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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 NTRSDate not supplied

Stationary Testing of a Pulse Tube Cryocooler Designed to Rotate at 6800 RPM with the Superconducting Rotor of an Electric Machine

Electrified aircraft are being developed to increase the efficiency and reduce the cost of operating subsonic transport aircraft. Achieving a substantial impact necessitates focusing on single- and twin-aisle aircraft which use propulsion systems with >20 MW ratings. For these aircraft, multi-MW superconducting electric machines are being developed due to their high specific power and high efficiency. Most of these electric machines employ superconductors on their rotor, thereby requiring cryogenic cooling of the rotating system. An attractive solution is to conductively cool the rotor using a cryocooler that rotates with the rotor. NASA has been developing a 50 K pulse tube cryocooler for its High Efficiency Megawatt Motor (HEMM) that can operate while rotating at 6,800 rpm. The design of this cryocooler and testing of its linear motor have been discussed in prior work. This presentation presents the first measurements of the complete HEMM cryocooler. The design and results of a stationary (non-rotating) test of the cryocooler are described.

electrified aircraft propulsion↗
NASA NTRSDate not supplied

Stationary Testing of a Pulse Tube Cryocooler Designed to Rotate at 6800 RPM with the Superconducting Rotor of an Electric Machine

Electrified aircraft are being developed to increase the efficiency and reduce the cost of operating subsonic transport aircraft. Achieving a substantial impact necessitates focusing on single- and twin-aisle aircraft which use propulsion systems with >20 MW ratings. For these aircraft, multi-MW superconducting electric machines are being developed due to their high specific power and high efficiency. Most of these electric machines employ superconductors on their rotor, thereby requiring cryogenic cooling of the rotating system. An attractive solution is to conductively cool the rotor using a cryocooler that rotates with the rotor. NASA has been developing a 50 K pulse tube cryocooler for its High Efficiency Megawatt Motor (HEMM) that can operate while rotating at up to 6,800 rpm. The first non-rotating tests of the fully assembled HEMM cryocooler have been completed, and initial testing has yielded a no-load temperature of 112 K. A small helium leak into the vacuum system has been identified as the major bottleneck to performance, and based on measurements with the motor turned off there is an observed vacuum-side heat leak of approximately 30 W at 115 K. Immediate next steps for testing are to locate and mitigate the apparent helium leaks into the vacuum chamber. Thus far, compressor performance and the apparent heat lift after correcting for the heat leak are on par with expectations.

Electrified Aircraft Propulsion↗
NASA NTRS2009

Establishing a Ballistic Test Methodology for Documenting the Containment Capability of Small Gas Turbine Engine Compressors

A test methodology currently employed for large engines was extended to quantify the ballistic containment capability of a small turboshaft engine compressor case. The approach involved impacting the inside of a compressor case with a compressor blade. A gas gun propelled the blade into the case at energy levels representative of failed compressor blades. The test target was a full compressor case. The aft flange was rigidly attached to a test stand and the forward flange was attached to a main frame to provide accurate boundary conditions. A window machined in the case allowed the projectile to pass through and impact the case wall from the inside with the orientation, direction and speed that would occur in a blade-out event. High-peed, digital-video cameras provided accurate velocity and orientation data. Calibrated cameras and digital image correlation software generated full field displacement and strain information at the back side of the impact point.

Heady, Joel↗
NASA NTRS2009

A Comparison of the Unpressurized Rover and Small Pressurized Rover During a Desert Field Evaluation

To effectively explore the lunar surface, astronauts will need a transportation vehicle which can traverse all types of terrain. Currently, the National Aeronautics and Space Administration s (NASA) is investigating two lunar rover configurations to meet such a requirement. Under the Lunar Electric Rover (LER) project, a comparison study between the unpressurized rover (UPR) and the small pressurized rover (SPR) was conducted at the Black Point Lava Flow in Arizona. The objective of the study was to obtain human-in-the-loop performance data on the vehicles with respect to human-machine interfaces, vehicle impacts on crew productivity, and scientific observations. Four male participants took part in four, one-day field tests using the exact same terrain and scientific sites for an accurate comparison between vehicle configurations. Subjective data was collected using several human factors performance measures. Results indicate either vehicle configuration was generally acceptable for a lunar mission; however, the SPR configuration was preferred over the UPR configuration primarily for the SPR s ability to cause less fatigue and enabling greater crew productivity.

