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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
DOE OSTI2022

Upgrade of Core Conduction Cooldown Test Facility Control System

The CCCTF was designed and installed at ORNL in the 1990s for high-temperature gas-cooled reactor accident simulation. It is located within a modular hot cell housed in the IFEL facility. In 2008 and 2009, modifications were made to the CCCTF in preparation for AGR safety testing. A new airlock was designed and installed to better support periodic exchange of the fission product deposition cups while maintaining the fuel at safety test temperature, and modifications were made to add routines to the existing user interface software for computer-controlled automation of the He sweep gas flow and liquid nitrogen supply to the 85Kr cold traps. However, the furnace control hardware and software remained essentially unchanged. At the conclusion of the AGR-1 and AGR-2 PIE campaigns, continued use of the CCCTF was in question because of the gradual obsolescence of the hardware and software used to control the furnace and ancillary systems that make up the CCCTF. Therefore, an effort was undertaken to replace all the obsolete components with new hardware and update the software to increase system reliability and ensure this capability’s maintenance for future research and fuel qualification efforts. The modifications included creating a new National Instruments (NI) LabVIEW-based control system with a graphical user interface (GUI).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS2005

Hardware Progress Made in the Early Flight Fission Test Facilities (EFF-TF) To Support Near-Term Space Fission Systems

The EFF-TF provides a facility to experimentally evaluate thermal hydraulic issues through the use of highly effective non-nuclear testing. These techniques provide a rapid, more cost effective method of evaluating designs and support development risk mitigation when concerns are associated with non-nuclear aspects of space nuclear systems. For many systems, electrical resistance thermal simulators can be used to closely mimic the heat deposition of the fission process, providing axial and radial profiles. A number of experimental and design programs were underway in 2004. Initial evaluation of the SAFE-100a (19 module stainless steel/sodium heat pipe reactor with integral gas neat exchanger) was performed with tests up to 17.5 kW of input power at core temperatures of 1000 K. A stainless steel sodium SAFE-100 heat pipe module was placed through repeated freeze/thaw cyclic testing accumulating over 200 restarts to a temperature of 1000 K. Additionally, the design of a 37-fuel pin stainless steel pumped sodium/potassium (NaK) loop was finalized and components procured. Ongoing testing at the EFF-TF is geared towards facilitating both research and development necessary to field a near term space nuclear system. Efforts are coordinated with DOE laboratories, industry, universities, and other NASA centers. This paper describes some of the 2004 efforts.

VanDyke, Melissa↗
NASA NTRS2002

Test Facilities in Support of High Power Electric Propulsion Systems

Successful development of space fission systems requires an extensive program of affordable and realistic testing. In addition to tests related to design/development of the fission system, realistic testing of the actual flight unit must also be performed. If the system is designed to operate within established radiation damage and fuel burn up limits while simultaneously being designed to allow close simulation of heat from fission using resistance heaters, high confidence in fission system performance and lifetime can be attained through non-nuclear testing. Through demonstration of systems concepts (designed by DOE National Laboratories) in relevant environments, this philosophy has been demonstrated through hardware testing in the High Power Propulsion Thermal Simulator (HPPTS). The HPPTS is designed to enable very realistic non-nuclear testing of space fission systems. Ongoing research at the HPPTS is geared towards facilitating research, development, system integration, and system utilization via cooperative efforts with DOE labs, industry, universities, and other NASA centers. Through hardware based design and testing, the HPPTS investigates High Power Electric Propulsion (HPEP) component, subsystem, and integrated system design and performance.

VanDyke, Melissa↗
DOE OSTI2024

Monitoring Helium Cryogen Usage with iFix Software at IB1 Test Facility

At the IB1 facility of the Applied Physics and Superconducting Technology Directorate within the Cryogenic Division at Fermilab, Liquid Helium is essential to the testing activities. The test stands require large amounts of Helium to test the thermal and superconducting cavities and magnets. The Liquid Helium that enters the test stand is monitored through a series of valves and controls to determine the start and stop for monitoring time. There are 3 phases of cryogen usage that must be considered for each stand, cooldown, warming and overnight mode. With a new system in place, cold hour tracking will be more objective and precise within each test stand ensuring better calculations for User s fees which are charged to various groups that employ the facility and aid replenishment of Helium and continual operation at IB1.

