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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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NASA NTRS2010

Ares I-X Flight Test Vehicle:Stack 1 Modal Test

Ares I-X was the first flight test vehicle used in the development of NASA s Ares I crew launch vehicle. The Ares I-X used a 4-segment reusable solid rocket booster from the Space Shuttle heritage with mass simulators for the 5th segment, upper stage, crew module and launch abort system. Three modal tests were defined to verify the dynamic finite element model of the Ares I-X flight test vehicle. Test configurations included two partial stacks and the full Ares I-X flight test vehicle on the Mobile Launcher Platform. This report focuses on the second modal test that was performed on the middle section of the vehicle referred to as Stack 1, which consisted of the subassembly from the 5th segment simulator through the interstage. This report describes the test requirements, constraints, pre-test analysis, test operations and data analysis for the Ares I-X Stack 1 modal test.

Buehrle, Ralph D.↗
NASA NTRS2009

Extended Life PZT Stack Test Fixture

Piezoelectric stacks are being sought to be used as actuators for precision positioning and deployment of mechanisms in future planetary missions. Beside the requirement for very high operation reliability, these actuators are required for operation at space environments that are considered harsh compared to normal terrestrial conditions.These environmental conditions include low and high temperatures and vacuum or high pressure. Additionally, the stacks are subjected to high stress and in some applications need to operate with a very long lifetime durability.Many of these requirements are beyond the current industry design margins for nominal terrestrial applications. In order to investigate some of the properties that will indicate the durability of such actuators and their limitations we have developed a new type of test fixture that can be easily integrated in various test chambers for simulating environmental conditions, can provide access for multiple measurements while being exposed to adjustable stress levels. We designed and built two test fixtures and these fixtures were made to be adjustable for testing stacks with different dimensions and can be easily used in small or large numbers. The properties that were measured using these fixtures include impedance, capacitance, dielectric loss factor, leakage current, displacement, breakdown voltage, and lifetime performance. The fixtures characteristics and the test capabilities are presented in this paper.

test fixtures↗
NASA NTRS2010

Modeling and Simulation of the ARES UPPER STAGE Transportation, Lifting, Stacking and Mating Operations Within the Vehicle Assembly Building at KSC

This viewgraph presentation describes the modeling and simulation of the Ares Upper Stage Transportation, lifting, stacking, and mating operations within the Vehicle Assembly Building (VAB) at Kennedy Space Center (KSC). An aerial view of KSC Launch Shuttle Complex, two views of the Delmia process control layout, and an upper stage move subroutine and breakdown are shown. An overhead image of the VAB and the turning basin along with the Pegasus barge at the turning basin are also shown. This viewgraph presentation also shows the actual design and the removal of the mid-section spring tensioners, the removal of the AFT rear and forward tensioners tie downs, and removing the AFT hold down post and mount. US leaving the Pegasus Barge, the upper stage arriving at transfer aisle, upper stage receiving/inspection in transfer aisle, and an overhead view of upper stage receiving/inspection in transfer aisle are depicted. Five views of the actual connection of the cabling to the upper stage aft lifting hardware are shown. The upper stage transporter forward connector, two views of the rotation horizontal to vertical, the disconnection of the rear bolt ring cabling, the lowering of the upper stage to the inspection stand, disconnection of the rear bolt ring from the upper stage, the lifting of the upper stage and inspection of AFT fange, and the transfer of upper stage in an integrated stack are shown. Six views of the mating of the upper stage to the first stage are depicted. The preparation, inspection, and removal of the forward dome are shown. The upper stage mated on the integrated stack and crawler is also shown. This presentation concludes with A Rapid Upper Limb Assessment (RULA) utilizing male and female models for assessing risk factors to the upper extremities of human beings in an actual physical environment.

Kromis, Phillip A.↗
NASA NTRS2016

Manufacturing Challenges and Benefits when Scaling the HIAD Stacked-Torus Aeroshell to a 15m Class System

