collection of force/moment and pressure data without sacrificing data quality thereby reducing the overall testing time. Both improvements can be implemented at any wind tunnel. Additionally the NTF is working to develop and implement continuous pitch as a testing option as an additional method to reduce costs and maintain data quality.

Kilgore, W. A.↗
DOE OSTI2015

Single Event Effects Test Facility Options at the Oak Ridge National Laboratory

Increasing use of microelectronics of ever diminishing feature size in avionics systems has led to a growing Single Event Effects (SEE) susceptibility arising from the highly ionizing interactions of cosmic rays and solar particles. Single event effects caused by atmospheric radiation have been recognized in recent years as a design issue for avionics equipment and systems. To ensure a system meets all its safety and reliability requirements, SEE induced upsets and potential system failures need to be considered, including testing of the components and systems in a neutron beam. Testing of integrated circuits (ICs) and systems for use in radiation environments requires the utilization of highly advanced laboratory facilities that can run evaluations on microcircuits for the effects of radiation. This paper provides a background of the atmospheric radiation phenomenon and the resulting single event effects, including single event upset (SEU) and latch up conditions. A study investigating requirements for future single event effect irradiation test facilities and developing options at the Spallation Neutron Source (SNS) is summarized. The relatively new SNS—with its 1.0 GeV proton beam, typical operation of 5000 h per year, expertise in spallation neutron sources, user program infrastructure, and decades of useful life ahead—is well suited for hosting a world-class SEE test facility in North America. Emphasis was put on testing of large avionics systems while still providing tunable high flux irradiation conditions for component tests. Makers of ground-based systems would also be served well by these facilities. Three options are described; the most capable, flexible, and highest-test-capacity option is a new stand-alone target station using about one kW of proton beam power on a gas-cooled tungsten target, with dual test enclosures. Less expensive options are also described.

Digital avionics↗
NASA NTRSDate not supplied

It’s Hip To Be Square - Refurbishment of the NASA Langley National Transonic Facility Test Section Plenum Door

The “nearside” plenum door (NPD) at the 39-year-old NASA Langley Research Center (LARC) National Transonic Facility (NTF) has become increasingly recalcitrant during the opening /closing sequence. The NPD is the primary means of entry into the test section for personnel and for model installation. The sliding NPD hardware guide bearings have failed three (3) times within a one-year period and “quick fixes” were able to be made to guide rails, wheels and bearings to put the NPD back into operation. The NPD no longer can utilize a “quick fix” as the rolling hardware is at its limit for further modifications. This presentation will describe the NPD situation, the findings as to the cause of the periodic NPD failures, and the solution to remove, refurbish, and reinstall the NPD.

Test Facilities↗