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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 721 records · Page 40
All sourcesNASA NTRSDOE OSTI
NASA NTRS1989

Techniques and potential capabilities of multi-resolutional information (knowledge) processing

A concept of nested hierarchical (multi-resolutional, pyramidal) information (knowledge) processing is introduced for a variety of systems including data and/or knowledge bases, vision, control, and manufacturing systems, industrial automated robots, and (self-programmed) autonomous intelligent machines. A set of practical recommendations is presented using a case study of a multiresolutional object representation. It is demonstrated here that any intelligent module transforms (sometimes, irreversibly) the knowledge it deals with, and this tranformation affects the subsequent computation processes, e.g., those of decision and control. Several types of knowledge transformation are reviewed. Definite conditions are analyzed, satisfaction of which is required for organization and processing of redundant information (knowledge) in the multi-resolutional systems. Providing a definite degree of redundancy is one of these conditions.

Meystel, A.↗
NASA NTRS1994

Bipolar Ag-Zn battery

The silver-zinc (AgZn) battery system has been unique in its ability to safely satisfy high power demand applications with low mass and volume. However, a new generation of defense, aerospace, and commercial applications will impose even higher power demands. These new power demands can be satisfied by the development of a bipolar battery design. In this configuration the power consuming, interelectrode current conductors are eliminated while the current is then conducted via the large cross-section electrode substrate. Negative and positive active materials are applied to opposite sides of a solid silver foil substrate. In addition to reducing the weight and volume required for a specified power level, the output voltage performance is also improved as follows. Reduced weight through: elimination of the plastic cell container; elimination of plate leads and intercell connector; and elimination of internal plate current collector. Increased voltage through: elimination of resistance of current collector; elimination of resistance of plate lead; and elimination of resistance of intercell connector. EPI worked previously on development of a secondary bipolar silver zinc battery. This development demonstrated the electrical capability of the system and manufacturing techniques. One difficulty with this development was mechanical problems with the seals. However, recent improvements in plastics and adhesives should eliminate the major problem of maintaining a seal around the periphery of the bipolar module. The seal problem is not as significant for a primary battery application or for a requirement for only a few discharge cycles. A second difficulty encountered was with activation (introducing electrolyte into the cell) and with venting gas from the cell without loss of electrolyte. During previous work, the following projections for energy density were made from test data for a high power system which demonstrated in excess of 50 discharge/charge cycles. Projected system power = 100 kilowatts; discharge time = 30 seconds; discharge current density = 1.75 amps/sq in.; system weight = 86 lbs (9.7 WH/lb); and system volume = 1071 cu. in. (.78 WH/cu. in.). EPI is currently working on a development program to produce a bipolar silver-zinc battery design for NASA. The potential application would be to power electromechanical actuators for space launch vehicles.

Giltner, L. John↗
NASA NTRS2014

The European Robotic Arm: A High-performance Mechanism Finally on Its Way to Space

This paper describes the design and qualification of the European Robotic Arm (ERA), which is planned to be launched by the end of 2015. After years of changes, a shift of launcher and new loads, launch preparation is underway. The European Robotic Arm ERA has been designed and manufactured by Dutch Space and its subcontractors such as Astrium, SABCA and Stork with key roles for the mechanical aspects. The arm was originally designed to be launched by the STS (mounted on a Russian module for the ISS) in 2001. However, due to delays and the STS disaster, a shift was made to the Russian Proton rocket. ERA will be launched on the Multipurpose Laboratory Module (MLM). This module, which is now planned for launch to the ISS in 2015, will carry the ERA. The symmetrical design of the arm with a complete 3 degree-of-freedom wrist and general-purpose end effector on both sides, allows ERA to relocate on the station by grappling a new base point and releasing the old one, and move to different working locations.