Over a decade of work has been conducted in the development of NASA's Hypersonic Inflatable Aerodynamic Decelerator (HIAD) deployable aeroshell technology. This effort has included multiple ground test campaigns and flight tests culminating in the HIAD project's second generation (Gen-2) aeroshell system. The HIAD project team has developed, fabricated, and tested stacked-torus inflatable structures (IS) with flexible thermal protection systems (F-TPS) ranging in diameters from 3-6m, with cone angles of 60 and 70 deg. To meet NASA and commercial near term objectives, the HIAD team must scale the current technology up to 12-15m in diameter. The HIAD project's experience in scaling the technology has reached a critical juncture. Growing from a 6m to a 15m class system will introduce many new structural and logistical challenges to an already complicated manufacturing process. Although the general architecture and key aspects of the HIAD design scale well to larger vehicles, details of the technology will need to be reevaluated and possibly redesigned for use in a 15m-class HIAD system. These include: layout and size of the structural webbing that transfers load throughout the IS, inflatable gas barrier design, torus diameter and braid construction, internal pressure and inflation line routing, adhesives used for coating and bonding, and F-TPS gore design and seam fabrication. The logistics of fabricating and testing the IS and the F-TPS also become more challenging with increased scale. Compared to the 6m aeroshell (the largest HIAD built to date), a 12m aeroshell has four times the cross-sectional area, and a 15m one has over six times the area. This means that fabrication and test procedures will need to be reexamined to account for the sheer size and weight of the aeroshell components. This will affect a variety of steps in the manufacturing process, such as: stacking the tori during assembly, stitching the structural webbing, initial inflation of tori, and stitching of F-TPS gores. Additionally, new approaches and hardware will be required for handling and ground testing of both individual tori and the fully assembled HIADs. There are also noteworthy benefits of scaling up the HIAD aeroshell to 15m-class system. Two complications in working with handmade textiles structures are the non-linearity of the materials and the role of human accuracy during fabrication. Larger, more capable, HIAD structures should see much larger operational loads, potentially bringing the structural response of the materials out of the non-linear regime and into the preferred linear response range. Also, making the reasonable assumption that the magnitude of fabrication accuracy remains constant as the structures grow, the relative effect of fabrication errors should decrease as a percentage of the textile component size. Combined, these two effects improve the predictive capability and the uniformity of the structural response for a 12-15m class HIAD. In this paper, the challenges and associated mitigation plans related to scaling up the HIAD stacked-torus aeroshell to a 15m class system will be discussed. In addition, the benefits of enlarging the structure will be further explored.

Decellerators↗
NASA NTRS1973

Detection of S02 and N02 in Stack Plume by Raman Scattering and Fluorescence

We have been studying laser-Raman radar which can be used as the remote detector of sulfur dioxide concentration in the stack plume of boiler exhaust gas, and some results have been published. In this paper, we report the interference of nitrogen dioxide fluorescence against sulfur dioxide Raman scattering and the measuring method of sulfur dioxide and nitrogen dioxide concentration. In a stack plume, high density dust and high concentration carbon dioxide are included, therefore very strong Mie back-scattering and carbon dioxide Raman scattering are observed. The separation of these scattering signals from sulfur dioxide Raman signal was the first problem for the laser-Raman radar. But, this problem was solved by using the filter which have high resolving power. It is well known that nitrogen dioxide can be excited to emit fluorescence of broad spectrum by blue-green light. The light source of the laser-Raman radar is SH of Nd:YAG laser, and boiler exhaust gas includes several tens ppm of nitrogen dioxide, then the interference of nitrogen dioxide fluorescence brings the error to sulfur dioxide measurement. 'rhe rejection of the interference can be achieved by the subtraction of the nitrogen dioxide fluorescence contribution from detected signal at sulfur dioxide Raman scattering wavelength. The nitrogen dioxide fluorescence contribution can be measured by two methods. The first is to convert the nitrogen dioxide fluorescence intensity which is measured at a different wavelength from sulfur dioxide Raman line into the one at sulfur dioxide Raman line. The second is to convert the detected signal intensity, which is obtained when the range gate is set just behind the plume, into the one obtained at the range of the plume using the difference of the time dependence between sulfur dioxide Raman scattering and nitrogen dioxide fluorescence. Nitrogen dioxide fluorescence has lifetime of about 300nS, while Raman scattering has none. By either of the two methods, the contribution of nitrogen dioxide fluorescence is determined. Then, we can measure the nitrogen dioxide and sulfur dioxide concentration.The minimum detectable concentration and the experimental results of the remote sensing of sulfur dioxide and nitrogen dioxide in stack plume will be discussed in detail.

Nakahara, S.↗
NASA NTRS2018

Segregation and Phase Transformations Along Superlattice Intrinsic Stacking Faults in Ni-Based Superalloys

In this study, local chemical and structural changes along superlattice intrinsic stacking faults combine to represent an atomic-scale phase transformation. In order to elicit stacking fault shear, creep tests of two different single crystal Ni-base superalloys, ME501 and CMSX-4, were performed near 750 degrees Centigrade using stresses of 552 megapascals and 750 megapascals, respectively. Through high resolution Scanning Transmission Electron Microscopy (STEM) and state-of-the-art energy dispersive x-ray spectroscopy, ordered compositional changes were measured along SISFs (Superlattice Intrinsic Stacking Faults) in both alloys. For both instances, the elemental segregation and local crystal structure present along the SISFs are consistent with a nanoscale to D019 (ordering of a hexagonal close-packed crystal) phase transformation. Another notable observation is prominent Cr- and Co-rich Cottrell atmospheres and new evidence of more complex reordering processes responsible for the formation of these faults. These findings are further supported using density functional theory calculations and High Angle Annular Dark Field (HAADF) STEM image simulations.