Trillo, Angelica↗
NASA NTRS2000

Automation and Upgrade of Thermal System for Large 38-Year-Young Test Facility

The Goddard Space Flight Center's Space Environment Simulator (SES) facility has been improved by the upgrade of its thermal control hardware and software. This paper describes the preliminary design process, funding constraints, and the proposed enhancements as well as the installation details, the testing difficulties, and the overall benefits realized from this upgrade. The preliminary design process was discussed in a paper presented in October 1996 and will be recapped in this paper to provide background and comparison to actual product. Structuring the procurement process to match the funding constraints allowed Goddard to enhance its capabilities in an environment of reduced budgets. The installation of the new system into a location that has been occupied for over 38 years was one of the driving design factors for the size of the equipment. The installation was completed on time and under budget. The tuning of the automatic sequences for the new thermal system to the existing shroud system required more time and ultimately presented some setbacks to the vendor and the final completion of the system. However, the end product and its benefits to Goddard's thermal vacuum test portfolio will carry the usefulness of this facility well into the next century.

Webb, Andrew T.↗
NASA NTRS2000

Automation and Upgrade of Thermal System for Large 38-Year Young Test Facility

The Goddard Space Flight Center's Space Environment Simulator (SES) facility has been improved by the upgrade of its thermal control hardware and software. This paper describes the preliminary design process, funding constraints, and the proposed enhancements as well as the installation details, the testing difficulties, and the overall benefits realized from this upgrade. The preliminary design process was discussed in a paper presented in October 1996 and will be recapped in this paper to provide background and comparison to actual product. Structuring the procurement process to match the funding constraints allowed Goddard to enhance its capabilities in an environment of reduced budgets. The installation of the new system into a location that has been occupied for over 38-years was one of the driving design factors for the size of the equipment. The installation was completed on-time and under budget. The tuning of the automatic sequences for the new thermal system to the existing shroud system required more time and ultimately presented some setbacks to the vendor and the final completion of the system. However, the end product and its benefits to Goddard's thermal vacuum test portfolio will carry the usefulness of this facility well into the next century.

Webb, Andrew↗
DOE OSTI2025

Operational Experience of the NML Cryogenic Plant at the FAST Test Facility

The NML cryogenic plant cools two individually cryostated superconducting radio frequency (SRF) capture cavities and one prototype ILC cryomodule with eight SRF cavities. This complex accelerates electrons at 150 MeV for the Integrable Optics Test Accelerator (IOTA) ring, located at the Fermilab Accelerator Science and Technology (FAST) facility. The cryogenic plant is composed of two nitrogen precooled Tevatron satellite refrigerators, two Mycom 2016C compressors, a cryogenic distribution system, a Frick purifier compressor, two charcoal bed adsorber purifiers, and a liquid ring vacuum pump with a roots booster. The SRF cavities are immersed in a 2.0 K liquid helium bath, shielded with a 5 K gaseous helium shield and a liquid nitrogen cooled thermal shield. Since 2019, this R&D accelerator complex has gone through four science runs with an average duration of 12 months. Operational experience for each run, availability metrics, performance data and common outages are presented in this paper.

Wallace, Timothy [Fermilab] (ORCID:000900051589302↗
NASA NTRS1997

Unique Tuft Test Facility Dramatically Reduces Brush Seal Development Costs

Brush seals have been incorporated in the latest turbine engines to reduce leakage and improve efficiency. However, the life of these seals is limited by wear. Studies have shown that optimal sealing characteristics for a brush seal occur before the interference fit between the brush and shaft is excessively worn. Research to develop improved tribopairs (brush and coating) with reduced wear and lower friction has been hindered by the lack of an accurate, low-cost, efficient test methodology. Estimated costs for evaluating a new material combination in an engine company seal test program are on the order of $100,000. To address this need, the NASA Lewis Research Center designed, built, and validated a unique, innovative brush seal tuft tester that slides a single tuft of brush seal wire against a rotating shaft under controlled loads, speeds, and temperatures comparable to those in turbine engines. As an initial screening tool, the brush seal tuft tester can tribologicaly evaluate candidate seal materials for 1/10th the cost of full-scale seal tests. Previous to the development of the brush seal tuft tester facility, most relevant tribological data had been obtained from full-scale seal tests conducted primarily to determine seal leakage characteristics. However, from a tribological point of view, these tests included the confounding effects of varying contact pressures, bristle flaring, high-temperature oxidation, and varying bristle contact angles. These confounding effects are overcome in tuft testing. The interface contact pressures can be either constant or varying depending on the tuft mounting device, and bristle wear can be measured optically with inscribed witness marks. In a recent cooperative program with a U.S. turbine engine manufacturer, five metallic wire candidates were tested against a plasma-sprayed Nichrome-bonded chrome carbide. The wire materials used during this collaboration were either nickel-chrome- or cobaltchrome-based superalloys. These tests corroborated full-scale seal test results and provided insight into previously untested combinations. As the cycle temperature for improved efficiency turbine engines increases, new brush seal materials combinations must be considered. Future brush seal tuft testing will include both metallic and ceramic bristles versus commercial and NASA-developed shaft coatings. The ultimate goal of this work is to expand the current data base so that seal designers can tailor brush seal materials to specific applications.