Cruijssen, H. J.↗
NASA NTRS2005

Film Delivery Module For Fiber Placement Fabrication of Hybridized Composite Structures

A new fabrication technology has been developed at the NASA Marshall Space Flight Center that will allow for the fabrication of hybridized composite structures using fiber placement processing. This technology was originally developed in response to a need to address the issue of hydrogen permeation and microcracking in cryogenic propellant tanks. Numerous thin polymeric and metallized films were investigated under low temperatures conditions for use as barrier films in a composite tank. Manufacturing studies conducted at that time did not address the processing issues related to fabrication of a hybridized tank wall. A film processing head was developed that will allow for the processing of thin polymeric and metallized films, metallic foils, and adhesives using fiber placement processing machinery. The film head is designed to enable the simultaneous processing of film materials and composite tape/tow during the composite part layup process and is also capable of processing the film during an independent operation. Several initial demonstrations were conducted to assess the performance of the film module device. Such assessments included film strip lay-up accuracy, capability to fabricate panels having internal film liners, and fabrication of laminates with embedded film layers.

Hulcher, Anthony Bruce↗
DOE OSTI2023

Finned-tube-integrated modular thermal storage systems for HVAC load modulation in buildings

While there is considerable focus on latent-based thermal energy storage (TES) systems, the low thermal conductivity of phase change materials (PCMs) remains a critical concern. Many approaches to enhance PCM conductivity either require complicated synthesis processes or are cost prohibitive. In this study, we investigate finned-tube modular TES systems, which are simple in design, easy to manufacture, and cost-effective due to their standard materials and components. The study includes detailed modeling and experimentation of two devices containing similar amounts of PCM but different fin spacings. The study reveals that having more fins does not necessarily increase the TES thermal performance because the reduction in the PCM volume fraction can reduce the TES volumetric and specific energy densities. We find that larger fin spacings provide a higher specific energy for lower C rates (<1C), while smaller fin spacings provide a higher specific energy for higher C rates (>1C).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1985

Amorphous silicon photovoltaic modules and test devices design, fabrication and testing

In July of 1984, Hughes and JPL initiated a contract for Hughes to design, fabricate and test 10 thin film Amorphous Silicon (a-Si) photovoltaic power modules. These modules were to be 1 ft x 4 ft in size. They were to be preceded by the delivery of 10 a-Si 4 in. square test devices. This effort is very timely since thin film PV development has progressed to the point where intermediate load power applications are on the horizon. It is important to know if current a-Si submodule design and manufacturing processes yield a product that is compatible with the packaging needed to meet a 20 to 30 year life span expectancy. The term submodule is assigned to an interconnected assembly of 28 a-Si cells deposited on a 1 foot square glass superstrate. These assemblies are equipped with electrical terminations, i.e., copper tabs at the four corners of the inverted submodules. It is these submodules that are to be interconnected and packaged into power modules, as opposed to the interconnected individual crystalline cells packaged into todays PV modules. A discussion of the fabrication methods and results follows.

