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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 73 records · Page 4
All sourcesNASA NTRSDOE OSTI
NASA NTRS2017

Greased Lightning (GL-10) Performance Flight Research: Flight Data Report

Modern aircraft design methods have produced acceptable designs for large conventional aircraft performance. With revolutionary electronic propulsion technologies fueled by the growth in the small UAS (Unmanned Aerial Systems) industry, these same prediction models are being applied to new smaller, and experimental design concepts requiring a VTOL (Vertical Take Off and Landing) capability for ODM (On Demand Mobility). A 50% sub-scale GL-10 flight model was built and tested to demonstrate the transition from hover to forward flight utilizing DEP (Distributed Electric Propulsion)[1][2]. In 2016 plans were put in place to conduct performance flight testing on the 50% sub-scale GL-10 flight model to support a NASA project called DELIVER (Design Environment for Novel Vertical Lift Vehicles). DELIVER was investigating the feasibility of including smaller and more experimental aircraft configurations into a NASA design tool called NDARC (NASA Design and Analysis of Rotorcraft)[3]. This report covers the performance flight data collected during flight testing of the GL-10 50% sub-scale flight model conducted at Beaver Dam Airpark, VA. Overall the flight test data provides great insight into how well our existing conceptual design tools predict the performance of small scale experimental DEP concepts. Low fidelity conceptual design tools estimated the (L/D)( sub max)of the GL-10 50% sub-scale flight model to be 16. Experimentally measured (L/D)( sub max) for the GL-10 50% scale flight model was 7.2. The aerodynamic performance predicted versus measured highlights the complexity of wing and nacelle interactions which is not currently accounted for in existing low fidelity tools.

McSwain, Robert G.↗
DOE OSTI2022

Techno-economic Analysis and Life-Cycle Analysis of Renewable Diesel Fuels Produced with Waste Feedstocks

Wet waste feedstocks represent an important category of resources that could be utilized to produce biofuels. Diversion of the wet waste resources from going through conventional waste management practices to utilization as feedstocks for energy production also benefits from avoided cost and pollutant emissions of waste management and disposal. This study investigates the economic and environmental implications of producing bio-blendstocks for mixing controlled compression ignition (MCCI) engines from two waste-to-fuel pathways: hydroprocessed esters and fatty acids (HEFA) from yellow grease, and swine manure hydrothermal liquefaction (HTL) followed by biocrude upgrading. Detailed process models were developed for both pathways, which informed the techno-economic analysis (TEA) and life-cycle analysis (LCA). Conventional swine manure management practice was also modeled in detail as the business-as-usual (BAU) scenario for the swine manure HTL pathway. The estimated minimum fuel selling prices (MFSP) were $4.47/gasoline gallon equivalent (GGE) and $3.57/GGE for the yellow grease to HEFA and swine manure HTL pathways, respectively. The life-cycle greenhouse gas (GHG) emissions of the two pathways were 11.2 and -33.3 g CO2e/MJ, respectively, for the yellow grease to HEFA and swine manure HTL pathways. The credits of avoided emissions from conventional swine manure management were the main reason for the negative GHG emissions of the swine manure HTL pathway. The marginal GHG emissions abatement costs were estimated to be $100 – $253/tonne CO2e and $5 – $103/tonne CO2e for the yellow grease HEFA and swine manure HTL pathways, respectively, for a diesel price ranging between $2.0/GGE and $3.5/GGE. Since the yellow grease HEFA pathway is already commercialized, it can benefit from the $200/tonne carbon credit in the California Low Carbon Fuel Standard (LCFS) market, which could help the yellow grease HEFA pathway to achieve near-zero marginal GHG emissions abatement cost.

renewable diesel, techno economic analysis, life c↗
NASA NTRS2008

Evaluation of Perfluoropolyether Lubricant Lifetime in the High Stress and High Stress-Cycle Regime for Mars Applications

The successful operation of long-life, highly loaded mechanisms used for planetary exploration or autonomous structures assembly will depend upon the ability to effectively lubricate rolling-element bearings. As new tools are developed (i.e., drill, abraders, robotic manipulators, etc.) that interact with their environment in a more direct manner, lubricants will be pushed past the bounds that current scientific literature has published. This paper details results from bearing lubrication lifetime testing performed in support of Honeybee Robotics development of the Mars Science Laboratory (MSL) Surface Removal Tool (SRT). This testing was done due to the lack of available data in research literature that is applicable to the lubrication regime the SRT bearings are being designed for. Based on the test results, the chosen bearing arrangement can be used for the SRT Grind Shaft bearings with the use of a Braycote Micronic 601EF grease-plate with a 10 vol% grease slurry fill (50/50 wt% Braycote Micronic 601EF and Brayco 815Z). This arrangement showed no signs of detrimental degradation over the course of the 3x life test. The purely grease-plated bearing ran at a consistently higher torque and showed signs of failure beginning at approximately 2.2 x 10(exp 7) revs (approximately 6.3 x 10(exp 7) stress-cycles) with a torque over-limit failure at approximately 4.5 x 10(exp 7) revs (approximately 1.3 x 10(exp 8) stress-cycles). Barring cold-start torque margin limitations, it is recommended that any long-life bearing application include some vol% grease-pack in addition to a standard grease-plate to reduce parasitic torque and increase bearing life. While these results are specific to a particular environment and loading condition, they demonstrate the extended capabilities of a commonly used flight lubricant outside of the range that is published in current research literature.

