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At least 73 records · Page 4

High-Temperature Structures, Adhesives, and Advanced Thermal Protection Materials for Next-Generation Aeroshell Design

The next generation of planetary exploration vehicles will rely heavily on robust aero-assist technologies, especially those that include aerocapture. This paper provides an overview of an ongoing development program, led by NASA Langley Research Center (LaRC) and aimed at introducing high-temperature structures, adhesives, and advanced thermal protection system (TPS) materials into the aeroshell design process. The purpose of this work is to demonstrate TPS materials that can withstand the higher heating rates of NASA's next generation planetary missions, and to validate high-temperature structures and adhesives that can reduce required TPS thickness and total aeroshell mass, thus allowing for larger science payloads. The effort described consists of parallel work in several advanced aeroshell technology areas. The areas of work include high-temperature adhesives, high-temperature composite materials, advanced ablator (TPS) materials, sub-scale demonstration test articles, and aeroshell modeling and analysis. The status of screening test results for a broad selection of available higher-temperature adhesives is presented. It appears that at least one (and perhaps a few) adhesives have working temperatures ranging from 315-400 C (600-750 F), and are suitable for TPS-to-structure bondline temperatures that are significantly above the traditional allowable of 250 C (482 F). The status of mechanical testing of advanced high-temperature composite materials is also summarized. To date, these tests indicate the potential for good material performance at temperatures of at least 600 F. Application of these materials and adhesives to aeroshell systems that incorporate advanced TPS materials may reduce aeroshell TPS mass by 15% - 30%. A brief outline is given of work scheduled for completion in 2006 that will include fabrication and testing of large panels and subscale aeroshell test articles at the Solar-Tower Test Facility located at Kirtland AFB and operated by Sandia National Laboratories. These tests are designed to validate aeroshell manufacturability using advanced material systems, and to demonstrate the maintenance of bondline integrity at realistically high temperatures and heating rates. Finally, a status is given of ongoing aeroshell modeling and analysis efforts which will be used to correlate with experimental testing, and to provide a reliable means of extrapolating to performance under actual flight conditions. The modeling and analysis effort includes a parallel series of experimental tests to determine TSP thermal expansion and other mechanical properties which are required for input to the analysis models.

Collins, Timothy J.↗

Application of a Near Infrared Imaging System for Thermographic Imaging of the Space Shuttle during Hypersonic Re-Entry

High resolution calibrated near infrared (NIR) imagery was obtained of the Space Shuttle s reentry during STS-119, STS-125, and STS-128 missions. The infrared imagery was collected using a US Navy NP-3D Orion aircraft using a long-range infrared optical package referred to as Cast Glance. The slant ranges between the Space Shuttle and Cast Glance were approximately 26-41 nautical miles at point of closest approach. The Hypersonic Thermodynamic Infrared Measurements (HYTHIRM) project was a NASA Langley led endeavor sponsored by the NASA Engineering Safety Center, the Space Shuttle Program Office and the NASA Aeronautics Research Mission Directorate to demonstrate a quantitative thermal imaging capability. HYTHIRM required several mission tools to acquire the imagery. These tools include pre-mission acquisition simulations of the Shuttle trajectory in relationship to the Cast Glance aircraft flight path, radiance modeling to predict the infrared response of the Shuttle, and post mission analysis tools to process the infrared imagery to quantitative temperature maps. The spatially resolved global thermal measurements made during the Shuttle s hypersonic reentry provides valuable flight data for reducing the uncertainty associated with present day ground-to-flight extrapolation techniques and current state-of-the-art empirical boundary-layer transition or turbulent heating prediction methods. Laminar and turbulent flight data is considered critical for the development of turbulence models supporting NASA s next-generation spacecraft. This paper will provide the motivation and details behind the use of an upgraded NIR imaging system used onboard a Navy Cast Glance aircraft and describe the characterizations and procedures performed to obtain quantitative temperature maps. A brief description and assessment will be provided of the previously used analog NIR camera along with image examples from Shuttle missions STS-121, STS-115, and solar tower test. These thermal observations confirmed the challenge of a long-range acquisition during re-entry. These challenges are due to unknown atmospheric conditions, image saturation, vibration etc. This provides the motivation for the use of a digital NIR sensor. The characterizations performed on the digital NIR sensor included radiometric, spatial, and spectral measurements using blackbody radiation sources and known targets. An assessment of the collected data for three Space Shuttle atmospheric re-entries, STS-119, STS-125, and STS-128, are provided along with a description of various events of interest captured using the digital NIR imaging system such as RCS firings and boundary layer transitions. Lastly the process used to convert the raw image counts to quantitative temperatures is presented along with comparisons to the Space Shuttle's onboard thermocouples.

