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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 631 records · Page 35
All sourcesNASA NTRSDOE OSTI
DOE OSTI2017

Development of Integrated Die Casting Process for Large Thin-Wall Magnesium Applications

The purpose of this project was to develop a process and product which would utilize magnesium die casting and result in energy savings when compared to the baseline steel product. The specific product chosen was a side door inner panel for a mid-size car. The scope of the project included: re-design of major structural parts of the door, design and build of the tooling required to make the parts, making of parts, assembly of doors, and testing (both physical and simulation) of doors. Additional work was done on alloy development, vacuum die casting, and overcasting, all in order to improve the performance of the doors and reduce cost. The project achieved the following objectives: 1. Demonstrated ability to design a large thin-wall magnesium die casting. 2. Demonstrated ability to manufacture a large thin-wall magnesium die casting in AM60 alloy. 3. Tested via simulations and/or physical tests the mechanical behavior and corrosion behavior of magnesium die castings and/or lightweight experimental automotive side doors which incorporate a large, thin-wall, powder coated, magnesium die casting. Under some load cases, the results revealed cracking of the casting, which can be addressed with re-design and better material models for CAE analysis. No corrosion of the magnesium panel was observed. 4. Using life cycle analysis models, compared the energy consumption and global warming potential of the lightweight door with those of a conventional steel door, both during manufacture and in service. Compared to a steel door, the lightweight door requires more energy to manufacture but less energy during operation (i.e., fuel consumption when driving vehicle). Similarly, compared to a steel door, the lightweight door has higher global warming potential (GWP) during manufacture, but lower GWP during operation. 5. Compared the conventional magnesium die casting process with the “super-vacuum” die casting process. Results achieved with cast tensile bars suggest some improvement in tensile properties with vacuum casting. Plant trials with large castings revealed cavity fill issues attributed to cooling and partial solidification of metal in the shot sleeve while waiting for vacuum to be established in the die cavity. 6. Developed age-hardenable Mg-based alloys as potential alternatives to the AM60 and AZ91 alloys typically used in automotive applications. Mg-7%Al-based alloys having Sn or Sn+Si additions exhibited significant age hardening, but more work is needed to demonstrate significant improvement in tensile properties. Corrosion behavior of these alloys is between those of AM60 and AZ91 alloys. 7. Evaluated the die casting of magnesium directly onto either steel or aluminum tubes as a potential process to make large lightweight subassemblies. Samples were free of gross defects, but additional work is needed to increase the interfacial shear strength. Overall, the project demonstrated that an automotive door-in-white design incorporating a die cast magnesium inner panel and a stamped aluminum outer panel can achieve approximately 50% mass reduction compared to the stamped steel baseline door-in-white. This leads to reduced energy consumption when driving the vehicle, which should more than offset the increased embedded energy of manufacture associated with the lighter metals. However, additional design work would be needed in order to meet the mechanical performance required of a door. Development of high-strength, high-ductility magnesium alloy castings would help make this technology more attractive for potential use in the side doors on automobiles. Also, increased use of recycled magnesium and aluminum would reduce the embedded energy and greenhouse gas emissions associated with the manufacture of this type of lightweight door. Commercialization planning of the type of lightweight door technology addressed in this project would be contingent upon the doors meeting all technical performance requirements of the car maker. The specific lightweight door developed in this project didn’t meet some of those requirements, but a preliminary business case study was conducted anyhow. This study considered the ratio of cost increase to mass decrease when the lightweight door is compared to a baseline steel door. The ratio was found to be in an acceptable range for some vehicle programs, especially if the number of such vehicles to be produced is equal to or slightly less than the estimated 250,000-shot life of the die set. This would allow for the investment in the dies to be spread across many parts and thereby help minimize the cost increase.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Rethink hydrologic modeling framework with AI integrating multi-processes across scales

The proposed work is to develop a new hydrologic modeling framework that leverages vast amount earth and human system observational data, AI technologies, and data-driven information flows to improve predictability of hydrologic system that involves hydrologic, terrestrial, and biogeochemical processes and their interactions with the human and atmosphere systems.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

An Integrated Flame Spray Process for Low Cost Production of Battery Materials for Lithium Ion Batteries and Beyond

The overall objective of this project was to develop an advanced manufacturing technology for Li-ion battery materials production at low cost and in a green chemical process using glycerol as solvent to replace water. It was aimed at developing a prototype pilot production line to reduce production cost by at least 25% to the baseline. During the course of this project, research was conducted to understand spray drying and combustion of eutectic solvent precursors of glycerol and metal salts (acetates) in the formation of mixed metal oxide powders. Reactor design and optimization were done to facilitate spray drying and combustion in powder formation and processing. Various cathode materials powders were produced, including lithium nickel-cobalt-manganese oxide (NCM) and lithium nickel-cobalt-aluminum oxide (NCA). These cathode materials powders were tested in half coin cells for their performances, with materials performances of 160 mAh/g for NCM111 and 200 mAh/g for NCA. NCA powders were also produced using a slurry spray-drying process and tested in full pouch cells. A pilot scale flame assisted spray drying reactor was constructed and demonstrated for its production rate exceeding the target of production rate of four metric tons per year. The work performed in this project has been documented in 9 peer reviewed journal publications, 8 conference presentations, and two IP disclosures/patent applications.