Herman, Jason↗
NASA NTRS2012

Examination of Surface Residuals Obtained During Re-Lubrication of the International Space Station (ISS) Solar Alpha Rotary Joint (SARJ)

The starboard SARJ mechanism on the ISS suffered a premature lubrication failure, resulting in widespread loss of the nitride case layer on its 10.3 meter circumference, 15-5PH steel race ring [1, 2]. To restore functionality, vacuum-stable grease was applied on-orbit, first to the port SARJ mechanism to save it from the damage suffered by the starboard mechanism. After 3 years of greased operation, telemetry indicated that the port mechanism required relubrication, so part of that process included sampling each of the three race ring surfaces to evaluate any wear debris recovered and the state of the originally applied grease. Extensive microscopic examination was conducted, which directed subsequent microanalysis of particulate. Since the SARJ mechanism operates in the vacuum of space, a sampling method and tool had to be developed for use by astronauts while working in the extravehicular mobility unit (EMU). The sampling tool developed was a cotton terry-cloth mitt for the EMU glove, with samples taken by swiping each of the three port SARJ race-ring surfaces. The sample mitts for each surface were folded inward after sampling to preserve sample integrity, for return and ground analysis. The sample mitt for what is termed the outer canted surface of the SARJ race-ring is shown in Figure 1. Figure 1 also demonstrates how increasing levels of magnification were used to survey the contamination removed in sampling, specifically looking for signs of wear debris or other features which could be further evaluated using Scanning Electron Microscopy (SEM) methods. The most surprising overall result at this point in the analysis was the relatively small amounts of grease recovered during sampling. It is clear that the mechanism was not operating with surplus lubricant. Obviously, evidence of molybdenum disulfide (MoS2), a major component in the grease applied, was prevalent in the analysis conducted. But a small amount of mechanism wear debris was observed. Figure 2 shows an example of a region of concentrated wear debris. Although some MoS2 is observed, most of the contaminant in this location is nitrided 15-5PH steel, as verified by the associated chemical analysis. High oxygen content was also observed which, when associated with the apparent friable nature of the steel material, suggests that this contaminant could be quite old, perhaps even associated with the mechanism s original manufacture and acceptance testing. Additional microscopic

Martinez, J. E.↗
NASA NTRS2016

Roller Testing to Mimic Damage of the ISS SARJ Ring and Durability Test to Simulate Fifteen Years of SARJ Operation Using the Damaged Surface

The International Space Station's starboard Solar Alpha Rotary Joint (SARJ) experienced a breakdown of the joint's race ring surface. The starboard SARJ mechanism was cleaned and lubricated with grease. To provide some guidance on the expected behavior of the damaged SARJ ring with continued operations, experiments were conducted using rollers and a vacuum roller test rig. The approach of the experimental work involved three main steps: (1) initiate damage using conditions representative of the SARJ with inadequate lubrication; (2) propagate the damage by operating the test rollers without lubrication; and (3) assess the durability of the roller by testing to simulate the equivalent of 15 years of SARJ operation on the damaged surface assuming adequate grease lubrication. During the rig testing, additional and/or replacement grease was introduced at regular intervals to maintain good lubrication in the rig. The damage to the nitride layer continued even after application of grease. The grease lubrication proved to be effective for limiting the value of the axial force that can be developed. Limiting the axial force on the SARJ mechanism is important since the larger the axial force the more concentrated the load pressure becomes on the blend-radius location on the SARJ roller. After the testing simulating 15 years of SARJ operations, the wear depths were the order of 0.2 mm for the nitrided 15-5 roller and the order of 0.06 mm for the mating 440C roller. Metallographic inspections were done to search for indications of impending fatigue or other fracture indications that might eventually propagate and cause structural failure. There were no indications or features found that could eventually compromise structural integrity.

mechanical devices↗
DOE OSTI2023

Life-cycle analysis of sustainable aviation fuel production through catalytic hydrothermolysis