STEM-EDS↗
NASA NTRS2019

An Exploration of the Performance and Acoustic Characteristics of UAV-Scale Stacked Rotor Configurations

As interest grows in rotor- and propeller-driven electric vertical takeoff and landing (eVTOL) aircraft for the Urban Air Mobility market, there is a potential for previously studied concepts to reemerge due to the opportunities afforded by novel technologies and operating modes. One such concept is the “stacked” rotor, which consists of multiple co-rotating rotors positioned co-axially with a small axial offset. The goal of the work presented in this paper is to determine whether stacked rotors offer a compelling advantage for eVTOL aircraft in terms of both performance and acoustic characteristics. Results are presented for new experimental tests and computational modeling of multiple stacked rotor configurations, and comparisons are made with conventional rotor configurations. Testing of thirteen separate configurations— each using the same blade shape—revealed a configuration that resulted in an increase in the rotor power loading efficiency by more than 7% and reduced noise by more than 3 dBA when compared with a conventional rotor with all blades located in the same rotational plane.

Whiteside, Siena K. S.↗
NASA NTRSDate not supplied

Implementation of Combinatorial Optimization Techniques for Automated Fiber Placement Through Thickness Defect Stack-Up Minimization

The Computer Aided Process Planning (CAPP) module was developed to facilitate and accelerate the process planning workflow for Automated Fiber Placement (AFP). CAPP assists process planners in identifying optimal starting point locations and layup strategies for each ply of a laminate. Ply optimization operates on measurement and scoring of geometry-based defects such as gaps, overlaps, angle deviation, and steering. This paper expands on the established framework for analyzing defect stack-up through thickness of a laminate. Four different combinatorial optimization algorithms are implemented and evaluated: (1) genetic algorithm, (2) differential evolution, (3) particle swarm, and (4) greedy search. The algorithms identify the optimal combination of ply-level layup strategies, by scoring potential laminates on defect stacking, using two different objective functions. A final optimization approach is also presented which trades some performance for a large gain in efficiency. These approaches are compared to a randomized combination using a complex tool surface in a virtual case study. The result is a streamlined methodology for comparing different laminate-level manufacturing strategies and minimizing the through thickness defect stack up.

CAPP↗
NASA NTRS2024

Masses of Sunyaev-Zel’dovich Galaxy Clusters Detected by the Atacama Cosmology Telescope: Stacked Lensing Measurements with Subaru HSC Year 3 Data

We present a stacked lensing analysis of 96 galaxy clusters selected by the thermal Sunyaev-Zel’dovich (SZ) effect in maps of the cosmic microwave background (CMB). We select foreground galaxy clusters with a 5σ-level SZ threshold in CMB observations from the Atacama Cosmology Telescope, while we define background source galaxies for the lensing analysis with secure photometric redshift cuts in Year 3 data of the Subaru Hyper Suprime Cam survey. We detect the stacked lensing signal in the range of 0.1 < R[h −1 Mpc] < 100 in each of three cluster redshift bins, 0.092 < z ≤ 0.445, 0.445 < z ≤ 0.695, and 0.695 < z ≤ 1.180, with 32 galaxy clusters in each bin. The cumulative signal-to-noise ratios of the lensing signal are 14.6, 12.0, and 6.6, respectively. Using a halo-based forward model, we then constrain statistical relationships between the mass inferred from the SZ observation (i.e. SZ mass) and the total mass derived from our stacked lensing measurements. At the average SZ mass in the cluster sample (2.1 − 2.4 × 10 14 h −1 M⊙), our likelihood analysis shows that the average total mass differs from the SZ counterpart by a factor of 1.3 ± 0.2, 1.6 ± 0.2, and 1.6 ± 0.3 (68%) in the aforementioned redshift ranges, respectively. Our limits are consistent with previous lensing measurements, and we find that the cluster modeling choices can introduce a 1σ-level difference in our parameter inferences.

Masato Shirasaki↗
NASA NTRS1999

Review of Stack CSP Technologies

CSP is an emerging technology with significant potential growth in stacking. Many of the stacking techniques for conventional packages could be implemented for CSP once materials, process, and system development for finer features are developed.