Vanleeuwen, M.↗
DOE OSTI2016

Center for Efficiency in Sustainable Energy Systems

The main goal of the Center for Efficiency in Sustainable Energy Systems is to produce a methodology that evaluates a variety of energy systems. Task I. Improved Energy Efficiency for Industrial Processes: This task, completed in partnership with area manufacturers, analyzes the operation of complex manufacturing facilities to provide flexibilities that allow them to improve active-mode power efficiency, lower standby-mode power consumption, and use low cost energy resources to control energy costs in meeting their economic incentives; (2) Identify devices for the efficient transformation of instantaneous or continuous power to different devices and sections of industrial plants; and (3) use these manufacturing sites to demonstrate and validate general principles of power management. Task II. Analysis of a solid oxide fuel cell operating on landfill gas: This task consists of: (1) analysis of a typical landfill gas; (2) establishment of a comprehensive design of the fuel cell system (including the SOFC stack and BOP), including durability analysis; (3) development of suitable reforming methods and catalysts that are tailored to the specific SOFC system concept; and (4) SOFC stack fabrication with testing to demonstrate the salient operational characteristics of the stack, including an analysis of the overall energy conversion efficiency of the system. Task III. Demonstration of an urban wind turbine system: This task consists of (1) design and construction of two side-by-side wind turbine systems on the YSU campus, integrated through power control systems with grid power; (2) preliminary testing of aerodynamic control effectors (provided by a small business partner) to demonstrate improved power control, and evaluation of the system performance, including economic estimates of viability in an urban environment; and (3) computational analysis of the wind turbine system as an enabling activity for development of smart rotor blades that contain integrated sensor/actuator/controller modules to enhance energy capture and reduce aerodynamic loading and noise by way of virtual aerodynamic shaping. Accomplishments: Task I. Improved Energy Efficiency for Industrial Processes: We organized an energy management training session held on February 22, 2011, which was advertised through a regional manufacturing association to provide wide-ranging notification. Over two dozen companies were represented a the seminar, ranging from heavy manufacturing businesses with $5,000,000 per year energy expenses, to small, light manufacturing facilities. Task 2. Landfill Fuel Cell Power Generation Solid Oxide Fuel Cells (SOFCs) were constructed and evaluated as a means of obtaining electrical energy from landfill gas. Analysis of landfill gas. Attempts at collecting gas samples at the landfill and evaluating them on campus were still unsuccessful. Even a Teflon® sample bag would lose its H2S content. Evaluation of Gas Clean-up We consider this a confirmation of the CO2 effect on the solubility of H2S in water making much less sulfide available for the photocatalyst. It also means that another method should be employed to clean up landfill gas. Nonetheless, composition of impurities in landfill gas was reduced sufficiently to allow successful operation of the test fuel cell. Comparison to a PEM fuel cell system. If a PEMFC were to be operated with landfill gas as the fuel, the gas would have to be treated for sulfur removal, and then processed in a reformer large enough to drive the equilibrium far toward the products, so that negligible CO would flow into the fuel cell. Analysis of a fuel cell running on landfill gas. Using a Gow-Mac gas chromatograph with a thermal conductivity detector, unambiguous determination of CO can be made, at least as a primary constituent Task 3: Task 3 Plasma Controlled Turbine Blades Wind Turbine Selection. After carefully reviewing the various model available in the market the team selected the ARE 110 (2.5kW). The ARE 110 provides a very long life with little maintenance due to their relatively low rotational speeds (low RPM). The turbines large swept area (10.2ms2/110sq.ft), high-efficiency blades, purpose built alternator, and optimized power electronics ensure maximum energy capture from a wide range of wind speeds. Two wind turbines were installed side-by-side at the Melnick Hall site to compare their performance. Evaluate and Optimize Aerodynamically Enhanced Turbine Blades Due to delays in the installation of the wind turbines, no actual data was obtained within the contract period. At this time, the turbines are installed and operational at YSU with standard blades. We are in contact with Orbital Research and in discussion as to how best the required data can be obtained.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1983

Engineering and fabrication cost considerations for cryogenic wind tunnel models

Design and fabrication cost drivers for cryogenic transonic wind tunnel models are defined. The major cost factors for wind tunnel models are model complexity, tolerances, surface finishes, materials, material validation, and model inspection. The cryogenic temperatures require the use of materials with relatively high fracture toughness but at the same time high strength. Some of these materials are very difficult to machine, requiring extensive machine hours which can add significantly to the manufacturing costs. Some additional engineering costs are incurred to certify the materials through mechanical tests and nondestructive evaluation techniques, which are not normally required with conventional models. When instrumentation such as accelerometers and electronically scanned pressure modules is required, temperature control of these devices needs to be incorporated into the design, which requires added effort. Additional thermal analyses and subsystem tests may be necessary, which also adds to the design costs. The largest driver to the design costs is potentially the additional static and dynamic analyses required to insure structural integrity of the model and support system.

Boykin, R. M., Jr.↗
NASA NTRS1989

Fiber optic links for microwave/millimeter-wave systems

Recent advances in device technology for microwave/mm-wave (M/MMW) analog fiber-optic communication systems are surveyed, with discussion of system parameters, design optimization methods, and hardware selection and manufacturing considerations. Particular attention is given to 1-km-link systems operating at 21, 30, and 12 GHz for satellite-communication, electronic-warfare, and radar applications. The design and fabrication simplicity of direct modulation is weighed against the wide bandwidth, low distortion, and mm-wave and frequency operation advantages of external modulation. Homodyne or heterodyne coherent detection is shown to improve system S/N by 10-20 dB over conventional detection methods. Diagrams, drawings, photographs, and graphs of typical performance data are included.