Zalameda, Joseph N.↗

Thermal Testing of Thermal Protection System (TPS) Materials

High temperature testing of thermal protection system (TPS) materials is a critical aspect of heat-shield materials development, as it determines the suitability and performance envelope of the materials. The present talk provides an overview of different high temperature test facilities that are available for conducting thermal tests for TPS materials. The facilities include arcjet testing, solar tower testing facilities and laser test facility. The facilities are selected based on the requirements and objectives of the tests and each have their benefits and limitations. The paper also describes the process of determining the test environments based on mission profiles and requirements. Some of the recent thermal tests of TPS materials are discussed in this paper. These tests have helped improve the TRL (Technology Readiness Level) level of novel TPS materials and make them viable TPS material candidates for future missions.

Thermal Protection Materials↗

Thermostructural Testing of PICA-D for NASA Planetary Science Missions

Phenolic Impregnated Carbon Ablator–Domestic (PICA‑D) has been selected as the heatshield thermal protection system (TPS) material for two upcoming NASA planetary science missions: the Dragonfly mission to Titan and the Mars Sample Retrieval Lander (SRL). Early testing revealed differences between PICA‑D and heritage PICA, particularly in in‑plane (IP) tensile stiffness and thermal expansion. Thermostructural analyses using Finite Element Method (FEM) tools subsequently predicted the potential for IP compressive failure in the near‑surface layers of PICA‑D under both Dragonfly and SRL flight environments. Over the past three years, the Dragonfly and SRL teams have carried out an extensive thermostructural qualification campaign to address these concerns and validate PICA‑D for flight. This effort began with a comprehensive mechanical property characterization program at Kratos test laboratories, which significantly improved understanding of PICA‑D mechanical behavior and increased the fidelity of FEM predictions. The teams also conducted six large‑scale test entries at the National Solar Thermal Test Facility (NSTTF) solar tower, exposing PICA‑D articles—including gap fillers and representative design features or flaws—to combined thermal and mechanical loads. The talk will summarize key findings from these mechanical and thermostructural test campaigns and present the current status of PICA‑D qualification for NASA’s planetary science missions.

TPS↗

Case Study: The Tower Companies' Commercial Office Solar PV

This case study describes how the Tower Companies selected and successfully executed onsite solar photovoltaic installations at its commercial office properties and highlights the resulting increase in asset value.

solar, solar PV, photovoltaic, onsite solar, comme↗

A Method for Projecting Cloud Shadows Onto a Central Receiver Field to Predict Receiver Damage

This work demonstrates methods of mapping high-spatial-resolution direct normal irradiance (DNI) data from satellites, Total Sky Imagers (TSIs), and analogous data sources onto a heliostat field for characterizing the spatial and temporal variation of the incident flux on a central receiver tower during cloud transient events. The mapping methods are incorporated into an optical software module that interfaces with CoPylot–SolarPILOT’s python API– to provide computationally efficient optical simulation of the heliostat field and the solar power tower. Eventually, this optical model will be incorporated into optimization models whereby a plant operator can understand the effects of cloud transient events on overall power production and receiver lifetime due to creep-fatigue damage and therefore make better informed decisions about receiver shutdown events. By more accurately modelling the effects of cloud events on receiver flux maps, this work may determine the magnitude and frequency of thermal cycling on receiver tubes and panels using actual or realistic cloud shapes instead of averaged DNI values–which may undercount the total cycle number. This work may also prevent unnecessary plant shutdowns due to overly precautionary control strategies and characterize the relative impact of various cloud types on receiver life. We plan to eventually integrate this methodology into the System Advisor Model (SAM) to improve performance model accuracy during periods of cloudiness. In this paper, we demonstrate generating DNI maps and mapping them to a solar field in CoPylot using 10 m resolution data from publicly available Sentinel-2 satellite data over the Crescent Dunes plant.