Catalytic hydrothermolysis (CH) is a sustainable aviation fuel (SAF) pathway that has been recently approved for use in aircraft fuel production. In alignment with broader sustainable aviation goals, SAF production through CH requires a quantitative assessment of carbon intensity (CI) impacts. In this study, a current-day life-cycle analysis (LCA) was performed on SAF produced via CH to determine the CI. Various oily feedstocks were considered, including vegetable oils (soybean, carinata, camelina and canola) and low-burden oils and greases (corn oil, yellow grease and brown grease). Life-cycle inventory data were collected on all processes within the CH LCA boundary: feedstock cultivation and/or collection, preprocessing, hydrothermal cleanup and CH, biocrude refining, fuel transportation and end use through combustion. Baseline results show that the CH-produced SAF can be generated with CI reductions ranging from 48 to 82% compared with conventional jet fuel. Modest improvements to CI can be achieved through incremental changes to the brown grease CH process, such as relaxing the dewatering specification and implementing renewable natural gas and electricity, which could decrease the CI from 22.9 to 7.9 g CO 2 e/MJ. Total CH fuel production potential was also assessed on the basis of current or near-future feedstock availability and CI. The total biofuel production potential of CH (SAF and renewable fuel co-products) in the US sums to approximately 3487 million gallons per year, with 97% of these volumes having a CI below 50% of that for petroleum jet fuel. The study shows that from an LCA perspective, CH offers a viable SAF pathway that is comparable with existing SAF pathways like hydroprocessed esters and fatty acids.

09 BIOMASS FUELS↗
DOE OSTI2016

Thermal contact resistance measurement of conduction cooled binary current lead joint block in cryocooler based self field I-V characterization facility

In the present study thermal resistance of conduction cooled current lead joint block employing two different interfacial material namely AlN sheet and Kapton Film have been studied in the temperature range 5K-35K. In each case, the performance of different interlayer materials e.g. Indium foil for moderately pressurized contacts (contact pressure <1 MPa), and Apiezon N Grease, GE varnish for low pressurized contact (contact pressure <1 MPa) is studied. The performances of AlN joint with Indium foil and with Apeizon N Grease are studied and it is observed that the contact resistance reduces more with indium foil as compared to greased contact. The contact resistance measurements of Kapton film with Apiezon N grease and with GE varnish were also carried out in the same temperature range. A comparative study of AlN joint with Indium foil and Kapton with GE varnish as filler material is carried out to demonstrate better candidate material among Kapton and AlN for a particular filler material in the same temperature range.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
NASA NTRS1975

An evaluation of various ball bearing lubricants operating in various environments /A status report/

Testing of both fluid and solid lubricants in small ball bearings is reported for a period of up to one year in various environments. The testing equipment, procedures and detailed results of five different lubricants, operating in a vacuum at ambient temperature, are described. Specially made motors were shimmed to maintain a 2.27 kg thrust load on both bearings, having a speed of 3600 rpm allowing 216,000 revolutions on each bearing per hour until failure. The commercial perfluoropolyether (PFPE-1) grease, having the best results, was recommended for long term bearing operation under hard vacuum conditions. It had an average life of over 8760 hrs. The ester based grease was recommended for moderate life requirements in vacuum conditions, while the silicone based grease and the fluorosilicone based grease were not recommended for vacuum operation due to extensive metal damage in the bearings.

Demorest, k. E.↗
NASA NTRS2013

Green Solvents for Precision Cleaning

Aerospace machinery used in liquid oxygen (LOX) fuel systems must be precision cleaned to achieve a very low level of non-volatile residue (< 1 mg0.1 m2), especially flammable residue. Traditionally chlorofluorocarbons (CFCs) have been used in the precision cleaning of LOX systems, specifically CFC 113 (C2Cl3F3). CFCs have been known to cause the depletion of ozone and in 1987, were banned by the Montreal Protocol due to health, safety and environmental concerns. This has now led to the development of new processes in the precision cleaning of aerospace components. An ideal solvent-replacement is non-flammable, environmentally benign, non-corrosive, inexpensive, effective and evaporates completely, leaving no residue. Highlighted is a green precision cleaning process, which is contaminant removal using supercritical carbon dioxide as the environmentally benign solvent. In this process, the contaminant is dissolved in carbon dioxide, and the parts are recovered at the end of the cleaning process completely dry and ready for use. Typical contaminants of aerospace components include hydrocarbon greases, hydraulic fluids, silicone fluids and greases, fluorocarbon fluids and greases and fingerprint oil. Metallic aerospace components range from small nuts and bolts to much larger parts, such as butterfly valves 18 in diameter. A fluorinated grease, Krytox, is investigated as a model contaminant in these preliminary studies, and aluminum coupons are employed as a model aerospace component. Preliminary studies are presented in which the experimental parameters are optimized for removal of Krytox from aluminum coupons in a stirred-batch process. The experimental conditions investigated are temperature, pressure, exposure time and impeller speed. Temperatures of 308 - 423 K, pressures in the range of 8.3 - 41.4 MPa, exposure times between 5 - 60 min and impeller speeds of 0 - 1000 rpm were investigated. Preliminary results showed up to 86 cleaning efficiency with the moderate processing conditions of 323 K, 13.8 MPa, 30 min and 750 rpm.

solvents↗