Pan, J. J.↗
NASA NTRS2000

TransHab: NASA's Large-Scale Inflatable Spacecraft

TransHab is a, 27-foot diameter by 40-foot, lightweight inflatable habitation module for space applications. TransHab consists of a lightweight graphite-composite core, 11-foot diameter by 23-foot tall, surrounded by a 27-foot diameter inflatable shell. Originally envisioned to be the habitation module of an interplanetary transit vehicle, TransHab is currently being considered as a module for use on the International Space Station (ISS). During the past two years, several tests have been performed at the NASA/Johnson Space Center to demonstrate and prove the technologies required in building a large-scale inflatable habitation module. This paper discusses the results of these tests which including the following: 1) a structural integrity development test article hydJ"Ostatically tested to four times ambient pressure, 2) a full-scale development test article manufactured, assembled, folded and deployed at vacuum, and 3) extensive hypervelocity impact testing of the micro meteoroid and orbital debris protection system.

delaFuente, Horacio↗
NASA NTRS2023

Automated Fiber Placement Through Thickness Defect Stacking Optimization

In its 2022 commercial market outlook, Boeing forecasted an 80% increase in the global fleet through 2041 compared to 2019 pre-pandemic levels. This sharp rise in demand will drive pressure onto airframe manufacturers to ramp up production and find more efficient ways to design and manufacture airplanes. Complicating this challenge is the industry’s recent transformation from traditional metal-based airframes towards hybrid composite-metal aircraft. While composites have been used in aviation for decades, aircraft manufacturers are still struggling to design and manufacture quality parts at a high rate. Automated Fiber Placement (AFP) is one of the main manufacturing techniques used to produce large-scale composite parts. After a design has been created, a manufacturing strategy has to be developed based on the working material, part geometry, and machine capabilities. This process planning stage is essential to the AFP workflow and currently requires a high level of manual input from an experienced process planner. In an effort to automate and optimize this stage, the Computer Aided Process Planning (CAPP) module was developed. CAPP assists process planners in identifying optimal starting point location and layup strategy for each ply of a laminate. This Ply-Level Optimization (PLO) phase operates on the quantification of ply quality through predictable geometry-based defects such as gaps, overlaps, angle deviation, and steering. As you move from PLO to Laminate-Level Optimization (LLO) the design space grows exponentially, emphasizing the need for automated optimization. The work presented in this thesis expands CAPP’s functionality by comparing the planned fiber paths through the thickness of the laminate to mitigate stacked area defects and achieve an optimal laminate-level manufacturing strategy. Within CAPP, predicted gap and overlap defects are imported from Vericut Composites Programming (VCP) and then discretized to streamline the through-thickness comparison. Two objective functions are used to score different combinations of ply layup strategies based on defect stacking both globally and locally. Four combinatorial optimization algorithms were coupled with these objective functions to investigate the laminate-level manufacturing strategy design space and converge on the optimal plan. These algorithms were evaluated based on accuracy and efficiency through virtual testing on a complex tool surface. A separate LLO approach was developed to achieve near-optimal laminates in significantly less time. The end result is a software package which greatly reduces the required input from process planners, shortening the design-build cycle time and improving part quality.

AFP↗
NASA NTRS2012

An efficient plant production system for eXploration habitat demonstration module

The National Aeronautics and Space Administration (NASA) annually provides an academic challenge to colleges around the United States. The goal of this XHab project was to design, enhance and implement a monitoring and control network for a plant production system. This project emphasized on hands-on design, research, development, and manufacture of a functional prototype subsystem. This prototype is to be integrated onto an existing NASA built habitat prototype.