Mullin, Matthew↗

Final Report for CSP Tower Public Opinion and Education Project

As part of the CSP Plant Optimization Study for the California Power Market (DE-EE0009809) the project wanted to understand the public’s opinion of the technology and and explore the types of community engagement that is needed to support such development. The initial objectives for the public perception activities were twofold. The primary objective was to gather public opinion and feedback from the communities living near the two operating solar power tower plants, Ivanpah and Crescent Dunes, and to distill lessons learned from the community engagement conducted before, during, and after the plants were developed to inform future development. This included outreach to nearby airports. The other objective was to gauge public opinion about large-scale solar, specifically CSP towers, to start educating the public on the benefits and to begin building relationships with communities of interest, initially targeting the Kingman, Arizona area. The objectives shifted after the first exploratory trip to Ivanpah and Kingman, however, as it became apparent that it would be challenging to gather public opinion from the community surrounding Ivanpah that could be useful for other community profiles, and the company wasn’t ready to address the concerns in Kingman. Another area was chosen, therefore, to represent those where future development is possible. The recently published Lawrence Berkeley National Lab Perceptions of Large-Scale Solar Project Neighbors Study exemplified public perception polling based on social science and served as the foundation for the survey questions taken to the field. The intent was to ensure that people knew their input was valued and that the time they spent was valuable for the participant as well. It has been noted in the literature that in-person interaction has greater benefits than activities online or via mail, as well as limits the expense.

14 SOLAR ENERGY↗

Automated Reconfigurable Mission Adaptive Digital Assembly Systems (ARMADAS): Robotically Assembled Sustainable Lunar Infrastructure

Introduction: The Automated Reconfigurable Mission Adaptive Digital Assembly Systems (ARMADAS) project at NASA Ames Research Center is developing autonomous infrastructure, instrumentation, and spacecraft assembly and manufacturing capabilities for next generation exploration and science missions, with a goal to change the cost scaling of these missions relative to mission size and duration. Using a building-block approach with a 'kit of parts' composed of ultra-light, high-performance mechanical metamaterials, simplified robots leverage the period environment to achieve high levels of autonomy and reliability for in-space and surface assembly of large-scale apertures, solar-arrays, towers, habitats, and other infrastructure. Robots and structure break down into a compact form factor for launch. By leveraging economies of scale and achieving high-packing ratios, ARMADAS technology can revolutionize possible space missions by breaking the tyranny of the launch shroud, decreasing development times, decreasing mission costs for transformative science capability, and providing a scalable and versatile space infrastructure strategy. Capabilities: To date, the ARMADAS project has demonstrated autonomous assembly of large numbers of structural modules into a meters-scale structure in an earth gravity environment. The mechanical performance is on par with conventional space structures, at a fraction of the cost. By using highly repeatable manufacturing processes (injection molding carbon fiber reinforced space-rated polymers), the structures are both cost effective and highly precise. The ARAMADAS system carefully designs parts for high-precision assembly–the simple and cost-effective robots build structures much larger and more precise than themselves. While maintaining structural efficiency, the ARMADAS system encompasses many functional module types, including for solar power, comm/power routing, etc., that will enable entire infrastructure systems to be engineered and autonomously assembled with modular parts. With well-defined interfaces, custom instrumentation modules can easily be added to fit many mission objectives. Lunar Infrastructure Vision: At the LSIC spring meeting, ARMADAS will present a vision for a general-purpose lunar construction kit capable of meeting a wide variety of lunar surface infrastructure needs (Figure 1). Investing in an ecosystem of reconfigurable, discretely repairable parts and robots enables systems than can expand their capability, reconfigure to meet emergency or unforeseen needs, self-repair and reduce spare-part needs. With a small set of parts (module types), a wide variety of infrastructure needs can be met. Footing modules will allow infrastructure construction at locations with no surface preparation. Footer, primary structure, and rail modules can create reconfigurable rail systems. These rail systems can be used to reduce cost-of-transport between frequently accessed sites, provide dust mitigation, and convey power and communications. High-performance structure modules combined with power-routing and solar modules can create tall towers for power and communication. Concepts for habitats and garages encompass a structure to support regolith cover for a pre-integrated module to an entirely ARMADAS system-based structure. This system can be leveraged by many in-situ resource utilization (ISRU) technologies to simplify processes and augment capabilities.