Litaker, Harry↗
NASA NTRS2010

AutoGNC Testbed

A simulation testbed architecture was developed and implemented for the integration, test, and development of a TRL-6 flight software set called Auto- GNC. The AutoGNC software will combine the TRL-9 Deep Impact AutoNAV flight software suite, the TRL-9 Virtual Machine Language (VML) executive, and the TRL-3 G-REX guidance, estimation, and control algorithms. The Auto- GNC testbed was architected to provide software interface connections among the AutoNAV and VML flight code written in C, the G-REX algorithms in MATLAB and C, stand-alone image rendering algorithms in C, and other Fortran algorithms, such as the OBIRON landmark tracking suite. The testbed architecture incorporates software components for propagating a high-fidelity truth model of the environment and the spacecraft dynamics, along with the flight software components for onboard guidance, navigation, and control (GN&C). The interface allows for the rapid integration and testing of new algorithms prior to development of the C code for implementation in flight software. This testbed is designed to test autonomous spacecraft proximity operations around small celestial bodies, moons, or other spacecraft. The software is baselined for upcoming comet and asteroid sample return missions. This architecture and testbed will provide a direct improvement upon the onboard flight software utilized for missions such as Deep Impact, Stardust, and Deep Space 1.

Carson, John M., III↗
DOE OSTI2024

Astronomaly at scale: searching for anomalies amongst 4 million galaxies

ABSTRACT Modern astronomical surveys are producing data sets of unprecedented size and richness, increasing the potential for high-impact scientific discovery. This possibility, coupled with the challenge of exploring a large number of sources, has led to the development of novel machine-learning-based anomaly detection approaches, such as astronomaly. For the first time, we test the scalability of astronomaly by applying it to almost 4 million images of galaxies from the Dark Energy Camera Legacy Survey. We use a trained deep learning algorithm to learn useful representations of the images and pass these to the anomaly detection algorithm isolation forest, coupled with astronomaly’s active learning method, to discover interesting sources. We find that data selection criteria have a significant impact on the trade-off between finding rare sources such as strong lenses and introducing artefacts into the data set. We demonstrate that active learning is required to identify the most interesting sources and reduce artefacts, while anomaly detection methods alone are insufficient. Using astronomaly, we find 1635 anomalies among the top 2000 sources in the data set after applying active learning, including eight strong gravitational lens candidates, 1609 galaxy merger candidates, and 18 previously unidentified sources exhibiting highly unusual morphology. Our results show that by leveraging the human–machine interface, astronomaly is able to rapidly identify sources of scientific interest even in large data sets.

Astronomy & Astrophysics↗
DOE OSTI2023

Self-assembled Seashell Like Coatings for Large Area Robust Debris Shields for Next Generation Pulsed Power Drivers

During this LDRD project, our team developed a technology which enables the fabrication of novel nanostructures replicating seashell – “nature’s toughest material”. The resulting coatings exhibit high thermal stability up to 1650°C, which exceeds the hardness of Spectra® by ~44%, as well as the compressive strength of aluminum by ~57%. Coatings made with this technology are stronger, environmentally friendly, more sustainable, and more versatile than other comparable materials. Beryllium wafers, the current, most favorable shielding material in terms of thermal and mechanical properties, are very toxic and cost hundreds of times more than the new material developed in this project. The coatings on silicon wafer and stainless steel, respectively, have been tested as ride-along on the Z machine and clearly outperform the bare substrate. Use of this technology will have a profound global impact for pulsed power and fusion energy development, debris mitigation for spacecraft and satellites, durability of drill bits used in deep well drilling and tunnel boring operations, thermal protection of aircraft and manned spacecraft, and various other thermal and mechanical protection applications.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Integrated High‐Throughput and Machine Learning Methods to Accelerate Discovery of Molten Salt Corrosion‐Resistant Alloys

Insufficient availability of molten salt corrosion-resistant alloys severely limits the fruition of a variety of promising molten salt technologies that could otherwise have significant societal impacts. To accelerate alloy development for molten salt applications and develop fundamental understanding of corrosion in these environments, here an integrated approach is presented using a set of high-throughput (HTP) alloy synthesis, corrosion testing, and modeling coupled with automated characterization and machine learning. By using this approach, a broad range of Cr-Fe-Mn-Ni alloys are evaluated for their corrosion resistances in molten salt simultaneously demonstrating that corrosion-resistant alloy development can be accelerated by 2 to 3 orders of magnitude. Based on the obtained results, a sacrificial protection mechanism is unveiled in the corrosion of Cr-Fe-Mn-Ni alloys in molten salts which can be applied to protect the less unstable elements in the alloy from being depleted, and provided new insights on the design of high-temperature molten salt corrosion-resistant alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Impacts of Superalloys on the Surface Quality of Additively Manufactured Channels