Fellenstein, James A.↗
NASA NTRS1972

Development of a digital control system for a spacecraft propulsion test facility

A digital computer control and abort system which is used at NASA-Lewis research center is described. The system was designed to control test operations such as rocket engine testing, structure testing, and wind tunnel tests. Because of the nature of spacecraft system testing, particularly rocket engine testing, the unique features of the system are, control function updating at a 20 millisecond rate, continuous abort monitoring and a software system designed for short duration tests rather than continuous on-line control. To accomplish these system requirements, special hardware was designed. The presentation includes a description of the computer system and special interface hardware as well as a general description of the software used.

Smalley, R. R.↗
NASA NTRS1976

Ames T-3 fire test facility - Aircraft crash fire simulation

There is a need to characterize the thermal response of materials exposed to aircraft fuel fires. Large scale open fire tests are costly and pollute the local environment. This paper describes the construction and operation of a subscale fire test that simulates the heat flux levels and thermochemistry of typical open pool fires. It has been termed the Ames T-3 Test and has been used extensively by NASA since 1969 to observe the behavior of materials exposed to JP-4 fuel fires.

Fish, R. H.↗
DOE OSTI2025

Operational Experience of the NML Cryogenic Plant at the FAST Test Facility

The New Muon Laboratory (NML) cools two individually cryostated superconducting radio frequency (SRF) capture cavities (CC) and one prototype ILC cryomodule (CM) with eight SRF cavities. This complex accelerates electrons at 150 MeV for the Integrable Optics Test Accelerator (IOTA) ring, located at the Fermilab Accelerator Science and Technology (FAST) facility. Since 2019, this R&D accelerator complex has gone through four science runs.

Wallace, T. [Fermilab]↗
DOE OSTI2013

Functional and operational requirements document : building 1012, Battery and Energy Storage Device Test Facility, Sandia National Laboratories, New Mexico.

This report provides an overview of information, prior studies, and analyses relevant to the development of functional and operational requirements for electrochemical testing of batteries and energy storage devices carried out by Sandia Organization 2546, Advanced Power Sources R&D. Electrochemical operations for this group are scheduled to transition from Sandia Building 894 to a new Building located in Sandia TA-II referred to as Building 1012. This report also provides background on select design considerations and identifies the Safety Goals, Stakeholder Objectives, and Design Objectives required by the Sandia Design Team to develop the Performance Criteria necessary to the design of Building 1012. This document recognizes the Architecture-Engineering (A-E) Team as the primary design entity. Where safety considerations are identified, suggestions are provided to provide context for the corresponding operational requirement(s).

25 ENERGY STORAGE↗
NASA NTRS2009

Modeling Potential Carbon Monoxide Exposure Due to Operation of a Major Rocket Engine Altitude Test Facility Using Computational Fluid Dynamics

This viewgraph presentation reviews computational fluid dynamics as a tool for modelling the dispersion of carbon monoxide at the Stennis Space Center's A3 Test Stand. The contents include: 1) Constellation Program; 2) Constellation Launch Vehicles; 3) J2X Engine; 4) A-3 Test Stand; 5) Chemical Steam Generators; 6) Emission Estimates; 7) Located in Existing Test Complex; 8) Computational Fluid Dynamics; 9) Computational Tools; 10) CO Modeling; 11) CO Model results; and 12) Next steps.