C. E. Gregg↗

Damage modeling of power tower receiver tubes using the SRLIFE tool

Concentrating Solar Power (CSP) molten-salt central receivers are subject to high, transient incident flux during daily operation. The resulting creep-fatigue damage impacts the receiver’s reliability and restricts the permissible incident flux distribution for a given receiver. This paper aims to reduce CSP plants’ levelized cost of electricity by developing a methodology to predict lifetime and identifies the primary damage mechanism (creep vs fatigue) for any given fluid temperature and temperature gradient. Results are presented in the form of a damage map that serves as a valuable operation guide and design tool. Damage maps can be used to reduce maintenance costs by improving reliability and reduce receiver capital costs by better utilizing the receiver area. FEA simulation and damage modeling of tubes subject to asymmetrical flux conditions is performed in the open-source receiver design tool srlife. Parametric studies are performed over a range of inner tube temperatures and thermal gradients for A230, 316H, 740H, A282, A617, and 800H high temperature alloys. Damage maps are presented for each alloy. A parametric, FEA-based methodology is presented for comparison of fatigue-creep ratios and prediction of tube lifetime based on the critical thermal operating conditions. Fatigue is found to be negligible compared to creep for almost every case. Here, this finding suggests that fatigue effects associated with cloud events are insignificant compared to creep at these high temperature operating conditions. Additionally, lifetime predictions identify thermal conditions where small changes in operating conditions can result in large changes in predicted lifetime.

14 SOLAR ENERGY↗

Low cost solar array project. Cell and module formation research area. Process research of non-CZ silicon material

Liquid diffusion masks and liquid dopants to replace the more expensive CVD SiO2 mask and gaseous diffusion processes were investigated. Silicon pellets were prepared in the silicon shot tower; and solar cells were fabricated using web grown where the pellets were used as a replenishment material. Verification runs were made using the boron dopant and liquid diffusion mask materials. The average of cells produced in these runs was 13%. The relationship of sheet resistivity, temperature, gas flows, and gas composition for the diffusion of the P-8 liquid phosphorus solution was investigated. Solar cells processed from web grown from Si shot material were evaluated, and results qualified the use of the material produced in the shot tower for web furnace feed stock.

Source record↗

Advanced Electric Propulsion for Space Solar Power Satellites

The sun tower concept of collecting solar energy in space and beaming it down for commercial use will require very affordable in-space as well as earth-to-orbit transportation. Advanced electric propulsion using a 200 kW power and propulsion system added to the sun tower nodes can provide a factor of two reduction in the required number of launch vehicles when compared to in-space cryogenic chemical systems. In addition, the total time required to launch and deliver the complete sun tower system is of the same order of magnitude using high power electric propulsion or cryogenic chemical propulsion: around one year. Advanced electric propulsion can also be used to minimize the stationkeeping propulsion system mass for this unique space platform. 50 to 100 kW class Hall, ion, magnetoplasmadynamic, and pulsed inductive thrusters are compared. High power Hall thruster technology provides the best mix of launches saved and shortest ground to Geosynchronous Earth Orbital Environment (GEO) delivery time of all the systems, including chemical. More detailed studies comparing launch vehicle costs, transfer operations costs, and propulsion system costs and complexities must be made to down-select a technology. The concept of adding electric propulsion to the sun tower nodes was compared to a concept using re-useable electric propulsion tugs for Low Earth Orbital Environment (LEO) to GEO transfer. While the tug concept would reduce the total number of required propulsion systems, more launchers and notably longer LEO to GEO and complete sun tower ground to GEO times would be required. The tugs would also need more complex, longer life propulsion systems and the ability to dock with sun tower nodes.