Abstract Gas turbines feature many components that require superalloys capable of handling extreme thermal environments. Increasing the selection of materials available for these components is important to their use in these extremely high-temperature environments. This study investigated two recently developed materials intended to be used for additive manufacturing (AM), with one superalloy based on cobalt and the other on nickel. Sets of four test coupons were built using the materials, in addition to the commonly used Inconel-718, on multiple laser powder bed fusion machines. Several build conditions were varied between coupon sets, including coupon orientation, contour settings, and upskin and downskin treatment. Each set of test coupons featured four unique cooling designs to explore how different cooling technologies would be impacted by the variations in build conditions. After being built, coupons were computed tomography (CT) scanned to determine accuracy to design intent and quantify the surface roughness. The CT scans indicated that horizontally built test coupons had a significantly higher deviation from design intent and higher surface roughness than those built vertically. Results also indicated that the cobalt-based alloy consistently had a smoother surface quality with lower surface roughness compared to the nickel-based alloy. After geometric characterization, the cooling performance of the test coupons was measured experimentally. Pressure losses were found to correlate with increases in surface roughness; however, in some cases, the convective heat transfer did not increase proportionally to the pressure loss as a result of surface features significantly blocking the flow without proportionally increasing convective heat transfer.

Engineering↗
DOE OSTI2024

Annual Report on NCSP Technical Support task in BNL during FY24

This work reports on the investigations done during FY 24 in collaboration with two 2024 Summer undergraduate interns through the DOE SULI and BNL SURP programs. These efforts were partially funded by the Nuclear Criticality Safety Program through the Technical Support Succession Plan task. The first project, developed by Ian Snider, focused on testing the impact of uncertainties in thermal cross sections for multiple materials in nuclear reactor simulations. The second project aimed implement concurrent into BNL’s machine-learning code to correct spin mis-assignments in neutron resonances, the Bayesian Resonance Reclassifier (BRR).

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
NASA NTRS2001

Comparison of Origin 2000 and Origin 3000 Using NAS Parallel Benchmarks

This report describes results of benchmark tests on the Origin 3000 system currently being installed at the NASA Ames National Advanced Supercomputing facility. This machine will ultimately contain 1024 R14K processors. The first part of the system, installed in November, 2000 and named mendel, is an Origin 3000 with 128 R12K processors. For comparison purposes, the tests were also run on lomax, an Origin 2000 with R12K processors. The BT, LU, and SP application benchmarks in the NAS Parallel Benchmark Suite and the kernel benchmark FT were chosen to determine system performance and measure the impact of changes on the machine as it evolves. Having been written to measure performance on Computational Fluid Dynamics applications, these benchmarks are assumed appropriate to represent the NAS workload. Since the NAS runs both message passing (MPI) and shared-memory, compiler directive type codes, both MPI and OpenMP versions of the benchmarks were used. The MPI versions used were the latest official release of the NAS Parallel Benchmarks, version 2.3. The OpenMP versiqns used were PBN3b2, a beta version that is in the process of being released. NPB 2.3 and PBN 3b2 are technically different benchmarks, and NPB results are not directly comparable to PBN results.

Turney, Raymond D.↗
NASA NTRS2009

Structural Dynamic Behavior of Wind Turbines

The structural dynamicist s areas of responsibility require interaction with most other members of the wind turbine project team. These responsibilities are to predict structural loads and deflections that will occur over the lifetime of the machine, ensure favorable dynamic responses through appropriate design and operational procedures, evaluate potential design improvements for their impact on dynamic loads and stability, and correlate load and control test data with design predictions. Load prediction has been a major concern in wind turbine designs to date, and it is perhaps the single most important task faced by the structural dynamics engineer. However, even if we were able to predict all loads perfectly, this in itself would not lead to an economic system. Reduction of dynamic loads, not merely a "design to loads" policy, is required to achieve a cost-effective design. The two processes of load prediction and structural design are highly interactive: loads and deflections must be known before designers and stress analysts can perform structural sizing, which in turn influences the loads through changes in stiffness and mass. Structural design identifies "hot spots" (local areas of high stress) that would benefit most from dynamic load alleviation. Convergence of this cycle leads to a turbine structure that is neither under-designed (which may result in structural failure), nor over-designed (which will lead to excessive weight and cost).