Peter Ling↗
DOE OSTI2022

Transformational Challenge Reactor – On the Application of Design for Additive Manufacturing (DfAM) Techniques to the Conception of Nuclear Core

Additive manufacturing (AM) technologies are radically changing the way objects are designed and manufactured. They allow building by deposition and solidification of material layer by layer, enabling the possibility to create simple and complex features alike, almost seamlessly. Generally, the design optimization process requires to define objectives, design variables and constraints. Additive manufacturing does not challenge this process per se but does allow designers to completely redefine the constraints space as the ones originating from fabrication can be considerably relaxed compared to more “traditional” manufacturing. Thus, design optimization becomes naturally far more responsive to the actual physics being solved and considerably less influenced by fabrication limitations, leading to dramatically different designs. To take advantage of these new opportunities, so-called Designing for Additive Manufacturing (DfAM) techniques are emerging. Development of design techniques specifically tailored for additive manufacturing is warranted because, considering AM, the design space is typically considerably larger than with traditional manufacturing. The ability to explore the design space efficiently is of paramount importance for designers. This study proposes to investigate and apply some of these DfAM techniques to the conception of nuclear core. The goal being to assess if these new methods can be applied to core design and if core design could benefits from additive manufacturing technologies. After a brief investigation on the pertinence of some DfAM techniques for core design, algorithms are proposed and a workflow is established to carry neutronics and steady-state thermal-hydraulics analyses. To diminish the work load, the workflow has been automated using python modules. These modules allow the rapid creation of input files, post-treatment of output files and visualization. To test the pertinence of the proposed workflow, three test cases have been investigated: a research and test reactor, a micro-reactor and a space propulsion reactor. These test cases offered a variety of objectives, constraints and operating conditions. It is observed that the proposed workflow is capable of converging quickly and efficiently to valid design solutions. It is then concluded that DfAM techniques can be applied to core design.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2024

Advanced Perovskite Solar Cells and Modules

The “Advanced perovskite Cells and Modules” research project was the final agreement focused on enhancing perovskite solar cell (PSC) technologies funded by the US Department of Energy's Solar Energy Technologies Office. The project was designed to address three crucial areas in PSC development: stability, manufacturability, and efficiency. The project was then structured around three main tasks, each targeting one of these strategic goals. The team of experienced researchers in these materials worked collaboratively to address the targets outlined in the technical work plan. building on existing PSC research while also exploring promising new concepts arising in the field. An overview of each primary task is summarized below: Task 1 Stability: This first task, aims to identify material characteristics and metrics that can help predict the primary degradation mechanisms impacting PSC stability. This involved developing specific device tests based on hypotheses regarding mechanisms impacting stability, including fast failure procedures to speed up PSC development and improvement. Various strategies to enhance stability, like incorporating additives, post-treatments, novel contact materials etc. were developed using this fast feedback approach. The relationships between indoor and outdoor stresses were also validated. Task 2 Manufacturability: This second task, focused on creating a scalable production process for PSCs. Initially the objective is to establish a best-known method for a 182 cm2 minimodule. However, given resource limitations, these metrics were modified to focus on the other goal of outlined in the TWP. Specifically, this task worked to demonstrate the transferability of this best-known method to another research institution. Work scope in this area was expanded to material purity and understanding of reagent/process relationships. Examination of other difficulties in PSC production and potential solutions for large-scale production were also evaluated. Given challenges observed in process transfer, work to develop data infrastructure and recording tools for processing of material and devices was then also prioritized in this task. Task 3 Efficiency: This task was focused on improvements to PCE, while still considering Task 1 and Task 2 goal. The efforts targeted a PCE greater than 22% with a T95 exceeding 1000 hours at 25°C in a nitrogen environment for lab-scale devices (approximately 0.1 cm2 devices) across a range of solar-relevant perovskite compositions, including wide-gap (around 1.7 eV) and low-gap (around 1.3 eV) materials, using standard metal contacts. This work then provides a foundation for MHP-based tandem efforts undertaken in other projects and the All-MHP tandem efforts outlined in this projects TWP. Work in this project emphasized disseminating its findings through peer-reviewed publications (PRP), conference presentations, and industrial collaborations. Significant products were produced in all these areas, over 53 peer reviewed publications, 32 conference presentations and industrial investment based on NLR assistance on precompetitive challenges. The team also developed significant intellectual property and awards for their technical excellence, innovations and leadership. The team also leveraged traditional and social media platforms to engage with stakeholders and the public.