Oleson, Steve↗

AATTENUATION—The Atmospheric Attenuation Model for CSP Tower Plants: A Look-Up Table for Operational Implementation

Attenuation of solar radiation between the receiver and the heliostat field in concentrated solar power (CSP) tower plants can reduce the overall system performance significantly. The attenuation varies strongly with time and the average attenuation at different sites might also vary strongly from each other. If no site specific attenuation data is available, the optimal plant design cannot be determined and rough estimations of the attenuation effect are required leading to high uncertainties of yield analysis calculations. The attenuation is caused mainly by water vapor content and aerosol particles in the lower atmospheric layer above ground. Although several on-site measurement systems have been developed during recent years, attenuation data sets are usually not available to be included during the plant project development. An Atmospheric Attenuation (AATTENUATION) model to derive the atmospheric transmittance between a heliostat and receiver on the basis of common direct normal irradiance (DNI), temperature, relative humidity, and barometric pressure measurements was developed and validated by the authors earlier. The model allows the accurate estimation of attenuation for sites with low attenuation and gives an estimation of the attenuation for less clear sites. However, the site-dependent coefficients of the AATTENUATION model had to be developed individually for each site of interest, which required time-consuming radiative transfer simulations, considering the exact location and altitude, as well as the pre-dominant aerosol type at the location. This strongly limited the application of the model despite its typically available input data. In this manuscript, a look-up table (LUT) is presented which enables the application of the AATTENUATION model at the site of interest without the necessity to perform the according complex radiative transfer calculations for each site individually. This enables the application of the AATTENUATION model for virtually all resource assessments for tower plants and in an operational mode in real time within plant monitoring systems around the world. The LUT also facilitates the generation of solar attenuation maps on the basis of long-term meteorological data sets which can be considered during resource assessment for CSP tower plant projects. The LUTs are provided together with this manuscript as supplementary files. The LUT for the AATTENUATION model was developed for a solar zenith angle (SZA) grid of 1°, an altitude grid of 100 m, 7 different standard aerosol types and the standard AFGL atmospheres for mid-latitudes and the tropics. The LUT was tested against the original version of the AATTENUATION model at 4 sites in Morocco and Spain, and it was found that the additional uncertainty introduced by the application of the LUT is negligible. With the information of latitude, longitude, altitude above mean sea level, DNI, relative humidity (RH), ambient temperature (Tair), and barometric pressure (bp), the attenuation can be now derived easily for each site of interest.

14 SOLAR ENERGY↗

Heliostat Aiming Strategies for Arbitrary Flux Profiles for High Temperature Gas-Based Receivers

High temperature gas-based receivers are seen as one potential path toward achieving the next generation of concentrated solar power tower systems. A key challenge associated with high temperature, high pressure heat transfer fluids is the lifetime of receiver containment materials. Achieving the desired lifetime while also designing an efficient receiver requires implementation of unique flux profiles, tailored to place high fluxes at cold fluid injection points. An aimpoint selection methodology was developed in the present study to allow user-defined flux profiles to be prescribed for a receiver. The methodology was implemented in NREL's open-source software SolarPILOT, modifying the existing “image size priority” aimpoint strategy. A case study for a tubular gas-based receiver is presented, examining the effect of various parameters on the ability to replicate the desired flux profile.

41 EE - Solar Energy Technologies Office (EE-4S)↗

Off-design performance of molten salt-driven Rankine cycles and its impact on the optimal dispatch of concentrating solar power systems

This paper presents a model for improving off-design performance predictions for molten salt-driven Rankine power cycles, such as in concentrating solar power tower applications. The model predicts cycle off-design performance under various boundary conditions, including molten salt inlet temperature, mass flow rate, and ambient temperature. The model is validated using industry performance data and benchmarked with results from the literature. A complete concentrating solar power plant, inclusive of solar heliostat field and receiver, is then considered, by implementing the Rankine cycle off-design performance results into the National Renewable Energy Laboratory’s System Advisor Model software, which includes a tool that determines optimal power production schedules. The work improves upon the current System Advisor Model by updating off-design performance characteristics. A case study demonstrates the impact of cycle off-design behavior on annual performance for a stand-alone concentrating solar power system and a concentrating solar power-photovoltaic hybrid system. In addition, we demonstrate how cycle off-design performance influences optimal operator dispatch decisions and, thereby, overall system design and economics. We conclude that off-design cycle performance impacts “optimal” sub-system sizing, especially for a concentrating solar power-photovoltaic hybrid configuration in which concentrating solar power must dispatch in conjunction with photovoltaic generation.