3D CSP stack CSP Chip Scale Package MCM Mulitchip ↗
NASA NTRS1976

A four-channel portable solar radiometer for measuring particulate and/or aerosol opacity and concentration of NO2 and SO2 in stack plumes

Solar absorption radiometry has been investigated as a method of measuring stackplume effluents. A simple and inexpensive instrument was constructed for observing the sun at four wavelengths: 800, 600, 400, and 310 nm. Higher wavelength channels measured the effect of the particulates and NO2, and an ultraviolet channel measured the contribution of SO2 to the attenuation. Stack-plume measurements of opacity and concentration of NO2 and SO2 were in basic agreement with in-stack measurements. The major limitation on the use of the radiometer is the requirement for an accessible viewing position which allows the sun-plume-observer relationship to be attained. It was concluded that the solar radiometer offers an inexpensive method for monitoring plume effluents when the viewing position is not restricted.

Exton, R. J.↗
NASA NTRS1977

An ultraviolet video technique for visualization of stack plumes and for measuring sulfur dioxide concentration and effluent velocity

Absorption spectroscopy utilizing a video sensing technique was investigated as a means of visualizing SO2 in power plant stack plumes and for measuring SO2 concentration and effluent velocity in these plumes. The absorption of SO2 is measured in the ultraviolet region by using the sky as a background source. An additional spectral channel is used to correct for particulate scattering encountered in coal fired power plant plumes. The video system also tracks fluctuations in the SO2 concentration which leads to the determination of an eddy convection velocity. Field measurements were performed to show that the eddy convection velocity is proportional to the average in-stack velocity and to empirically determine their relationship. It was concluded that the video absorption technique is an attractive method for remotely determining both SO2 concentration and plume velocity with the same instrument.

Exton, R. J.↗
NASA NTRS1980

Simultaneous stack-gas scrubbing and waste water treatment

Simultaneous treatment of wastewater and S02-laden stack gas make both treatments more efficient and economical. According to results of preliminary tests, solution generated by stack gas scrubbing cycle reduces bacterial content of wastewater. Both processess benefit by sharing concentrations of iron.

Poradek, J. C.↗
NASA NTRS1980

Effect on combined cycle efficiency of stack gas temperature constraints to avoid acid corrosion

To avoid condensation of sulfuric acid in the gas turbine exhaust when burning fuel oils contaning sulfur, the exhaust stack temperature and cold-end heat exchanger surfaces must be kept above the condensation temperature. Raising the exhaust stack temperature, however, results in lower combined cycle efficiency compared to that achievable by a combined cycle burning a sulfur-free fuel. The maximum difference in efficiency between the use of sulfur-free and fuels containing 0.8 percent sulfur is found to be less than one percentage point. The effect of using a ceramic thermal barrier coating (TBC) and a fuel containing sulfur is also evaluated. The combined-cycle efficiency gain using a TBC with a fuel containing sulfur compared to a sulfur-free fuel without TBC is 0.6 to 1.0 percentage points with air-cooled gas turbines and 1.6 to 1.8 percentage points with water-cooled gas turbines.

Nainiger, J. J.↗
NASA NTRS1982

The determination of the stacking fault energy in copper-nickel alloys

Methods for determining the stacking fault energies of a series of nickel-copper alloys to gain an insight into the embrittling effect of hydrogen are evaluated. Plans for employing weak beam dark field electron microscopy to determine stacking fault energies are outlined.

Leighly, H. P., Jr.↗
NASA NTRS1982

NASA Redox cell stack shunt current, pumping power, and cell performance tradeoffs

The NASA Redox energy storage system is under active technology development. The hardware undergoing laboratory testing is either 310 sq. cm. or 929 sq. cm. (0.33 sq. ft. or 1.0 sq. ft. per cell active area with up to 40 individual cells connected to make up a modular cell stack. This size of hardware allows rather accurate projections to be made of the shunt power/pump power tradeoffs. The modeling studies that were completed on the system concept are reviewed along with the approach of mapping the performance of Redox cells over a wide range of flow rates and depths of discharge of the Redox solutions. Methods are outlined for estimating the pumping and shunt current losses for any type of cell and stack combination. These methods are applicable to a variety of pumping options that are present with Redox systems. The results show that a fully developed Redox system has acceptable parasitic losses when using a fixed flow rate adequate to meet the worst conditions of current density and depth of discharge. These losses are reduced by about 65 percent if variable flow schedules are used. The exact value of the overall parasitics will depend on the specific system requirements of current density, voltage limits, charge, discharge time, etc.

Hagedorn, N.↗