14 SOLAR ENERGY↗
DOE OSTI2025

Inverse design of cellular structures with the targeted nonlinear mechanical response

Advanced additive manufacturing capabilities have enabled a transformational ability to create sophisticated cellular structures using diverse materials. By altering the topology of the unit cell, the mechanical behavior, such as the stress-strain response during compression, can be modulated. Nevertheless, identifying a printable topology within an enormous design space that would precisely deliver the targeted nonlinear material response is challenging. We propose a data-driven generative framework based on a conditional variational autoencoder (cVAE) architecture that can inverse design the cellular structure based on the intended nonlinear stress-strain response. Trained on a dataset of structure-property pairs, the cVAE learns a compact and expressive latent space that enables efficient mapping from targets to feasible geometries. Two inference modes are explored: (1) decoder-only generation, which enables the exploration of diverse designs conditioned solely on the desired mechanical response, and (2) encoder-decoder generation, which further allows for the incorporation of desired topologies, ensuring the generated structure conforms to both mechanical properties and to desired-topology constraints. The results demonstrate that the model can generate structurally plausible and mechanically accurate designs, with the predicted stress-strain curves closely matching the targets. Even under joint conditioning, the model effectively balances geometric fidelity and functional performance.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Initial Radiation of Nuclear Power Plant Components (CRADA NFE-17-06892 Final Report)

As advanced reactor concepts are developed, instrumentation and control (I&C) cables and sensors will play a significant role in assuring their operation is well understood, and safety-related process information can be collected reliably over the course of their design life. As a first step to develop acceptance criteria and define the limits of currently available nuclear I&C cable and sensor technology, a collaboration between Oak Ridge National Laboratory and Analysis and Measurement Services (AMS) Corporation was initiated under the Gateway for Accelerated Innovation in Nuclear (GAIN) Program. This collaborative effort focused on providing technical information related to the combined thermal and radiation aging of nuclear power plant (NPP) cables, companion NPP cable insulation samples, and two prototype temperature and two pressure sensors. This work was carried out using the instrumented gamma irradiation system that is part of the High Flux Isotope Reactor Gamma Irradiation Facility (HFIR GIF). This system provided the opportunity for the condition of the prototype sensors to be tracked during the irradiation in order to determine their functional limits with greater granularity when compared to a simple irradiation insertion at the HFIRGIF. Experimental assemblies for sensor irradiation were successfully completed, and sensor irradiation to accumulated dose of 3000 kGy at a rate of approximately 6 kGy/hr was carried out. Two prototype temperature assemblies were continuously monitored during exposure to 3000 kGy and found to have no observable degradation from the irradiation. Two pressure sensors were first irradiated to 1000 kGy. At which point, one of the sensors was found to operate normally; however, a second sensor failed the operability test. The operable pressure sensor output was then continuously monitored from 1000 kGy to 3000 kGy. The sensor output exhibited steady trendable drift versus the accumulated radiation dose. At the conclusion of the irradiation, the four test sensors were released for laboratory calibration checks. The calibration check of the temperature sensors found no significant change after irradiation compared to baseline measurements before irradiation; however, both pressure sensors failed the post-test calibration checks and both sensors were not functioning properly. These results will help inform sensor manufacturers and I&C design engineers of potential limitations of these types of sensors for use in high radiation environments associated with the compact configuration of new Small Modular Reactors (SMRs) such as NuScale’s reactor power module. Irradiations on NPP cables and companion samples were not completed due to programmatic delays, however a path forward that was based on lessons learned from this project was defined to accommodate future, comparable instrumented gamma irradiations at the HFIR GIF.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
NASA NTRS1986

The Space Station program

Likely configurations and goals of the Space Station are delineated. The Station will be a permanent facility designed to be amenable to evolutionary changes. It will be highly automated and user friendly, will be used to perform basic scientific research and observations and to study technologies and processes that may lead to products manufactured in space, and will allow the repair, refurbishment and launch of satellites. The configuration of the Station is being guided by input from future users, which have already helped identify a need to place the laboratory modules at the center of the station to minimize accelerations imparted by other Station activities. Materials which have commercial potential and can only be produced in space after process definition on the Station are discussed, along with NASA efforts to inform industries of the benefits of participation in the program.

Raney, William P.↗