14 SOLAR ENERGY↗

Optimal Heliostat Assignment Strategy for Multiple-Receiver Systems

Next-generation concentrating solar power concepts currently being developed under the U.S. Department of Energy's Gen3 program include several novel heliostat field and receiver arrangements. Among these concepts are solar fields utilizing multiple receivers or several distinct receiver flux control zones, and each of which has particular power or peak flux constraints. In this paper, we present a linear program that identifies optimal heliostat-to-receiver assignment strategies for multi-receiver or multi-zone solar fields based on detailed calculations made by an optics modeling package. Two distinct problems are addressed: namely, (1) a design problem that chooses the optimal set of heliostats to include in a final layout given receiver constraints and performance, and (2) an operations problem that assigns existing heliostats to a receiver, maximizing field power output while maintaining receiver power constraints. The optimization methodology is integrated into the concentrating solar power tower modeling package SolarPILOTTM, and results are presented showing that heliostat assignment strategies can impact both initial heliostat field layout characteristics and the cost of thermal energy produced by the field. The methodology succeeds in maintaining power requirements but at the expense of producing different flux profiles on each receiver surface. Consequently, the paper also discusses additional measures that are applied to ensure that desirable flux distribution properties are maintained, reducing local flux mean-absolute-deviation values from a baseline of 17% or greater to less than 5% compared to a desired reference flux profile.

41 EE - Solar Energy Technologies Office (EE-4S)↗

Development and Validation of Dense Discrete Phase Flow Models for Concentrating Solar Power Particle Receivers

This report summarizes a recent project aimed at developing and validating the necessary tools to enable more accurate modeling of denser and more complex particle flows in next-generation particle receivers used in concentrating solar power towers. A newly developed CFD/DEM simulation capability was created by coupling existing the modeling and simulation tools Sierra and LAMMPS. This new capability permitted the inclusion of additional physics for particle drag and particle collisions to model

14 SOLAR ENERGY↗

System-Level Comparison of Sodium and Salt Systems in Support of the Gen3 Liquids Pathway

This paper presents the comparison of the annual performance and the Levelised Cost of Energy (LCOE) of two high- temperature solar power tower configurations using a 565MWth chloride salt receiver and a 540 MWth liquid sodium receiver. Each power tower consists of a sodium or salt receiver, a 175 m high concrete tower, and a two-tank chloride salt system for thermal energy storage (TES). The power plants were simulated using SolarTherm to estimate their energy per year, capacity factor, and LCOE. The simulation was verified against the System Advisor Model (SAM), showing that the LCOE calculation differences are within ±1.0%. Results showed that the sodium-receiver system yields 69.60 USD/MWh real LCOE, versus 78.55 USD/MWh for the chloride salt system. Results also showed that sodium wins here due to a smaller and more efficient receiver, enabled by higher flux limits and reduced field size, leading to less mirror reflective area and site improvement cost.

capacity factor↗

Surface Net Solar Radiation Estimated from Satellite Measurements: Comparisons with Tower Observations

A parameterization that relates the reflected solar flux at the top of the atmosphere to the net solar flux at the surface in terms of only the column water vapor amount and the solar zenith angle was tested against surface observations. Net surface fluxes deduced from coincidental collocated satellite-measured radiances and from measurements from towers in Boulder during summer and near Saskatoon in winter have mean differences of about 2 W/sq m, regardless of whether the sky is clear or cloudy. Furthermore, comparisons between the net fluxes deduced from the parameterization and from surface measurements showed equally good agreement when the data were partitioned into morning and afternoon observations. This is in contrast to results from an empirical clear-sky algorithm that is unable to account adequately for the effects of clouds and that shows, at Boulder, a distinct morning to afternoon variation, which is presumably due to the predominance of different cloud types throughout the day. It is also demonstrated that the parameterization may be applied to irradiances at the top of the atmosphere that have been temporally averaged by using the temporally averaged column water vapor amount and the temporally averaged cosine of the solar zenith angle. The good agreement between the results of the parameterization and surface measurements suggests that the algorithm is a useful tool for a variety of climate studies.

Li, Zhanqing↗