Thresher, Robert W.↗
NASA NTRS2000

Ultrasonic Assessment of Impact-Induced Damage and Microcracking in Polymer Matrix Composites

The main objective of this NASA FAR project is to conduct ultrasonic assessment of impact-induced damage and microcracking in polymer matrix composites at various temperatures. It is believed that the proposed study of impact damage assessment on polymer matrix composites will benefit several NASA's missions and current interests, such as ballistic impact testing of composite fan containment and high strain rate deformation modeling of polymer matrix composites. Currently, impact-induced delamination and fracture in 6061-T6 aluminum/cast acrylic sandwich plates adhered by epoxy were generated in an instrumented drop-weight impact machine. Although only a small dent was produced on the aluminum side when a hemispherical penetrator tup was dropped onto it from a couple of inches, a large ring of delamination at the interface was observed. The delamination damage was often accompanied by severe shattering in the acrylic substratum. Damage patterns in the acrylic layer include radial and ring cracks and, together with delamination at the interface, may cause peeling-off of acrylic material from the sandwich plate. Theory of stress-wave propagation can be used to explain these damage patterns. The impact tests were conducted at various temperatures. The results also show clearly that temperature effect is very important in impact damage. For pure cast acrylic nil-ductile transition (NDT) occurs between 185-195 F Excessive impact energy was dissipated into fracture energy when tested at temperature below this range or through plastic deformation when tested at temperature above the NDT temperature. Results from this study will be used as baseline data for studying fiber-metal laminates, such as GLARE and ARALL for advanced aeronautical and astronautical applications.

Liaw, Benjamin↗
NASA NTRSDate not supplied

Digitally-Engineered Impact Resistant Aerogel Composites for MMOD Protection (DIRAC-MP)

This project implemented a digital-engineering approach to optimize the impact absorption performance of polymer aerogels and aerogel-based composites for Micrometeoroids and Orbital Debris (MMOD) containment. We developed a curated materials database and a machine-learning framework to derive composition-response relationships, enabling predictive design and targeted material selection. In support of experimental validation, a split Hopkinson pressure bar (SHPB) test rig, specifically adapted for low-density aerogel materials, was designed and built in-house. This project accelerates the development of new aerogel formulations, producing candidate materials tailored for enhanced impact-absorption behavior.

Sadeq Malakooti↗
DOE OSTI2024

Machine tool cross beam design, fabrication, and testing using metal big area additive manufacturing

This paper describes the application of metal Big Area Additive Manufacturing (mBAAM) to the fabrication of a machine tool cross beam. The replacement of a traditional box design weldment with a new design printed by wire arc additive manufacturing using the MedUSA system at Oak Ridge National Laboratory (ORNL) is detailed. This requires a new design strategy based on the unique mBAAM capabilities. The intent of the new design is to reduce mass, while maintaining the dynamic stiffness. To compare the two designs, the natural frequencies and mode shapes are measured using impact testing and predicted using finite element analysis. It is confirmed that the printed structure dynamics agreed with the numerical model predictions, which demonstrates that it is feasible to model a large-scale mBAAM part and understand its behavior prior to printing. Another notable outcome of this study is that the significant residual stress and distortion in the print indicate that knowledge gaps remain for widespread implementation of mBAAM.

42 ENGINEERING↗
DOE OSTI2023

Science & Technology Review (April/May 2023)

NASA’s Double Asteroid Redirection Test (DART), featured beginning on p.4, has been a testament to Lawrence Livermore’s multidisciplinary expertise. For DART, the Laboratory developed planetary defense strategies, modeled materials and impacts, and utilized advanced machine learning to create and evaluate multitudes of impact scenarios—informing prediction and analysis of the intercept of a small spacecraft with a much larger asteroid of unknown properties. The success of the project heralds a bright future for space science and security work at the Laboratory.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1973

A mechanical property and stress corrosion evaluation of 431 stainless steel alloy

The mechanical properties of type 431 stainless steel in two conditions: annealed bar and hardened and tempered bar are presented. Test specimens, manufactured from approximately 1.0 inch (2.54 cm) diameter bar stock, were tested at temperatures of 80 F (+26.7 C), 0 F (-17.8 C), -100 F (-73 C), and -200 F (-129 C). The test data indicated excellent tensile strength, notched/unnotched tensile ratio, ductility, shear, and impact properties at all testing temperatures. Results of the alternate immersion stress corrosion tests on stressed and unstressed longitudinal tensile specimens 0.1250 inch (0.3175 cm) diameter and transverse C-ring specimens, machined from 1.0 inch (2.54 cm) diameter bar stock, indicated that the material is not susceptible to stress corrosion cracking when tested in a 3.5 percent NaCl solution for 180 days.

Montano, J. W.↗