25 ENERGY STORAGE↗
NASA NTRS1992

Integration mockup and process material management system

Work to define and develop a full scale Space Station Freedom (SSF) mockup with the flexibility to evolve into future designs, to validate techniques for maintenance and logistics and verify human task allocations and support trade studies is described. This work began in early 1985 and ended in August, 1991. The mockups are presently being used at MSFC in Building 4755 as a technology and design testbed, as well as for public display. Micro Craft also began work on the Process Material Management System (PMMS) under this contract. The PMMS simulator was a sealed enclosure for testing to identify liquids, gaseous, particulate samples, and specimen including, urine, waste water, condensate, hazardous gases, surrogate gasses, liquids, and solids. The SSF would require many trade studies to validate techniques for maintenance and logistics and verify system task allocations; it was necessary to develop a full scale mockup which would be representative of current SSF design with the ease of changing those designs as the SSF design evolved and changed. The tasks defined for Micro Craft were to provide the personnel, services, tools, and materials for the SSF mockup which would consist of four modules, nodes, interior components, and part task mockups of MSFC responsible engineering systems. This included the Engineering Control and Life Support Systems (ECLSS) testbed. For the initial study, the mockups were low fidelity, soft mockups of graphics art bottle, and other low cost materials, which evolved into higher fidelity mockups as the R&D design evolved, by modifying or rebuilding, an important cost saving factor in the design process. We designed, fabricated, and maintained the full size mockup shells and support stands. The shells consisted of cylinders, end cones, rings, longerons, docking ports, crew airlocks, and windows. The ECLSS required a heavier cylinder to support the ECLSS systems test program. Details of this activity will be covered. Support stands were designed and built for each module to sufficiently move and rotate each module. Secondary structures such as floors, ceilings, bulkheads, standoffs, racks, etc. were developed and built.

Verble, Adas James, Jr.↗
NASA NTRS2009

Fast Ray Tracing of Lunar Digital Elevation Models

Ray-tracing (RT) of Lunar Digital Elevation Models (DEM)'s is performed to virtually derive the degree of radiation incident to terrain as a function of time, orbital and ephemeris constraints [I- 4]. This process is an integral modeling process in lunar polar research and exploration due to the present paucity of terrain information at the poles and mission planning activities for the anticipated spring 2009 launch of the Lunar Reconnaissance Orbiter (LRO). As part of the Lunar Exploration Neutron Detector (LEND) and Lunar Crater Observation and Sensing Satellite (LCROSS) preparations RI methods are used to estimate the critical conditions presented by the combined effects of high latitude, terrain and the moons low obliquity [5-7]. These factors yield low incident solar illumination and subsequently extreme thermal, and radiation conditions. The presented research uses RT methods both for radiation transport modeling in space and regolith related research as well as to derive permanently shadowed regions (PSR)'s in high latitude topographic minima, e.g craters. These regions are of scientific and human exploration interest due to the near constant low temperatures in PSRs, inferred to be < 100 K. Hydrogen is thought to have accumulated in PSR's through the combined effects of periodic cometary bombardment and/or solar wind processes, and the extreme cold which minimizes hydrogen sublimation [8-9]. RT methods are also of use in surface position optimization for future illumination dependent on surface resources e.g. power and communications equipment.

McClanahan, Timothy P.↗
NASA NTRS2011

Framework for Integrating Science Data Processing Algorithms Into Process Control Systems

A software framework called PCS Task Wrapper is responsible for standardizing the setup, process initiation, execution, and file management tasks surrounding the execution of science data algorithms, which are referred to by NASA as Product Generation Executives (PGEs). PGEs codify a scientific algorithm, some step in the overall scientific process involved in a mission science workflow. The PCS Task Wrapper provides a stable operating environment to the underlying PGE during its execution lifecycle. If the PGE requires a file, or metadata regarding the file, the PCS Task Wrapper is responsible for delivering that information to the PGE in a manner that meets its requirements. If the PGE requires knowledge of upstream or downstream PGEs in a sequence of executions, that information is also made available. Finally, if information regarding disk space, or node information such as CPU availability, etc., is required, the PCS Task Wrapper provides this information to the underlying PGE. After this information is collected, the PGE is executed, and its output Product file and Metadata generation is managed via the PCS Task Wrapper framework. The innovation is responsible for marshalling output Products and Metadata back to a PCS File Management component for use in downstream data processing and pedigree. In support of this, the PCS Task Wrapper leverages the PCS Crawler Framework to ingest (during pipeline processing) the output Product files and Metadata produced by the PGE. The architectural components of the PCS Task Wrapper framework include PGE Task Instance, PGE Config File Builder, Config File Property Adder, Science PGE Config File Writer, and PCS Met file Writer. This innovative framework is really the unifying bridge between the execution of a step in the overall processing pipeline, and the available PCS component services as well as the information that they collectively manage.

Mattmann, Chris A.↗
DOE OSTI2023

Efficient turbine engine using integrated ammonia fuel processing

A gas turbine engine includes a core engine that includes a core flow path where air is compressed in a compressor section, communicated to a combustor section, mixed with an ammonia based fuel and ignited to generate a high energy combusted gas flow that is expanded through a turbine section. The turbine section is mechanically coupled to drive the compressor section. An ammonia flow path communicates an ammonia flow to the combustor section. A cracking device is disposed in the ammonia flow path. The cracking device is configured to decompose the ammonia flow into a fuel flow containing hydrogen (H2). At least one heat exchanger is upstream of the cracking device that provides thermal communication between the ammonia flow and a working fluid flow such that the ammonia fluid flow accepts thermal energy from the working fluid flow.

Smith, Lance L.↗
DOE OSTI2018

Integrated Salt Waste Processing at the Savannah River Site - 18549

An intricate shoring system to provide protection to the workers and to critical components in the area was designed and installed. Designing and installing shoring systems is commonplace around the world, but installing it adjacent to high-level radioactive waste transfer lines nearly twenty feet in depth with tolerances within one-one thousandths of an inch required a more robust design. Upon completion, approximately 671 square meters (or 7,225 square feet) of sheet piling was installed without issue. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