Blotzer, Michael J.↗
NASA NTRS2018

Validation & Verification of Electrical Components B2 Test Facility

The research focus of this project is to assist in the closure of Measurement, Monitoring and Control System (MMCS) and other electrical requirements in support of the B2 Space Launch System (SLS) Core Stage Green Run Test Project. Alongside this goal I am to understand project management tools to analyze and control activities/tasks associated with those items. The project I am working on will assist electrical engineers in developing and or identifying closure rationale for the MMCS and electrical requirements. Also as serving the role of a training project manager, I am to develop and maintain a method for tracking progress with estimate completion dates specifically identifying those items during this performance window. The methods I used in order to perform the research consisted of worddocuments, excel sheets, and pdf documents needed for review. For example, documents consisted of: a SLS Core Stage Green Run Facility Requirement Document (FRD) identifying the SSC MMCS and electrical requirements, a Stage Controller to SSC Interface Control Document (ICD) identifying the SSC requirements, and the B2 SLS Core Stage Green Run Test project System Requirements Document (SRD) which identifies the MMCS and electrical requirements. The files were sent to me by both mentors, Mr. Barry Robinson and Ms. Dawn Davis. Overall, the review process for the word documents and excel spreadsheets proved to be successful. The data for the electrical components were accurate and were consistent with the original recorded data. However, the consistency with the pdf documents did not follow up all the way. Attention to this mistake was made and further revisions were done in order for the data to agree with each other. Furthermore, an itinerary was designed using Microsoft Outlook in order to track progress with estimated completion dates. This project contributes to NASA/Center Missions and Goals through the Waterfall Model. The Waterfall Model is a linear system used for engineering design. In the Waterfall Model, the fourth step is Verification and Validation. This involves installation, testing, and debugging of the B2 SLS Core Stage electrical components. For the SLS Core Stage Green Run Test Project, each requirement contained in this approved requirements set will have at least one Verification Item (VI) assigned to it. During the design phase, VIs will mostly consist of Analysis or Inspection types. Design phase VIs and closure information will be documented in Dynamics Data Management System (DDMS) in the form of analysis reports and design documentation.

Bastian, Tyler↗
DOE OSTI2014

An Experimental Test Facility to Support Development of the Fluoride Salt Cooled High Temperature Reactor

The need for high-temperature (greater than 600 C) energy exchange and delivery systems is significantly increasing as the world strives to improve energy efficiency and develop alternatives to petroleum-based fuels. Liquid fluoride salts are one of the few energy transport fluids that have the capability of operating at high temperatures in combination with low system pressures. The Fluoride Salt-Cooled High-Temperature Reactor design uses fluoride salt to remove core heat and interface with a power conversion system. Although a significant amount of experimentation has been performed with these salts, specific aspects of this reactor concept will require experimental confirmation during the development process. The experimental facility described here has been constructed to support the development of the Fluoride Salt Cooled High Temperature Reactor concept. The facility is capable of operating at up to 700 C and incorporates a centrifugal pump to circulate FLiNaK salt through a removable test section. A unique inductive heating technique is used to apply heat to the test section, allowing heat transfer testing to be performed. An air-cooled heat exchanger removes added heat. Supporting loop infrastructure includes a pressure control system; trace heating system; and a complement of instrumentation to measure salt flow, temperatures, and pressures around the loop. The initial experiment is aimed at measuring fluoride salt heat transfer inside a heated pebble bed similar to that used for the core of the pebble bed advanced high-temperature reactor. This document describes the details of the loop design, auxiliary systems used to support the facility, the inductive heating system, and facility capabilities.

fluoride salt reactor FLiNaK↗
DOE OSTI2024

Monitoring Helium Cryogen Usage with iFix Software at IB1 Test Facility

At the IB1 facility of the Applied Physics and Superconducting Technology Directorate within the Cryogenic Division at Fermilab, liquid helium is essential to the testing activities. The test stands used require large amounts of Helium to test the thermal and superconducting cavities and magnets. The liquid helium that enters the test stand is monitored through a series of valves and controls to determine the start and stop for monitoring time. There are 3 phases of cryogen usage that must be considered for each stand, cooldown, warming and overnight mode. With a new system in place, cold hour tracking will be more objective and precise within each test stand ensuring better calculations for user s fees that will provide funding for the replenishment of helium and continual operation at IB1.

Trillo, Angelica↗
NASA NTRS1983

The impact of CFD on development test facilities - A National Research Council projection

The results of a National Research Council study on the effect that advances in computational fluid dynamics (CFD) will have on conventional aeronautical ground testing are reported. Current CFD capabilities include the depiction of linearized inviscid flows and a boundary layer, initial use of Euler coordinates using supercomputers to automatically generate a grid, research and development on Reynolds-averaged Navier-Stokes (N-S) equations, and preliminary research on solutions to the full N-S equations. Improvements in the range of CFD usage is dependent on the development of more powerful supercomputers, exceeding even the projected abilities of the NASA Numerical Aerodynamic Simulator (1 BFLOP/sec). Full representation of the Re-averaged N-S equations will require over one million grid points, a computing level predicted to be available in 15 yr. Present capabilities allow identification of data anomalies, confirmation of data accuracy, and adequateness of model design in wind tunnel trials. Account can be taken of the wall effects and the Re in any flight regime during simulation. CFD can actually be more accurate than instrumented tests, since all points in a flow can be modeled with CFD, while they cannot all be monitored with instrumentation in a wind tunnel.

Korkegi, R. H.↗